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NIRVANA CYCLING REFRIGERATED DRYERMODELS 200-400
OPERATORS MANUAL
C.C.N. : 80442775 DATE : APRIL 2007REV. : B
Ensure that the operator reads and understands thedecals and
consults the manuals before maintenanceor operation.
Ensure that the Operation and Maintenance manual isnot removed
permanently from the machine.
Ensure that maintenance personnel are adequatelytrained,
competent and have read the MaintenanceManuals.
a
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1Nirvana Cycling Refrigerated Dryer Models
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CONTENTS PAGE
1.0 CONTENTS 12.0 INTRODUCTION 23.0 WARRANTY 24.0 REFRIGERATED
DRYER
NOMENCLATURE 25.0 RECEIVING AND INSPECTION 35.1 INSPECTION5.2
UNPACKING AND HANDLING6.0 SAFETY AND OPERATION
PRECAUTIONS 37.0 PRINCIPLES OF OPERATION 57.1 INTRODUCTION7.2
AIR SYSTEM7.3 MOISTURE REMOVAL SYSTEM7.4 REFRIGERATION SYSTEM7.5
THERMAL MASS CIRCULATING
SYSTEM7.6 CONTROLS7.6.1 BASIC USER INTERFACE7.6.2 EXCHANGER
TEMPERATURE
SET POINT AND ALARMS7.6.3 ADJUSTING SET POINTS7.6.4 ALARMS
AND
THEIR FUNCTIONS7.6.5 ALERT MESSAGES7.6.6 START MODES7.6.6.1
Manual Mode7.6.6.2 Remote Mode (Optional)7.6.6.3 Auto Restart
CONTENTS PAGE
8.0 INSTALLATION AND INITIAL START-UP 8
8.1 LOCATION AND MOUNTING8.2 PIPING AND VALVES8.3 FILTRATION8.4
ELECTRICAL CONNECTION8.5 INITIAL START-UP8.5.1 START- UP
SEQUENCE9.0 SCHEDULED MAINTENANCE 109.1 INTRODUCTION9.2 REFRIGERANT
CONDENSER9.3 CONDENSATE DISCHARGE
SYSTEM9.4 PANEL FILTER ELEMENT9.5 PRE-FILTERS AND
POST-FILTERS9.5.1 THREADED FILTERS10.0 TROUBLESHOOTING 1310.1
INTRODUCTION10.2 PROBLEM / ACTION GUIDE11.0 WIRING DIAGRAMS 1512.0
GENERAL ARRANGEMENT 1713.0 REPLACEMENT PARTS 1814.0 ENGINEERING
SPECIFICATIONS 19
CONTENTS
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Ingersoll Rand Nirvana Cycling refrigerated air dryer
removesmoisture, oil vapor, and other contaminants from compressed
air. Thesecontaminants are detrimental to pneumatically operated
appliances,controls, instruments, machinery and tools. This removal
isaccomplished by cooling the air with a refrigeration unit to a
temperatureat which moisture in the air is condensed and separated
from the air
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stream. The temperature the air is cooled to, normally between
34 and38F (1 and 3C), is known as dew point. This dryer can be
easilyinstalled into various pneumatic systems in which dry air is
required ordesired. Please refer to Principles of Operation for
complete operatingdetails.
The Company warrants that the equipment manufactured by it
anddelivered hereunder will be free of defects in material and
workmanshipfor a period of twelve months from the date of placing
the Equipment inoperation or eighteen months from the date of
shipment from the factory,whichever shall first occur. The
Purchaser shall be obligated to promptlyreport any failure to
conform to this warranty, in writing to the Companyin said period,
whereupon the Company shall, at its option, correct
suchnonconformity, by suitable repair to such equipment or, furnish
areplacement part F.O.B. point of shipment, provided the Purchaser
hasstored, installed, maintained and operated such Equipment
inaccordance with good industry practices and has complied with
specificrecommendations of the Company. Accessories or equipment
furnishedby the Company, but manufactured by others, shall carry
whateverwarranty the manufacturers have conveyed to the Company and
whichcan be passed on to the Purchaser. The Company shall not be
liable forany repairs, replacements, or adjustments to the
Equipment or any costsof labor performed by the Purchaser or others
without Company's priorwritten approval.
The effects of corrosion, erosion and normal wear and tear
arespecifically excluded. Performance warranties are limited to
thosespecifically stated within the Company's proposal. Unless
responsibilityfor meeting such performance warranties are limited
to specified tests,the Company's obligation shall be to correct in
the manner and for theperiod of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY ORREPRESENTATION OF ANY KIND
WHATSOEVER, EXPRESSED ORIMPLIED, EXCEPT THAT OF TITLE, AND ALL
IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A
PARTICULARPURPOSE, ARE HERBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or
latent,in the manner and for the period of time provided above,
shall constitutefulfillment of all liabilities of the Company for
such nonconformitieswhether based on contract, warranty negligence,
indemnity, strict liabilityor otherwise with respect to or arising
out of such Equipment.
The Purchaser shall not operate Equipment which is considered to
bedefective, without first notifying the Company in writing of its
intention todo so. Any such use of Equipment will be at Purchaser's
sole risk andliability.
Note that this is Ingersoll Rand standard warranty. Any warranty
in forceat the time of purchase of the equipment or negotiated as
part of thepurchase order may take precedence over this
warranty.
2.0 INTRODUCTION
3.0 WARRANTY
4.0 REFRIGERATED DRYER NOMENCLATURE
NOMINAL*FLOW CONDENSER
PREFIX (SCFM) TYPE POWER RATINGNVC 200-400 A = AIR 2 = 230-1-60
0 = NEMA 1
W = WATER 4 = 460-3-60 H = NEMA 45 = 230-3-606 = 575-3-607 =
380-3-508 = 220-3-50
* Nominal Flows indicated are for 100F inlet temperature, 100F
ambient temperature and 100 psig compressed air pressure.
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5.1 INSPECTIONUpon receiving your Ingersoll Rand air dryer,
please inspect the unitclosely. If rough handling has been
detected, please note it on yourdelivery receipt, especially if the
dryer will not be uncrated immediately.Obtaining the delivery
persons signed agreement to any noteddamages will facilitate any
insurance claims.
5.2 UNPACKING AND HANDLING
a WARNINGUnder no circumstances should any person attempt to
lift heavyobjects without proper lifting equipment (i.e., crane,
hoist, slings or forktruck). Lifting any unit without proper
lifting equipment, may causeserious injury.
5.0 RECEIVING AND INSPECTION
To facilitate handling during shipment, all dryer packages have
beenmounted on a base that provides for forklifting between two
basechannels. Forks should extend all the way through forklift
channels toreduce unnecessary forces to the dryer during moving.
Slings can beused to lift the crates, but spreader bars must be
used to prevent theslings from exerting a force against the sides
of the crates or the dryer.
6.0 SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating parts,
thesame precautions should be observed as with any piece of
machineryof this type where carelessness in operation or
maintenance could behazardous to personnel. In addition to obvious
safety rules that shouldbe followed with this type of machinery,
safety precautions as listedbelow must be observed:
1. Only qualified personnel shall be permitted to adjust,
performmaintenance or repair this air dryer.
2. Read all instructions completely before operating unit.3.
Pull main electrical disconnect switch and disconnect any
separate
control lines, if used, before attempting to work or
performmaintenance on the unit.
4. Do not attempt to service any part while machine is in an
operationalmode.
5. Do not attempt to remove any parts without first relieving
the entireair system of pressure.
6. Do not attempt to remove any part of the refrigeration system
withoutremoving and containing refrigerant in accordance with the
EPA andlocal regulations.
7. Do not operate the dryer at pressures in excess of its
rating.8. Do not operate the dryer without guards, shields and
screen in place.9. Inspect unit daily to observe and correct any
unsafe operating
conditions.
OSHAHeading Descriptions
a WARNINGWarning is used to indicate a hazardous situation which
has someprobability of death or severe injury. Warning should not
be consideredfor property damage accidents unless personal injury
risk is present.
a CAUTIONCaution is used to indicate a hazardous situation which
may result inminor or moderate injury.
a NOTICENotice is used to indicate a statement of company policy
as themessage relates directly or indirectly to the safety of
personnel orprotection of property. Notice should not be associated
directly with ahazard or hazardous situation and must not be used
in place ofDanger, Warning, or Caution.
a NOTICEThe user of any air dryer manufactured by Ingersoll
Rand, is herebywarned that failure to follow the above Safety and
OperationPrecautions may result in personal injury or equipment
damage.However, Ingersoll Rand does not state as fact, nor does it
mean toimply, that the preceding list of Safety and Operating
Precautions is allinclusive, and further, that the observance of
this list will prevent allpersonal injury or equipment damage.
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6.0 SAFETY AND OPERATION PRECAUTIONS
Air Under Pressure Will CauseInjury, Death Or Property Damage.
Do Not Exceed Pressure Rating. Relieve Press. Before Servicing. Do
Not Modify/Repair/Rework ASME Coded Pressure Vessels As Insurance
Rating Affected.
READ TECHNICAL MANUAL
ELECTRICAL CONNECTION BOXAll Customer Connections To Be Made At
This Location.See Terminal Connection Diagrams, below.Be Certain To
Follow All NEC, State, Local and Other ApplicableCodes During
Installation.
1
2
3
4
5
6
GRNWHT
BLK
GN
L1
FACTORYWIRING
INCOMINGLINE VOLTAGE
100-125VAC1PH/50-60HZ(BY OTHERS)
(REFER TO UNITNAMEPLATE FOR
POWERREQUIREMENTS)
100-125VAC / 1 PH
1
2
3
4
5
6
GRN
BLK
G
L1
RED L2
FACTORYWIRING
INCOMINGLINE VOLTAGE
200-240VAC1PH/50-60HZ(BY OTHERS)
(REFER TO UNITNAMEPLATE FOR
POWERREQUIREMENTS)
200-240VAC / 1 PH
1
2
3
4
5
6
GRNRED
WHT
GL1
L2
BLK L3
FACTORYWIRING
INCOMINGLINE VOLTAGE
200-575VAC3PH/50-60HZ(BY OTHERS)
(REFER TO UNITNAMEPLATE FOR
POWERREQUIREMENTS)
200-575VAC / 3 PH
ELECTRICAL CONNECTION BOXCONTAINS HIGH VOLTAGE
Turn Off Power And Lock Out At ALL Sources Before Opening To
Perform Service. Remote Alarm Contact Wiring Has Control Power From
Separate Source.
READ TECHNICAL MANUAL
Air Under Pressure Will CauseInjury, 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 disconnectpower from dryer. Always
disconnectpower from ALL sources beforeperforming service.
READ TECHNICAL MANUAL
HIGH VOLTAGEThis unit is charged withrefrigerant under high
pressure.
FAN MAY AUTOMATICALLYSTART AT ANY TIME
Alternate three-phase wiring may be black / black / black.
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7.1 INTRODUCTIONIngersoll Rand Nirvana Cycling dryers remove
moisture fromcompressed air by cooling the air temperature to
between 34 and 38F(1 and 3C). This causes vapors to condense into
liquid droplets whichcan then be easily removed from the air. The
major systems of the dryerwhich contribute to its operation are the
Air System, the MoistureRemoval System, the Refrigeration System,
the Thermal MassCirculating System and the Controls. The following
paragraphsdescribe each of the systems in greater detail.
7.0 PRINCIPLES OF OPERATION
7.2 AIR SYSTEMThe air system consists of the dryer components
which are in contactwith the compressed air. Referring to Figure 1
and following the boldAIR FLOW, hot saturated air from the
compressor enters theprecooler/reheater where the air temperature
is reduced prior toentering the chiller by the cool air exiting the
air/moisture separator. Thisprecooling allows for the use of a
smaller refrigeration system. The airthen goes into the chiller
section where it is further cooled to the desireddew point by a
thermal mass fluid. The temperature of the thermal massfluid is
maintained by the refrigeration circuit and controls. The
aircontinues to the separator where moisture is removed, thereby,
allowingthe cool, dry air to return back to the precooler/reheater
to be heated bythe incoming moist hot air. The air exiting the
reheater portion of thedryer should be approximately 15- 20F lower
than the inlet airtemperature based on standard conditions at full
rated flow.
FLOW DIAGRAMFIGURE 1
7.3 MOISTURE REMOVAL SYSTEMIngersoll Rand condensate drains
discharge condensed moisture andlubricants (condensate) from
compressed air equipment. Thecondensate drain operates as a
zero-air-loss drain, returning air that isdisplaced in the drain
bowl back into the compressed air system.Consistent discharging of
condensate from compressed air equipmentis essential for proper
equipment operation and performance.
The condensate drain uses a unique sensing method to determine
thelevel of condensate in the drain bowl. A transducer located in
the drainbowl continuously sends out a signal 50 times per second.
Once thetransducer determines that the level of condensate has
reached apredetermined level within the drain bowl, a signal is
sent to the no-lossdrain valve to open. This operation permits
removal of condensate of upto 80 gallons per hour.
The drain also features a test button that permits manual
operation ofthe no-loss drain valve. Depressing the test button
illuminates the LEDand energizes the solenoid valve. The LED
illuminates to indicate"POWER ON" and goes off when the no-loss
drain valve is operated bythe transducer or manual test button.
The condensate flows through the feed line into the drain unit
andaccumulates in the container. A capacitive sensor continuously
registers
the liquid level and passes a signal to the electronic control
as soon asthe container is filled. The pilot valve is then
activated and thediaphragm opens the outlet line for discharging
the condensate. Whenthe drain unit has been emptied, the outlet
line is closed again quicklyand tightly without wasting compressed
air."
7.4 REFRIGERATION SYSTEMThe Refrigeration System consists of all
the components which handleR-404A. This is a hermetically sealed
closed-loop system. Referring toFigure 1 and following the phantom
REFRIG(R-404A) FLOW, refrigerantis shown leaving the evaporator
section where, in the process ofremoving heat, it is changed from a
low pressure liquid into a lowpressure gas. This gas enters the
suction side of the compressor whereit is compressed into a high
pressure gas. The high pressure gas iscooled in the condenser
section until it becomes a high pressure liquid.It then goes
through a permanent filter dryer that ensures therefrigeration
system is free of contaminants. A small diameter capillarytube
(expansion valve on water-cooled dryers) meters the refrigerant
forintroduction into the evaporator. The refrigerant pressure is
reducedupon entering the evaporator where as it evaporates, removes
heat fromthe thermal mass fluid.
PROCESS ANDINSTRUMENTATION
DIAGRAMNVC200-400
AIR ANDWATERCOOLED
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7.0 PRINCIPLES OF OPERATION
7.5 THERMAL MASS CIRCULATING SYSTEMThe thermal mass fluid in a
Ingersoll Rand Nirvana Cycling dryer iscontinuously circulated in a
closed pump loop system. Referring toFigure 1 and following the
dashed THERMAL FLUID line, the heat isremoved from the fluid in the
evaporator by the refrigeration system.The thermal mass reservoir
is sized to minimize refrigeration cyclesduring reduced air load
periods. The thermal mass fluid is pulled fromthe bottom of the
reservoir and pumped through the chiller, removingheat from the air
and then returned to the evaporator. The pump utilizedon the
Ingersoll Rand Nirvana Cycling dryer is a maintenance-free,quiet
cartridge circulator pump similar to those used in residential
watersystems. While the refrigeration system cycles on and off
based onloading conditions, the circulating pump runs continuously
to maintainflow through the chiller at all times. Note that when
the power switch isset to the off position, the circulating pump
will not operate.
7.6 CONTROLSThe Ingersoll Rand NVC200-400 Series dryers
incorporate automaticcontrols for proper operation. The thermal
mass fluid temperature ismaintained by a microprocessor control
that monitors the temperatureand cycles the refrigeration system in
response to varying air flow andtemperature. Upon an increase in
the temperature of the thermal massfluid, the refrigeration
compressor is cycled on. When the fluid is cooledto two deg.F below
its control set point, the refrigerant compressor iscycled off. The
thermal mass fluid functions as a thermal storage massin the NVC
Series dryer.
A low pressure cut out (LPCO) switch is provided for all NVC
seriesdryers. This switch is factory set to open at 20 psig. If the
refrigerantsuction pressure draws below 20 psig, the LPCO opens to
shut off therefrigerant compressor. Once the switch has opened, it
will prevent thecompressor from running until the suction pressure
rises above 60 psigand the LPCO has been manually reset.
All water cooled units come with a high pressure cut out (HPCO)
switch.This switch is set to open at 320 psig and close at 270
psig. Tocompensate for water temperature variation, it may be
necessary toadjust the water regulating valve to maintain a 250
psig dischargepressure. Adjustment can be done by rotating the
adjusting screwcounterclockwise for an increase in discharge
pressure. For conditionswhere low water temperature and/or high
water pressure are expectedit is advisable to install a water
pressure regulator ahead of thecondenser.
7.6.1 BASIC USER INTERFACEThe Controller provides the user with
information about thedryers operation and alarms.
The following illustration summarizes the keypad functions.
BUTTONS
ON / OFF Toggles the dryer operation between "On Line" and Off
Line status;Energizes glycol pump. Note that the refrigeration
system will operate basedon temperature.
EXCH SETWhen depressed, will display the current exchanger set
point in the LCDwindow. While the exchanger set point is displayed,
the up and down arrowsmay be used to increase or decrease the
exchanger set point temperature.
ALARM RESETPressing once clears the local alarm indication and
de-energizes the remotealarm contact. Should the alarm condition
persist, the alarm will return afterthe alarm inhibit time has
expired.
% SAVINGSDepressing once changes LCD display to indicate ratio
of refrigeration systemrunning time vs. total dryer ON time.
F / CToggles the LED temperature indicators between Fahrenheit
and Celsius unitsof measure.
+ / -Allows user to modify set point values. Set point values
cycle through a fixedrange.
LIGHTS
LCD DisplayDisplays exchanger temperature during normal
operation. Also used todisplay exchanger temperature set point,
alarm condition and timing functions.
SYSTEM ENERGIZED Indicates when power is applied to unit.
DRYER ONIlluminated when the On/Off switch has been pressed to
place the unit inoperation. The refrigerant system may start at any
time when the light is on.
REFRIGERATION COMPRESSOR ONIndicates that the refrigeration
system is operating.
DEGREES F / DEGREES CIndicates the temperature units of
measure.
HIGH TEMP ALARMIndicates that the exchanger temperature has
risen to 10F or 5C above theexchanger temperature set point.
LOW TEMP ALARMWhen activated, indicates that the exchanger
temperature has dropped below29F or -2C. This condition stops the
compressor. The compressor will notrestart until the temperature
has risen two degrees above exchanger set point.
ADJUSTMENTSCREW
FIGURE 2WATER REGULATING VALVE
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7.6.2 EXCHANGER TEMPERATURE SET POINT AND ALARMSThe Controller
allows the user to configure the dryersExchanger Temperature
Setpoint to operate according to siteconditions. The Controller is
shipped from the factory with theexchanger temperature having a
default value of 38 deg.
7.6.3 ADJUSTING SET POINTSAccessing and manipulating the
Exchanger TemperatureSetpoint is accomplished as follows.
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7.0 PRINCIPLES OF OPERATION
The alarm names and a brief description of each are described
indetail below.
HIGH TEMPERATURE ALARMWhen the thermal mass (glycol) temperature
reaches the alarm setpoint, the alarm will be activated. This alarm
condition may notnecessarily damage the dryer when subjected to
long-term exposure.It may, however, have a significant impact on
downstream processesand thus should be investigated upon detection.
Note that this alarmwill not shut down the dryer. This alarm will
activate the remote alarmcontact and reset automatically once the
alarm condition is rectified.
LOW TEMPERATURE SAFETY ALARMIf the dryer chiller temperature
falls below the factory set point, thealarm routine will activate.
This alarm condition may cause damage tothe dryer when subjected to
continuous or long-term exposure. Notethat this alarm will shut
down the dryer after a response time delay.This alarm will activate
the remote alarm contact and resetautomatically once the alarm
condition is rectified.
7.6.5 ALERT MESSAGESThe Controller features the following
readouts to communicate thestatus of the dryers operation.
EXCH.SET
Pressing EXCHANGER SETPOINT button will change the display
toshow the current setpoint.
36
Pressing the UP or DOWN arrows modifies the EXCHANGERSETPOINT in
one degree increment.
37
Pressing the UP or DOWN arrows modifies the EXCHANGERSETPOINT in
one degree increment.
38
The Controller accepts the last setpoint. After 5 seconds, the
readoutwill return to displaying the current Exchanger
Temperature.
38
a CAUTIONDo not set the Exchanger Temperature greater than 50
deg.F. Runningdryer at an Exchanger Temperature higher than 50
deg.F may damagerefrigeration system.
7.6.4 ALARMS AND THEIR FUNCTIONSThe Controller indicates
critical alarms to alert the user of anout of tolerance condition.
Once each alarm condition isdetected, the appropriate LED indicator
will illuminate and theremote alarm contact will close.
Alarm Display Alarm Set Point
HIGH TEMPERATURE ALARM HI TEMP ALARM EXCH SETPOINT + 10 F
LOW TEMPERATURE ALARM LOW TEMP ALARM 28 F
Indicates a probe failure. This conditionis usually caused by a
probe beingunplugged, damage to the probe lead ora defective
probe.
P F
Indicates that the refrigerant compressorwill not start until
the end of a threeminute safety delay. The display of cd
isimmediately followed by the number ofminutes left in the delay.
This is a normalfunction of the controller and not a
faultindication.
c d
7.6.6 START MODESThe NCV200-400 dryers are capable of starting
in one of thefollowing start modes:
7.6.6.1 Manual ModeAfter power is supplied to the dryer, the LCD
display willindicate the chiller temperature as well as the time
remainingfor the safety delay. Once the delay has timed
out,depressing the On/Off button will permit the
refrigerationsystem to operate. Should the chiller temperature be
greaterthan the set point, the refrigeration system will
energize.Should the chiller temperature be below the set point,
therefrigeration system will remain off until the chiller
temperaturerises to the setpoint.
7.6.6.2 Remote Mode (Optional)This mode of operation allows the
user to control the dryerremotely and requires the installation of
a customer-suppliedcontact. With power applied to the dryer and
once the safetydelay has timed out, the dryer will start once the
remote switchis closed. In addition, this mode of operation still
permitsmanual control of the dryer via the On/Off pushbutton on
thelocal control panel. Note that if the dryer was turned "On"from
the remote switch and then turned "Off" via the localcontrol panel,
the remote switch must be turned "Off" and then"On" to reinstate
the dryer.
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7.0 PRINCIPLES OF OPERATION
7.6.6.3 Auto RestartShould the dryer lose power while in the
"On" mode, the dryerwill revert to the "On" mode once power is
restored. Similarly,should power be removed from the dryer while
the dryer is inthe "Off" mode, the dryer will remain in the "Off"
mode oncepower is restored until the On/Off switch is depressed or
theremote switch is closed.
8.0 INSTALLATION AND INITIAL START-UP
8.1 LOCATION AND MOUNTINGThe dryer should not be located in an
area where ambient temperatureis likely to exceed 113F (45C) or be
less than 50F (10C). The dryermust be located in an area that
provides sufficient clearance from wallsand other adjoining
equipment to allow easy access for servicing andmaintenance
requirements. A minimum of 18 inches is required to allowfree flow
of air to the condenser inlet.
On installations with a relatively steady flow rate, the dryer
is normallyconnected after the air receiver. If loads fluctuate
widely, the dryershould be positioned ahead of the receiver and
sufficient storagecapacity downstream is necessary to prevent
excessive air flow throughthe dryer.
When installed after any compressor that causes significant
vibration orair pulsation, such as reciprocating compressors,
proper vibrationisolation and pulsation dampening devices should be
added to protectthe dryer.
a NOTICEFailure to comply to the above instructions may result
in equipmentmalfunction and will void warranty.
a NOTICEAlways use a backup wrench when making any threaded
connectionto the dryer. Failure to use a backup wrench may result
in damagedtubing and components internal to the cabinet.
8.2 PIPING AND VALVESInstall piping, fittings and accessories as
required for specific siteconditions and requirements. Figure 3
indicates a typical pipingarrangement for a refrigerated dryer,
including dryer and filter bypasses.This figure can be used as a
guide for valve and accessory placementin the system.
Ingersoll Rand NVC200-400 models come factory installed with a
drainisolation valve (D). The isolation valve permits maintenance
of theautomatic drain without isolating air flow to the dryer. To
operate dryer,all valves shown in Figure 3 are to be closed except
valves (B), (C) and(D). Valve (A) is used for bypass purposes and
valve (E) is for test andmanual drain purposes.
8.3 FILTRATIONTo protect the air dryer from gross contamination
associated withcompressor oil and debris and ensure maximum dryer
performance, apre-filter is recommended. Pre-filters and
post-filters sized to your dryingapplication can be provided by
Ingersoll Rand and are available factoryinstalled. Call your local
distributor to select the filter that best suits yourfiltration
requirements. In addition to air filtration, condensate
dischargeoil/water separators are also available to address
stringent EPAregulations.
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8.0 INSTALLATION AND INITIAL START-UP
FIGURE 3
TYPICAL PIPING ARRANGEMENT
8.4 ELECTRICAL CONNECTIONEquipment is available in various
electrical configurations. All customerconnections can be made at
the terminal connections located in thecustomer electrical
connection box on the rear of the dryer. (Refer toGeneral
Arrangement and appropriate Wiring Diagrams.)
A suitable fused disconnect switch or circuit breaker, in
accordance withnational and local code requirements, is recommended
for all IngersollRand equipment. Refer to Section 13 for voltage
requirements andload.
a CAUTIONNever wire directly or connect any additional wires to
the compressorjunction box. This will cause severe system
malfunction.
8.5 INITIAL START-UP
a NOTICEFor water cooled models, the water valve must be
manually opened toensure that the condenser is full of water prior
to start-up.
8.5.1 START- UP SEQUENCE Apply power to dryer. LCD Panel will
illuminate. The Anti-
Short Cycle delay will commence counting down.
a NOTICEAfter installation or a prolonged shutdown, start the
dryer with no airload (no air flow). This enables the dryer to
reach its proper operatingtemperature in the shortest time possible
(typically within 30 minutesfor Nirvana Cycling dryers).
Start Dryer, using one of the following methods, dependingon
Start Mode setting:
Manual Mode - Press the ON pushbutton.
Auto Restart Mode - No additional action required
Remote Automatic Mode - Close the remote contact.
AIRDRYER
OILSEPARATOR
DRAINVALVE
CHECKVALVE
CHECKVALVE
CHECKVALVE
DRAINVALVE
CHECKVALVE
PREFILTER
B
A
CAIR OUTAIR IN
UNIT AS DELIVERED
OPTIONAL ACCESSORY ITEMS
NOTE: DRAIN TUBE MUST NOT RISE OR BE CONNECTED TOEXCESSIVELY
LONG PIPE WHICH MAY CREATE BACK PRESSUREA CONNECTION TO OPEN FLOOR
DRAIN IS REQUIRED
DE
PRE-FILTER
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9.0 SCHEDULED MAINTENANCE
9.1 INTRODUCTIONIngersoll Rand Nirvana Cycling refrigerated air
dryers require littlemaintenance. These dryers utilize hermetically
sealed compressorswhich do not require any lubrication. Fan motors
require lubrication atboth oil ports every six months. Ingersoll
Rand recommends componentinspection and service at regular
intervals to obtain maximumperformance from your dryer.
9.2 REFRIGERANT CONDENSERFor standard dryers, regular inspection
and cleaning of the condenser isrecommended. Ingersoll Rand dryers
may be equipped with an optionalambient air filter designed to
protect the condenser from dirt and debristhat can accumulate on
the condenser. For proper operation with thisoption, it is
imperative that this filter be inspected and cleaned on aregular
basis. Annual replacement of the filter is recommended.
Forapplications where excessive dirt, dust or debris is
encountered, morefrequent inspection and cleaning may be
required.
8 9
9
5 6 7
1
6
2
4
1
3
108 9
5
7
1
3
24
9.3 CONDENSATE DISCHARGE SYSTEM
a WARNINGBefore drain maintenance work, always close the drain
isolation ballvalves 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)
orby undoing screws (8) at intermediate adapter (9) which is
then detached from the service unit by downward movement.
Check if new service unit (5) matches control unit (1)- type
designation and colour of latching hook (2)
Fit new service unit (5) in reverse order
Open drain isolation ball valve. Press drain test button to
verify properdrain operation.
2
1
3
4
567
-
11Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
9.4 PANEL FILTER ELEMENTAnnual replacement of the panel filter
element is recommended. Toreplace the panel filter element, remove
the panel filter by pulling up andout of its slots, then fit the
new element in.
9.5 PRE-FILTERS AND POST-FILTERS
a WARNINGDepressurize the system before disassembling filters.
Failure to do somay result in injury or death.
Filter elements should be changed as indicated on the
pressuredifferential gauge. Change carbon elements when
hydrocarbons arefirst detected downstream or every six months,
whichever comes first.
Certain filters contain multiple elements. When replacing filter
elements,all elements should be replaced simultaneously. Mixing new
and oldelements can result in reduced air quality.
9.5.1 THREADED FILTERS:
NO-LOSS DRAIN VALVE
GP,HE,DP 19-1380
?
2
5
4
3
2
1
6
43
1 Assembly Control unit onto service unit:
Check if service unit (3) matches control unit (1) (type
designation andcolour of latching hook)
Check if sensor tube plate (5) with contact springs (4) is
clean, dry and free from foreign matter.
Insert sensor (2) into sensor tube plate (5).
Fit latching hook (6) of control unit (1) into sensor tube plate
(5).
Press control unit (1) against service unit (3) and snap into
place
Open drain isolation ball valve. Press drain test button to
verify properdrain operation.
2
1
3
4
9.0 SCHEDULED MAINTENANCE
20(68)
30(86)
40(104)
50(122)
1,000
10,000
CF
`
AC19-1380
hrs
-
12 Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
9.0 SCHEDULED MAINTENANCE
1 2
1
11
2
4
5
67
1
23
34
21
3a 3b
1
21
2
5
2
1
3
4
16mm(5/8)
1
4
6 7
8 9
1
13
1
2 2
2
-
13Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
PROBLEM
Moisture down stream
Moisture down stream
SYMPTOM(S)
Dryer is properly cooling airstream (Check Chiller. Tempon
controller)
Inlet and outlet temperaturesare the same.
Inlet and outlet temperaturesare the same.
Compressor and fan arerunning, exchanger temphigh, pump not
running.
POSSIBLE CAUSE
Condensate drain failurecaused by defective serviceunit.
Excessive flow
Dryer by-pass valve notclosed
No power to the dryer
High suction pressure
Refrigerant leak
Compressor not running andfan is running
Compressor and fan notrunning.
Compressor and fan notrunning. Controller indicatescompressor is
ON.
Defective Pump
CORRECTIVE ACTION
Replace service unit.
Check inlet and outlet pressure and systemdesign capacity.
Correct cause of excessive flow.
Close by-pass valve
Check power supply and fuses/circuitbreakers
Check and clean condenser.
Check suction pressure gauge if reading is 0 psig, turn dryer
off and contact yourdistributor
Check and clean condenser.
Check ambient temperature and reducebelow 113F
Check Chiller Temperature
Check MAIN CONTROL fuse.
Compressor relay may be bad, replace relay
Check for loose wire connections atcontactor or loss of power at
control board
Defective control board - replace asnecessary
Contact your local distributor for furtherassistance.
Contact your local distributor for furtherassistance.
a WARNINGAn air dryer always operates under pressure. Any
maintenanceprocedure that involves disassembly of pipe fittings,
valves or anyother components requires the dryer be isolated from
the compressedair stream and fully depressurized.
a WARNINGPrior to working on the unit, make sure that all
circuit breakers ordisconnected switches are tagged Out of
Service.
10.2 PROBLEM / ACTION GUIDE
10.0 TROUBLESHOOTING
10.1 INTRODUCTIONIngersoll Rand Nirvana Cycling dryers are
designed for reliable, trouble-free operation. In the event of any
dryer malfunction, the guide belowhas been developed to facilitate
problem identification and corrective actions.
-
14 Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
10.0 TROUBLESHOOTING
PROBLEM
Apparent controller displaymalfunction
High pressure drop acrossdryer
Condensate drain does not fire
Condensate drain LED is off
Air bleed from condensatedrain outlet port
Condensate drain bowl doesnot seem to fill withcondensate, drain
does notseem to work due to airlocking
SYMPTOM(S)
Display Blank
Unrealistic temperaturedisplayed
Erratic or inaccuratetemperature readings
Unrealistic pressuredisplayed
Outlet pressure substantiallylower than inlet pressureSystem
operatingtemperature is above 32F
Outlet pressure substantiallylower than inlet pressureSystem
operatingtemperature is below 32F
POSSIBLE CAUSE
Blown Fuse
Board Failure
Probe loose,off connection ordefective probe
Probe not completely inthermal well
Defective probe
Transducer loose, offconnection or defectivetransducer
Inlet and outlet valves notcompletely open
Inlet and outlet filters blockedup
Compressor relay / contactorstuck.
Microprocessor Control relaybad
Probe not completely inthermal well
Problem persists
Inlet / outlet pipe internaldiameter too small causingair-lock
or back pressure.
Excessive use of bends /elbows in inlet / outlet pipework
causing air-lock/ backpressure.
Outlet pipe too long / toohigh causing back pressure.
More than one condensatesource connected providingalternative
path forcondensate.
Debris trapped under seal.Damage to seal.
CORRECTIVE ACTION
Check Fuses
Contact your local distributor for furtherassistance.
Inspect probe cable and terminal connectionReplace probe
Inspect probe and check readings againstindependent source (eg.
temperatureanalyzer/pyrometer/ice bath) both intemperature well and
to ambient
Replace probe
Inspect transducer cable and terminalconnection
Replace transducer
Open valves
Change filter elements
Replace relay / contactor.
Replace relay
Inspect probe and check readings againstindependent source (eg.
temperatureanalyzer/pyrometer/ice bath) both inexchanger well and
to ambient
Turn dryer off and consult your localdistributor for further
assistance
Check installation is in accordance with thismanual. Revise
installation accordingly.
Replace with larger diameter piping.
Reduce the amount of bends and elbows.
Reconfigure condensate piping.
Reroute condensate to eliminate secondarypath. Install check
valves as required.
Check power supply. Press test button forminimum 2 seconds and
observe. Locateand eliminate supply fault.
Press and hold the test button to clear (drainvalve will open).
Replace seal with ServiceKit.
If bottom inlet is used, top port must be usedas air bleed. Make
sure Connect the topinlet to a higher point in system, which
willfunction as an air bleed for the drain.
-
15Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
WH
T
RE
D
RE
D
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20
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TH
RU
38
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----
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5500
37
WIR
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MN
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11.0 WIRING DIAGRAMS
WIR
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DIA
GR
AM
NV
C20
0 A
IR A
ND
WAT
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CO
OLE
D23
0/1/
60, 2
20/1
/50
-
16 Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
11.0 WIRING DIAGRAMS
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X L
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S:
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57
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OF
OP
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NS
.
6.
----
----
DE
NO
TE
S O
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ION
AL
EQ
UIP
ME
NT
.
5500
31
WIR
ING
DIA
GRA
MN
VC20
0-40
0 A
IR A
ND
WA
TERC
OO
LED
208-
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/3PH
/60H
Z, 2
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3PH
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SE
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T
WH
T
RE
D
WHT
7.
ALT
ER
NA
TE
30
PO
WE
R L
EA
DS
MA
Y B
E B
LAC
K, R
ED
, WH
ITE
.
WIR
ING
DIA
GR
AM
NV
C20
0-40
0 A
IR A
ND
WAT
ER
CO
OLE
D20
8-57
5V/3
PH
/60H
Z, 2
00-4
40V
/3P
H/5
0HZ
-
17Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
CONT
ROL P
ANEL
COND
ENSA
TE D
RAIN
STAN
DARD
DRA
IN O
UTLE
T
LIFTI
NG B
ASE
WIT
HFO
RK LI
FT F
EATU
RE(R
EMOV
ABLE
)
AIR
OUTL
ET C
ONNE
CTIO
N1)
1 1/2
" MPT
FOR
200-
250 S
CFM
MODE
LS2)
2" F
OR 30
0-40
0 SCF
M MO
DELS
AIR
INLE
T CO
NNEC
TION
1) 1
1/2" M
PT F
OR 20
0-25
0 SCF
M MO
DELS
2) 2"
FOR
300-
400 S
CFM
MODE
LSCU
STOM
ER E
LECT
RICA
L CO
NNEC
TION
S AC
CESS
GLYC
OL P
UMP
ACCE
SS
AMBI
ENT
AIR
FILT
ER LO
CATI
ON(N
OT S
HOW
N)
WAT
ER C
OOLE
D IN
LET
CONN
ECTI
ON1/2
" FPT
FOR
250-
400 S
CFM
MODE
LS3/8
" FPT
FOR
200 S
CFM
MODE
LS
WAT
ER C
OOLE
D OU
TLET
CON
NECT
ION
1/2" F
PT F
OR 25
0-40
0 SCF
M MO
DELS
3/8" F
PT F
OR 20
0 SCF
M MO
DELS
OUTF
LOW
VAL
VEAD
JUST
MENT
ACCE
SS
MICR
OPRO
CESS
OR C
ONTR
OL(S
EE T
ECHN
ICAL
MAN
UAL F
OROP
ERAT
ION
DETA
ILS)
FRON
T VI
EWLE
FT S
IDE
VIEW
TOP
VIEW
RIGH
T SI
DE V
IEW
25.00
30.38
23.38
2.50
57.75
55.25
REAR
VIE
W
32.56
5500
30
28.12
2.38
51.19
12.0 GENERAL ARRANGEMENT
GE
NE
RA
LA
RR
AN
GE
ME
NT
NV
C20
0-40
0A
IR A
ND
WAT
ER
CO
OLE
D
-
Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
18
13.0 REPLACEMENT PARTS
Spare. Quantities under this heading reflect the number of each
item which we recommend be kept on hand for maintenance or repair.
The appropriate quantity for your application will depend on how
critical interruptions in service are to your operation.Class
Quantity Suggested for1 Minimum Domestic service where
interruptions in service are acceptable.2 Average Domestic service
where some interruptions in service are acceptable.3 Maximum Export
service or for domestic service where interruptions in service are
unacceptable.
QTY/ SPARES
CCN DESCRIPTION UNIT 1 2 3
38052197 BOARD, CONTROL 1 1 1 1
38052718 CONTACTOR, COMPRESSOR 1 1 1 1
22719421 DRAIN, CONDENSATE 1
38448239 DRAIN, SERVICE UNIT 1
38052916 DRYER, REFRIGERANT FILTER 1
38052437 PANEL FILTER ELEMENT 1
38054268 FUSE, TRANSFORMER PRIMARY 2 2 2 4
38052361 FUSE, TRANSFORMER SECONDARY (EXCEPT NVC200) 1 1 1 2
38052676 OVERLAY, CONTROL BOARD 1
38052908 PROBE, EXCHANGER TEMPERATURE 1 1 1 1
38052171 SWITCH, LOW REFRIGERANT PRESSURE 1
38053252 TRANSFORMER, CONTROL - 0.15 KVA (EXCEPT NVC200) 1
38052148 VALVE, DRAIN 1
38052320 VALVE, GLYCOL PUMP ISOLATION 1
MISCELLANEOUS PARTS
PARTS FOR AIR COOLED DRYERS
FAN MOTORSNVC NEMA 1 NEMA 4 NEMA 1 NEMA 4
MODEL CONDENSERS 230V 230V 460V 460V200 38053104 38053229
3854789 38446498 38446498300 38052700 38053229 3854789 38446498
38446498400 38052700 38053229 3854789 38446498 38446498
PARTS FOR WATER COOLED DRYERS
NVCMODEL CONDENSERS VALVES
200 38054581 38054623300 38450029 38054631400 38450029
38054631
COMPRESSORS
NVCMODEL 230/1/60 230/3/60 230/3/50 380/3/50 460/3/60
575/3/60
200 38446746 38054649 38054672 38450003 38450003 38450003300 -
38054656 38054680 38052288 38052270 38052270400 - 38054664 38054698
38054706 38052288 38052288
-
19Nirvana Cycling Refrigerated Dryer Models
200-400http://air.irco.com
MAXIMUM ALLOWABLE WORKING PRESSURE: 230 psig
a NOTICESpecification information above accurate at time of
publication. Refer to equipment serial labelfor actual refrigerant
charges and specifications for units.
14.0 ENGINEERING SPECIFICATIONS
AIR COOLED CONDENSERSWEIGHT R-404A MAX. FUSE
SIZEMIN. CIRCUIT
AMPACITYCOMPRESSOR RATINGS FAN RATINGS
MODEL NO. VOLTS/PH/HZ LBS. KG. LB-OZ KG. HP RLA LRA QTY HP RLA
LRANVC200 230/1/60 540 245 2-4 1.02 20 13.7 1 9.7 40 1 1/6 1
3NVC200 460/3/60 540 245 2-4 1.02 6 3.9 1 2.4 13 1 1/6 0.5
1.2NVC200 230/3/60 540 245 2-4 1.02 12 7.7 1 4.8 25 1 1/6 1 3NVC200
575/3/60 540 245 2-4 1.02 5 3.0 1 2.4 13 1 1/6 0.5 1.2NVC250
460/3/60 570 259 3-8 1.588 8 5.3 11/2 3.6 16 1 1/6 0.5 1.2NVC250
230/3/60 570 259 3-8 1.588 15 9.6 11/2 6.4 38 1 1/6 1 3NVC250
575/3/60 570 259 3-8 1.588 7 4.3 11/2 3.6 16 1 1/6 0.5 1.2NVC300
460/3/60 630 286 4-0 1.814 10 6.2 2 4.3 16 1 1/6 0.5 1.2NVC300
230/3/60 630 286 4-0 1.814 18 11.5 2 7.9 38 1 1/6 1 3NVC300
575/3/60 630 286 4-0 1.814 8 4.9 2 4.3 16 1 1/6 0.5 1.2NVC400
460/3/60 670 304 4-0 1.814 12 7.6 2 1/2 5.4 23 1 1/6 0.5 1.2NVC400
230/3/60 670 304 4-0 1.814 25 15.9 2 1/2 11.4 57 1 1/6 1 3NVC400
575/3/60 670 304 4-0 1.814 10 6.0 2 1/2 5.4 23 1 1/6 0.5 1.2
-
SECADORA REFRIGERANTE NIRVANA CYCLINGMODELOS 200-400
MANUAL DEL OPERADOR
C.C.N. : 80442775 FECHA : ABRIL DE 2007MOD. : B
Asegrese de que el operador lea y comprenda lascalcomanas y
consulte los manuales antes delmantenimiento o la operacin.
Asegrese de que el manual de operacin ymantenimiento no se saque
de la mquina.
Asegrese de que el personal de mantenimiento estadecuadamente
capacitado, sea competente y hayaledo los manuales de
mantenimiento.
a
-
1Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
NDICE PGINA
1.0 NDICE 12.0 INTRODUCCIN 23.0 GARANTA 24.0 NOMENCLATURA DE
LA
SECADORA REFRIGERANTE 25.0 RECEPCIN E INSPECCIN 35.1
INSPECCIN5.2 DESEMBALAJE Y MANIPULACIN6.0 PRECAUCIONES DE
SEGURIDAD Y OPERACIN 37.0 PRINCIPIOS DE
FUNCIONAMIENTO 57.1 INTRODUCCIN7.2 SISTEMA DE AIRE7.3 SISTEMA DE
ELIMINACIN
DE LA HUMEDAD7.4 SISTEMA DE REFRIGERACIN7.5 SISTEMA DE
CIRCULACIN
DE MASA TRMICA7.6 CONTROLES7.6.1 INTERFAZ DE USUARIO BSICA7.6.2
PUNTO DE REFERENCIA Y
ALARMAS DE TEMPERATURADEL INTERCAMBIADOR
7.6.3 AJUSTE DE LOS PUNTOS DE REFERENCIA
7.6.4 ALARMAS Y SUS FUNCIONES7.6.5 MENSAJES DE ALERTA7.6.6 MODOS
DE INICIO7.6.6.1 Modo manual7.6.6.2 Modo remoto (opcional)7.6.6.3
Reinicio automtico
NDICE PGINA
8.0 INSTALACIN Y PUESTAEN MARCHA INICIAL 8
8.1 UBICACIN E INSTALACIN8.2 TUBERAS Y VLVULAS8.3 FILTRACIN8.4
CONEXIN ELCTRICA8.5 PUESTA EN MARCHA INICIAL8.5.1 SECUENCIA DE
PUESTA
EN MARCHA9.0 MANTENIMIENTO
PROGRAMADO 109.1 INTRODUCCIN9.2 CONDENSADOR
DEL REFRIGERANTE9.3 SISTEMA DE DESCARGA
DE CONDENSADO9.4 ELEMENTO DE FILTRO
DEL PANEL9.5 PREFILTROS Y POSTFILTROS9.5.1 FILTROS ROSCADOS10.0
LOCALIZACIN DE FALLAS 1310.1 INTRODUCCIN10.2 GUA DE PROBLEMAS/
MEDIDAS11.0 DIAGRAMAS DE CABLEADO 1512.0 DISPOSICIN GENERAL
1713.0 PIEZAS DE REPUESTO 1814.0 ESPECIFICACIONES
DE INGENIERA 19
NDICE
-
La secadora de aire refrigerante Nirvana Cycling de Ingersoll
Randelimina la humedad, el vapor de aceite y otros contaminantes
del airecomprimido. Estos contaminantes provocan efectos adversos
en losaparatos, controles, instrumentos, mquinas y herramientas
operadosneumticamente. Esta eliminacin se logra mediante el
enfriamiento delaire con una unidad de refrigeracin a una
temperatura a la que la
2 Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
humedad en el aire se condensa y separa del flujo de aire.
Latemperatura a la que se enfra el aire, normalmente entre 34 y 38
F(1 y 3 C), se conoce como el punto de condensacin. Esta secadorase
puede instalar fcilmente en varios sistemas neumticos en loscuales
se requiere o desea aire seco. Consulte los Principios
defuncionamiento para obtener todos los detalles de
funcionamiento.
Ingersoll-Rand Company Limited garantiza que los equipos que
fabricay distribuye conforme a este documento estarn libres de
defectos tantode materiales como de mano de obra, durante un perodo
de docemeses desde la fecha en que los Equipos se ponen en
funcionamientoo de dieciocho meses desde la fecha de envo desde la
fbrica, lo quesuceda primero. El Comprador estar obligado a
informaroportunamente y por escrito a la Compaa de cualquier tipo
deincumplimiento de las condiciones de esta garanta dentro de
dichoperodo, y la Compaa corregir, a su discrecin, dicho
incumplimientoreparando el equipo en forma apropiada, o
proporcionar una pieza derepuesto F.O.B. en el punto de embarque,
siempre y cuando elComprador haya almacenado, instalado, mantenido
y operado dichosEquipos en conformidad con las buenas prcticas
industriales y hayacumplido con las recomendaciones especficas de
la Compaa. Losaccesorios o equipos que proporcione la Compaa pero
que fabriquenterceros, mantendrn cualquier garanta que los
fabricantes hayantraspasado a la Compaa y que se pueda transferir
al Comprador. LaCompaa no ser responsable de reparaciones,
reemplazos o ajustesa los Equipos ni de ningn tipo de costo por
mano de obra en queincurra el Comprador u otras personas que no
cuenten con la previaautorizacin por escrito de la Compaa.
Se excluyen especficamente de esta garanta los efectos de
lacorrosin, erosin y del desgaste normal. Las garantas
decumplimiento se encuentran limitadas a las que se
indicanespecficamente dentro de la propuesta de la Compaa. A menos
quela responsabilidad de cumplir tales garantas de rendimiento
se
encuentre limitada a pruebas especficas, la obligacin de la
Compaaser corregirla de la manera y dentro del plazo
estipuladoanteriormente.
LA COMPAA NO OTORGA NINGN OTRO TIPO DE GARANTA NIREALIZA NINGUNA
DECLARACIN, EXPRESA O IMPLCITA, SALVOLA DEL TTULO, Y POR MEDIO DE
ESTE DOCUMENTO SE NIEGANTODAS LAS GARANTAS IMPLCITAS DE
COMERCIABILIDAD EIDONEIDAD PARA UN FIN EN PARTICULAR.
La correccin de los incumplimientos por parte de la Compaa,
seanpatentes o latentes, en la forma y el plazo estipulado
anteriormente,debern constituir el cumplimiento de todas las
responsabilidades de laCompaa, para aquellos incumplimientos que se
basen ya sea en elcontrato, negligencia de la garanta,
indemnizacin, responsabilidadabsoluta u otros relativos a o que se
deriven de dichos Equipos.
El Comprador no operar los Equipos que se consideren
defectuosos,sin notificar por escrito primeramente a la Compaa de
su intencin dehacerlo. Cualquier uso tal de los Equipos ser bajo el
riesgo yresponsabilidad exclusivos del Comprador.
Observe que sta es una garanta estndar de Ingersoll
Rand.Cualquier garanta vigente al momento de la compra del equipo o
quese haya negociado como parte de la orden de compra podr
tenerprecedencia sobre esta garanta.
2.0 INTRODUCCIN
3.0 GARANTA
4.0 NOMENCLATURA DE LA SECADORA REFRIGERANTE
FLUJO NOMINAL * TIPO DE
PREFIJO (SCFM) CONDENSADOR ENERGA CLASIFICACINNVC 200-400 A =
AIRE 2 = 230-1-60 0 = NEMA 1
W = AGUA 4 = 460-3-60 H = NEMA 45 = 230-3-606 = 575-3-607 =
380-3-508 = 220-3-50
* Los flujos nominales que se indican son para una temperatura
de entrada de 100 F, una temperatura ambiente de 100 F y una presin
deaire comprimido de 100 psig.
-
3Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
5.1 INSPECCINAl recibir su secadora de aire Ingersoll Rand,
revise la unidaddetenidamente. Si detecta una manipulacin
descuidada, haga laobservacin en su recibo de entrega,
especialmente si la secadora nose desembalar inmediatamente. Es
recomendable obtener la firma dela persona que entregue el producto
por cualquier dao que puedaobservar a fin de facilitar cualquier
reclamacin de seguros.
5.2 DESEMBALAJE Y MANIPULACIN
a ADVERTENCIANinguna persona debe tratar de levantar objetos
pesados sin losequipos adecuados para este fin (es decir, gras,
montacargas,eslingas u horquillas elevadoras) bajo ninguna
circunstancia. Ellevantamiento de cualquier unidad sin los equipos
adecuados puedecausar lesiones graves.
5.0 RECEPCIN E INSPECCIN
Para facilitar la manipulacin durante el envo, todos los
paquetes desecadoras se han instalado sobre una base que
proporciona ranuraspara montacargas de horquilla entre dos canales
base. Las horquillasse deben extender a lo largo de los canales
para montacargas dehorquilla a fin de reducir las fuerzas
innecesarias en la secadoradurante su traslado. Se pueden usar
eslingas para levantar las cajas detransporte, pero se deben usar
barras separadoras para evitar que laseslingas ejerzan fuerza
contra los costados de las cajas de transporte ola secadora.
6.0 PRECAUCIONES DE SEGURIDAD Y OPERACIN
Debido a que una secadora de aire est presurizada y contiene
piezasgiratorias, se deben tomar las mismas precauciones como
concualquier maquinaria de este tipo, ya que el descuido en la
operacin yel mantenimiento puede ser peligroso para el personal.
Adems de lasnormas lgicas de seguridad que se deben seguir con este
tipo demaquinaria, se deben tomar las siguientes precauciones de
seguridad:
1. Slo se permitir que personal calificado ajuste,
realicemantenimiento o repare esta secadora de aire.
2. Lea todas las instrucciones completamente antes de operar
launidad.
3. Accione el interruptor principal de desconexin elctrico
ydesconecte todas las lneas de control separadas, si se usan,
antesde trabajar en la unidad o realizar mantenimiento en ella.
4. No intente realizar mantenimiento en ninguna pieza mientras
lamquina est en funcionamiento.
5. No intente sacar ninguna pieza sin antes aliviar la presin de
todo elsistema de aire.
6. No intente sacar ninguna pieza del sistema de refrigeracin
sineliminar y almacenar el refrigerante en conformidad con
lasnormativas de EPA y locales.
7. No opere la secadora con presiones superiores a su rgimen.8.
No opere la secadora sin las protecciones, blindajes y rejillas en
su
lugar.9. Inspeccione la unidad a diario para observar y corregir
cualquier
condicin de funcionamiento insegura.
OSHADescripciones del encabezado
a ADVERTENCIA"Advertencia" se usa para indicar una situacin
peligrosa con algunaprobabilidad de muerte o lesin grave.
Advertencia no debeconsiderarse para accidentes que provoquen daos
a la propiedad, amenos que exista riesgo de lesin personal.
a PRECAUCION"Precaucin" se usa para indicar una situacin
peligrosa que puedeprovocar lesiones menores o moderadas.
a AVISO"Aviso" se usa para indicar una declaracin de la poltica
de lacompaa, si el mensaje tiene relacin directa o indirecta con
laseguridad del personal, o la proteccin de la propiedad. Aviso no
sedebe asociar directamente con un peligro o una situacin peligrosa
yno se debe usar en lugar de "Peligro", "Advertencia" o
"Precaucin".
a AVISOPor medio de este documento se le advierte al usuario de
cualquiersecadora de aire fabricada por Ingersoll Rand que el
incumplimientode las Precauciones de seguridad y operacin
anteriores puedeprovocar lesiones personales o daos a los equipos.
Sin embargo,Ingersoll Rand no declara como hecho ni pretende
implicar que la listaanterior de Precauciones de seguridad y
operacin sea exhaustiva, nitampoco que su cumplimiento evitar todas
las lesiones personales ylos daos a los equipos.
-
Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
4
6.0 PRECAUCIONES DE SEGURIDAD Y OPERACIN
El aire bajo presin provocar lesiones, la muerte o daos a la
propiedad. No exceda la capacidad nominal de presin. Libere la
presin antes de realizar mantenimiento. No
modifique/repare/reprocese recipientes a presin con cdigo ASME ya
que eso afecta la tarificacin de seguros.
LEA EL MANUAL TCNICO
ADVERTENCIA
CAJA DE CONEXIONES ELCTRICASTodas las conexiones del cliente se
deben realizar en esta ubicacin.Consulte los diagramas de conexin
del terminal que se encuentran a continuacin.Asegrese de respetar
todos los cdigos NEC, estatales, locales y otros cdigos
correspondientes durante la instalacin.
1
2
3
4
5
6
VERDE
BLANCONEGRO
GN
L1
CABLEADO DE FBRICA
VOLTAJE DE LNEA
DE ENTRADA100 a 125 V CA1 PH/50 a 60 HZ(DE TERCEROS)
(CONSULTE LA PLACA DE
IDENTIFICACIN PARA CONOCER LOS REQUISITOS
DE POTENCIA)
100-125 V CA/1 PH
1
2
3
4
5
6
VERDE
NEGRO
G
L1
ROJO L2
CABLEADO DE FBRICA
200-240 V CA/1 PH
1
2
3
4
5
6
VERDE
ROJOBLANCO
GL1
L2
NEGRO L3
CABLEADO DE FBRICA
200-575 V CA/3 PH
CAJA DE CONEXIONES ELCTRICASCONTIENE ALTO VOLTAJE
Corte la energa y bloquee TODAS las fuentes antes de abrirla
para realizar mantenimiento. El cableado de contacto de la alarma
remota posee control de encendido de una fuente separada.
LEA EL MANUAL TCNICO
ADVERTENCIA
VOLTAJE DE LNEA
DE ENTRADA200 a 240 V CA
1 PH/50 a 60 HZ(DE TERCEROS)
(CONSULTE LA PLACA DE
IDENTIFICACIN PARA CONOCER LOS REQUISITOS
DE POTENCIA)
VOLTAJE DE LNEA
DE ENTRADA200 a 575 V CA3 PH/50 a 60 HZ(DE TERCEROS)
(CONSULTE LA PLACA DE
IDENTIFICACIN PARA CONOCER LOS REQUISITOS
DE POTENCIA)
El aire bajo presin provocar lesiones, la muerte o daos a la
propiedad. Libere la presin antes de realizar mantenimiento. El
drenaje del condensado se descarga bajo presin. El drenaje requiere
de limpieza (mantenimiento) peridica.
LEA EL MANUAL TCNICO
ADVERTENCIA
Si se quitan los fusibles no se desconectar la energa de la
secadora. Desconecte siempre la energa desde TODAS las fuentes
antes de realizar el mantenimiento.
LEA EL MANUAL TCNICO
ADVERTENCIA
ALTO VOLTAJEADVERTENCIA
Esta unidad est cargada con refrigerante bajo alta presin.
ADVERTENCIA
EL VENTILADOR SE PUEDE ENCENDER AUTOMTICAMENTE
EN CUALQUIER MOMENTO
ADVERTENCIA
El cableado trifsico alterno puede ser negro/negro/negro.
-
Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
5
7.1 INTRODUCCINLas secadoras Nirvana Cycling de Ingersoll Rand
eliminan la humedaddel aire comprimido enfriando la temperatura del
aire a entre 34 y 38 F (1y 3 C). Esto provoca que los vapores se
condensen en gotitas de lquidoque se pueden eliminar fcilmente del
aire. Los principales sistemas de lasecadora que contribuyen a su
funcionamiento son el sistema de aire, elsistema de eliminacin de
la humedad, el sistema de refrigeracin, elsistema de circulacin de
masa trmica y los controles. Los siguientesprrafos describen cada
uno de los sistemas con mayor detalle.
7.2 SISTEMA DE AIREEl sistema de aire est constituido por los
componentes de la secadora queestn en contacto con el aire
comprimido. De acuerdo con la Figura 1 y con
7.0 PRINCIPIOS DE FUNCIONAMIENTO
la leyenda "FLUJO DE AIRE" en negrita, el aire saturado caliente
queproviene del compresor ingresa al preenfriador/recalentador, en
donde latemperatura del aire se reduce antes de ingresar al
refrigerador mediante elaire fro que sale del separador de
aire/humedad. Este preenfriamientopermite el uso de un sistema de
refrigeracin ms pequeo. El aire pasaluego a la seccin del
refrigerador en donde se enfra ms hasta alcanzar elpunto de
condensacin que desee mediante un lquido de masa trmica.
Latemperatura del lquido de masa trmica se mantiene mediante el
circuito derefrigeracin y los controles. El aire sigue hasta el
separador en donde seelimina la humedad, lo que permite que el aire
fro y seco vuelva alpreenfriador/recalentador para que reciba calor
del aire caliente hmedoentrante. El aire que sale de la parte del
"recalentador" de la secadora debetener aproximadamente 15 a 20 F
menos que la temperatura de aire deentrada basado en las
condiciones estndar a un flujo de velocidad mxima.
DIAGRAMA DE FLUJOFIGURA 1
7.3 SISTEMA DE ELIMINACIN DE LA HUMEDADLos drenajes de
condensado Ingersoll Rand descargan humedadcondensada y lubricantes
(condensado) de compresores de aire. Eldrenaje de condensado
funciona como un drenaje de cero prdida deaire, lo que devuelve el
aire que se desplaza en el recipiente de drenajeal sistema de aire
comprimido. La descarga adecuada del condensadode los compresores
de aire es esencial para el funcionamiento yrendimiento correcto
del equipo.
El drenaje de condensado usa un mtodo de deteccin exclusivo
paradeterminar el nivel de condensado en el recipiente de drenaje.
Untransductor que se ubica en el recipiente de drenaje
envaconstantemente una seal 50 veces por segundo. Luego de que
eltransductor determine que el nivel de condensado ha alcanzado
unnivel predeterminado dentro del recipiente de drenaje, se enva
unaseal a la vlvula de drenaje sin prdidas para que se abra.
Esteproceso permite la eliminacin de condensado en hasta 80 galones
porhora.
El drenaje tambin cuenta con un botn de prueba que permite
laoperacin manual de la vlvula de drenaje sin prdidas. Al presionar
elbotn de prueba se enciende el LED y se activa la vlvula
solenoide. ElLED se enciende para indicar "ENCENDIDO" y se apaga
cuando lavlvula de drenaje sin prdidas se acciona mediante el
transductor o elbotn de prueba manual.
El condensado circula por la tubera de alimentacin hacia la
unidad dedrenaje y se acumula en el contenedor. Un sensor
capacitivo registraconstantemente el nivel de lquido y enva una
seal al controlelectrnico, tan pronto se llena el contenedor. Luego
se activa la vlvulapiloto y el diafragma abre la tubera de salida
para descargar elcondensado. Cuando se ha vaciado la unidad de
drenaje, la tubera desalida se cierra de nuevo rpida y
hermticamente sin desperdiciar airecomprimido.
7.4 SISTEMA DE REFRIGERACINEl sistema de refrigeracin se compone
de todos los componentes quemanejan R-404A. ste es un sistema de
ciclo cerrado hermticamentesellado. De acuerdo con la Figura 1 y
siguiendo el circuito fantasma"FLUJO DE REFRIG. (R-404A)," el
refrigerante se muestra saliendo de laseccin del evaporador, en
donde, en el proceso de eliminacin delcalor, cambia de un lquido de
baja presin a un gas de baja presin.Este gas ingresa al lado de
succin del compresor en donde secomprime en un gas de alta presin.
El gas de alta presin se enfra enla seccin del condensador hasta
que se convierte en un lquido de altapresin. Luego pasa por una
secadora con filtro permanente quegarantiza que el sistema de
refrigeracin est libre de contaminantes.Un tubo capilar de dimetro
pequeo (vlvula de expansin ensecadoras enfriadas por agua) mide el
refrigerante para introducirlo enel evaporador. La presin del
refrigerante se reduce al ingresar alevaporador a medida que se
evapora y elimina el calor del lquido demasa trmica.
DIAGRAMA DEPROCESOS E
INSTRUMENTACINNVC200-400
ENFRIADO POR AIRE Y AGUA
-
6 Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
7.0 PRINCIPIOS DE FUNCIONAMIENTO
7.5 SISTEMA DE CIRCULACIN DE MASA TRMICAEl lquido de masa trmica
de una secadora Nirvana Cycling deIngersoll Rand circula
continuamente en un sistema de bomba decircuito cerrado. De acuerdo
con la Figura 1 y con la lnea a rayas"LQUIDO TRMICO", se elimina el
calor del lquido en el evaporador pormedio del sistema de
refrigeracin. El tamao del depsito de masatrmica est diseado para
minimizar los ciclos de refrigeracin duranteperodos de carga de
aire reducida. El lquido de masa trmica seextrae de la parte
inferior del depsito y se bombea por el refrigerador,lo que elimina
el calor del aire y luego regresa al evaporador. La bombaque se
utiliza en la secadora Nirvana Cycling de Ingersoll Rand esuna
bomba de circulacin de cartucho silencioso que no
requieremantenimiento similar a las que se usan en redes
hidrulicasresidenciales. Si bien el sistema de refrigeracin realiza
ciclos deencendido y apagado basndose en las condiciones de carga,
la bombade circulacin funciona de manera continua para mantener el
flujo porel refrigerador en todo momento. Observe que cuando el
interruptor deencendido se ajuste en la posicin de apagado, no
funcionar la bombade circulacin.
7.6 CONTROLESLas secadoras Ingersoll Rand de la serie NVC200-400
incorporancontroles automticos para su funcionamiento adecuado.
Latemperatura del lquido de masa trmica se mantiene mediante
uncontrol de microprocesador que controla la temperatura y realiza
losciclos del sistema de refrigeracin en respuesta al flujo y la
temperaturavariables del aire. Al aumentar la temperatura del
lquido de masatrmica, el compresor de refrigeracin realiza un ciclo
de encendido.Cuando el lquido se enfra a dos grados F menos de su
punto dereferencia de control, el compresor refrigerante realiza un
ciclo deapagado. El lquido de masa trmica funciona como una masa
dealmacenamiento trmico en la secadora de la serie NVC.
Se proporciona un interruptor de desconexin por baja presin
(LPCO,por sus siglas en ingls) para todas las secadoras de la serie
NVC. Esteinterruptor est ajustado en fbrica en 20 psig. Si la
presin de succinde refrigerante consume menos de 20 psig, el LPCO
se abre para cerrarel compresor refrigerante. Luego de que se haya
abierto el interruptor,impedir que funcione el compresor hasta que
la presin de succinaumente a ms de 60 psig y se haya reiniciado
manualmente el LPCO.
Todas las unidades enfriadas por agua vienen con un interruptor
dedesconexin por alta presin (HPCO, por sus siglas en ingls).
Esteinterruptor est ajustado para que se abra a 320 psig y se
cierre a 270psig. Para compensar la variacin de la temperatura del
agua, esposible que sea necesario ajustar la vlvula de regulacin de
agua paramantener una presin de descarga de 250 psig. El ajuste se
puederealizar girando el tornillo de ajuste en el sentido contrario
al de lasagujas del reloj para aumentar la presin de descarga.
Paracondiciones en donde se espere una baja temperatura del agua o
unaalta presin del agua, se aconseja instalar un regulador de
presin deagua delante del condensador.
7.6.1 INTERFAZ DE USUARIO BSICAEl controlador proporciona al
usuario informacin sobre elfuncionamiento y las alarmas de la
secadora.
La siguiente ilustracin resume las funciones del teclado.
BOTONES
ON / OFF (Encendido/Apagado)Alterna el funcionamiento de la
secadora entre los estados "en lnea" y "fuerade lnea"; activa la
bomba de glicol. Observe que el sistema de refrigeracinfuncionar
basndose en la temperatura.
EXCH SET (Punto de referencia del intercambiador)Cuando se
presiona, mostrar el punto de referencia actual delintercambiador
en la ventana LCD. Mientras se muestre el punto dereferencia del
intercambiador, las flechas hacia arriba y hacia abajo sepueden
usar para aumentar o disminuir la temperatura del punto de
referenciadel intercambiador.
ALARM RESET (Reinicio de la alarma)Si se presiona una vez,
elimina la indicacin de alarma local y desactiva elcontacto de la
alarma remota. Si la condicin de alarma persiste, la alarmavolver a
aparecer luego de que expire el tiempo de inhibicin de la
alarma.
% SAVINGS (% de ahorro)Si se presiona una vez, cambia la
visualizacin del LCD para indicar larelacin del tiempo de
funcionamiento del sistema de refrigeracin con eltiempo de
encendido total de la secadora.
F / CAlterna los indicadores de temperatura del LED entre
unidades de medidaFahrenheit y Celsius.
+ / -Permiten que el usuario modifique los valores de punto de
referencia. Losvalores de punto de referencia varan dentro de un
rango fijo.
LUCES
Pantalla LCDMuestra la temperatura del intercambiador durante el
funcionamiento normal.Tambin se usa para mostrar el punto de
referencia de temperatura delintercambiador, la condicin de alarma
y las funciones de sincronizacin.
SYSTEM ENERGIZED (Sistema activado)Indica que se alimenta energa
a la unidad.
DRYER ON (Secadora encendida)Se enciende cuando se ha presionado
el interruptor de encendido/apagadopara poner la unidad en
funcionamiento. El sistema refrigerante se puedeiniciar en
cualquier momento cuando la luz est encendida.
REFRIGERATION COMPRESSOR ON (Compresor de
refrigeracinencendido)Indica que est en funcionamiento el sistema
de refrigeracin.
DEGREE F/DEGREE C (Grados F/Grados C)Indica las unidades de
medida de temperatura.
HIGH TEMP ALARM (Alarma de alta temperatura)Indica que la
temperatura del intercambiador ha subido a 10 F o 5 C porsobre el
punto de referencia de temperatura del intercambiador.
LOW TEMP ALARM (Alarma de baja temperatura)Cuando se activa,
indica que la temperatura del intercambiador ha bajado amenos de 29
F o -2 C. Esta condicin detiene el compresor. El compresorno se
reiniciar hasta que la temperatura haya subido dos grados por
sobreel punto de referencia del intercambiador.
TORNILLO DE AJUSTE
FIGURA 2VLVULA DE REGULACIN
DE AGUA
-
7.6.2 PUNTO DE REFERENCIA Y ALARMAS DETEMPERATURA DEL
INTERCAMBIADOREl controlador permite al usuario configurar el punto
dereferencia de temperatura del intercambiador de la secadorapara
funcionar de acuerdo con las condiciones del lugar. Elcontrolador
se enva desde fbrica con la temperatura delintercambiador en un
valor predeterminado de 38 grados.
7.6.3 AJUSTE DE LOS PUNTOS DE REFERENCIAEl acceso y la
manipulacin del punto de referencia detemperatura del
intercambiador se hacen de la siguientemanera.
7Secadora refrigerante Nirvana Cycling Modelos
200-400http://air.irco.com
7.0 PRINCIPIOS DE FUNCIONAMIENTO
Los nombres de las alarmas y una descripcin breve de cada una
deellas se indican a continuacin.
ALARMA DE ALTA TEMPERATURACuando la temperatura de la masa
trmica (glicol) alcance el punto dereferencia de la alarma, se
activar la alarma. Puede que estacondicin de alarma no dae
necesariamente la secadora cuando estsujeta a una exposicin
prolongada. Sin embargo, puede tener unimpacto significativo en los
procesos descendentes, por lo que sedebe investigar en el momento
de detectarla. Observe que estaalarma no apagar la secadora. Esta
alarma activar el contacto de laalarma remota y se reiniciar
automticamente luego de que serectifique la condicin de la
alarma.
ALARMA DE SEGURIDAD DE BAJA TEMPERATURASi la temperatura del
refrigerador de la secadora baja a menos delpunto de referencia de
fbrica, se activar la rutina de alarma. Puedeque esta condicin de
alarma dae la secadora cuando est sujeta auna exposicin prolongada
o continua. Observe que esta alarmaapagar la secadora despus de un
retardo de tiempo de respuesta.Esta alarma activar el contacto de
la alarma remota y se reiniciarautomticamente luego de que se
rectifique la condicin de la alarma.
7.6.5 MENSAJES DE ALERTAEl controlador cuenta con las siguientes
lecturas para comunicar elestado de funcionamiento de la
secadora.
EXCH.SET
Si se presiona el botn EXCHANGER SETPOINT, cambiar lapantalla
para mostrar el punto de referencia actual.
36
Si se presionan las flechas HACIA ARRIBA o HACIA ABAJO
semodifica el PUNTO DE REFERENCIA DEL INTERCAMBIADOR enincrementos
de un grado.
37
Si se presionan las flechas HACIA ARRIBA o HACIA ABAJO
semodifica el PUNTO DE REFERENCIA DEL INTERCAMBIADOR enincrementos
de un grado.
38
El controlador acepta el ltimo punto de referencia. Despus de 5
segundos, la lectura volver a mostrar la temperatura actual del
intercambiador.
38
a PRECAUCIONNo ajuste la temperatura del intercambiador a ms de
50 grados F. Sise hace funcionar la secadora con una temperatura
del intercambiadormayor que 50 grados F puede daar el sistema de
refrigeracin.
7.6.4 ALARMAS Y SUS FUNCIONESEl controlador indica las alarmas
crticas que deben alertar alusuario de una condicin fuera de
tolerancia. Luego de quese detecte cada condicin de alarma, se
encender elindicador LED correspondiente y se cerrar el contacto de
laalarma remota.
Alarma Pantalla Punto de referencia de alarma
ALARMA DE ALTATEMPERATURA HI TEMP ALARM
PTO. DE REF. DELINTERCAMBIADOR + 10 F
ALARMA DE BAJATEMPERATURA LOW TEMP ALARM 28 F
Indica una falla de la sonda. Esta condicinnormalmente se
produce cuando sedesenchufa una sonda, se daa elconductor de la
sonda o una sondapresenta defectos.
P F
Indica que el compresor refrigerante no seiniciar hasta el final
de un retardo deseguridad de tres minutos. Aparece "cd" enpantalla
e inmediatamente despus, elnmero de minutos que quedan del
retardo.sta es una funcin normal del controlador yno una indicacin
de falla.
c d
7.6.6 MODOS DE INI