Manual Secador de Aire Ingersolrand

D12IN to D480IN
Refrigerated Dryers
D-IN Dryers Service Manual Page 1

Ingersoll Rand Global Service Education Team
Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information

THIS PAGE IS LEFT INTENTIONALLY BLANK


CONTENTS
1. SAFETY INFORMATION 4
2. REFRIGERATION CIRCUITS 5
D12IN - D180IN
D180IN 6
D240IN - D480IN
D480IN 6
3. COMPONENT REVIEW 7
4. ELECTRICAL CIRCUITS 9
D12IN to D72IN (230v/1Ph/50Hz) 10
10
D108IN to D180IN (230v/1Ph/50Hz) 11
11
D240IN (230v/1Ph/50Hz) 12
12
D300IN to D380IN (230v/1Ph/50Hz) 13
13
D480 (230v/1Ph/50Hz) 14
14
D12IN to D72IN (115v/1Ph/60Hz) 15
15
D108IN to D180IN (115v/1Ph/60Hz) 16
16
D300IN to D380IN (230v/1Ph/60Hz) 17
17
5. D12IN to D480IN CONTROLLER 19
General Description 20
20
Automatic Re-start After Power Outage 21
21
LED Display 21
21
Functionality Of The Keys 22
22
Autotest Function 22
22
Condensate Discharge Parameters 23
23
Modification Of The Parameters 23
23
Description Of The Parameters 26
6. REPLACING THE CONTROLLER 28
Calibration Of the Temperature Probe D240IN - D480IN 29
29
7. WARNINGS 30
ESA 30
30
ES2 30
30
8. ALARMS 31
HtA 31
31
Ht2 31
31
PF1 33
33
ASt 35
35
9. DEHYDRATION AND EVACUATION PROCEDURE 35
10. KTY81-121 RESISTANCE CHART 37
11. PRESSURE / TEMPERATURE CHARTS (R134a) 39
Bara/ºC 40
40
Psig/ºF 41
41
12. DEFAULT CONTROLLER SETTINGS 43
50Hz Models 44
44
60Hz Models 45
13. CORRECTION FACTORS 46
46
14. TECHNICAL DATA SHEETS 49
50Hz Models 49
49
60 Hz Models 63
63
15. MATERIAL SAFETY DATA SHEETS (R134a) 83


1. SAFETY
Important:
Do not operate this equipment until the safety information and instructions in this
user guide have been read and understood by all personnel concerned. Only com-
petent personnel trained, qualified, and approved by Ingersoll Rand should perform
installation, commissioning, service and repair procedures.
Use of the equipment in a manner not specified within this user guide may result in
an unplanned release of pressure, which may cause serious personal injury or dam-
age. When handling, installing or operating this equipment, personnel must employ
safe engineering practices and observe all related regulation, health & safety proce-
dures, and legal requirements for safety. Ensure that the equipment is depressur-
ized and electrically isolated, prior to carrying out any of the scheduled maintenance
instructions specified within this user guide. Most accidents that occur during the
t he op-
eration and maintenance of machinery are the result of failure to observe basic
safety rules and procedures.
Accidents can be avoided by recognizing that any machinery is potentially hazard-

ous. Ingersoll Rand can not anticipate every possible circumstance which may rep-
resent a potential hazard. The warnings in this manual cover the most known poten-
tial hazards, but by definition can not be all-inclusive. If the user employs an operat-
ing procedure, item of equipment or a method of working which is not specifically
recommended by Ingersoll Rand the user must ensure that the equipment will not
be damaged or become hazardous to persons or property.
BEFORE SERVICING OR DISMANTLING ALL PRESSURE MUST BE

RELEASED FROM THE SYSTEM AND ITS ASSOCIATED PIPEWORK AND
ANY ELECTRICAL SUPPLY ISOLATED
I SOLATED..
Grounding
Improper grounding can result in electrical shock and can cause severe injury or
death.
This product must be connected to a grounded, metallic, permanent wiring system
or an equipment-grounding terminal.
All grounding must be performed by by a qualified electrician and comply with nnational
ational
and local electrical codes.
In the event of an electrical short circuit, grounding reduces the risk of electric shock
by providing an escape path for the electric current.
Ground must be established with a grounding wire sized according to the voltage
and minimum branch circuit requirements.
Ensure good bare metal contact at all grounding connection points, and ensure all
connections are clean and tight.
Check grounding connections after initial installation and periodically thereafter to
ensure good contact and continuity has been maintained.
Check with a qualified electrician or service technician if the grounding instructions
are not completely understood, or if in doubt as to whether the product is properly
grounded.


2. REFRIGERATION
CIRCUITS


Models D12IN to D180IN
Models D240IN to D480IN


3. COMPONENT REVIEW D12IN – D480IN
1M1
Refrigerant Compressor.
1M2
Condenser Fan Motor.
CND
Condenser.
1P1
High Pressure Switch. This switch protects the refrigeration system in the event of
an overpressure condition within the refrigeration circuit. This switch is set to 30 bar
( 435 psi )
FF
Dryer Filter.
CPL
Capillary Tube.
EVA
Evaporator. (See Air to Air and Refrigerant to Air Exchanger, Page 8)
SCO
Condensate Separator.
1V1
Solenoid Drain Valve. (230vac for 50hz models, 115vac for 60htz models)
PR
Air-to-Air Heat Exchanger.
RBF
Tap with Strainer ( D240IN to D480IN Only ).
VB
Hot Gas By-Pass Valve ( D240IN to D480IN Only ).
The HGBP valve should be set to maintain between 2.1 - 2.2 barg (30 - 32 psig),
depending on site and ambient conditions. As the a air
ir compressor modulates or
goes online/offline, the compressed air capacity entering the dryer fluctuates. It
should be noted that dryer loading can apply not only to capacity changes but ther-
mal load changes due to varying conditions. The dryer must be able to adjust to
these varying capacities and maintains performance. All models perform within a
wide range of ambient and compressed air temperatures, ensuring optimum per-
formance whatever the application if properly sized for the application.
application. In D-IN/T
dryers, refrigerant constantly flows through the evaporator. The flow varies depend-
ent on the percentage of rated air capacity flowing through the dryer. See page 29
for correct adjustment procedures.


Air to Air and Refrigerant to Air Exchanger

All D-IN dryers utilise an air to air and air to refrigerant heat exchanger horizontally
mounted on units D12IN - D180IN and a vertically mounted on models D240IN and
above (see illustration.
illustration. The air-to-air heat exchan
exchangerger pre-cools the incoming air and
re-heats the outgoing air, giving a high overall efficiency. This cools the incoming
compressed air, reducing the amount of refrigeration energy needed to dry the com-
pressed air. The re-heater section raises the temperature of the outgoing com-
pressed air, protecting the dew point, decreasing the relative humidity and eliminat-
ing condensation on downstream air piping.
Air to Air Heat

Exchanger
Air to Refrigerant
D Heat Exchanger
A large expansion chamber slows the compressed air down to its critical velocity,
forcing moisture to condense. This design ensures maximum separator efficiency
across the entire flow range. Liquid water in the air is removed by a high efficiency
demister separator.


4. ELECTRICAL
CIRCUITS


Models D12IN to D72IN (230v/1Ph/50Hz)






Models D240IN (230v/1Ph/50Hz)






Models D480 (230v/1Ph/50Hz

( 230v/1Ph/50Hz)
)








Models D300IN
D300IN to D360IN (230v/1Ph/60Hz)




5. D12IN to D480IN
CONTROLLER


Controller D12IN to D480IN
5.1 GENERAL DESCRIPTION
The controller controls all relative procedures in starting and stopping the refrigerant
compressor. The controller will display in °C or °F. The controller checks the ma-
chine and returns diagnostic information in the presence of a malfunction.
The controller also monitors the evaporation temperature via a highly sensitive tem-
perature probe this allows the c
controller
ontroller to govern the condenser fan motor speed.
speed.
A patented microprocessor allows dryer’s cooling capacity

capacity to be adjusted, by chang-
ing the fan motor speed. The controller will vary the speed of the condenser fan
based on the actual evaporator temperature and the programmed evaporator Set-
point. The default value for the Setpoint is 0.5ºC (32.9ºF) if the evaporator
temperature is below the setpoint the condensor fan will be off, if the temperature
rises above the setpoint the controller will firstly energise the fan for 0.5 seconds
(Models D12IN to D180IN) or 2 seconds (Models D240IN and above), then switch to
alogarithic control.
When operating in alogarithmic control the controller sends a series of ‘wave trains’
or pulses to the fan the quicker the frequency of the series of pulses the faster the
fan will rotate. The controller constantly mointors evaporator temperature and
adjusts the frequency of the wave trains accordingly to maintain the correct
temperature.


It is important to note that unlike inverter or other VSD drives neither the voltage or
hertz frequency of the electrical signal to the fan changes. It is the frequency and
length of the pulses or ‘wave trains’ that change the fan speed.
In models D240IN to D480IN, in order to greater adjust the dryer’s cooling capacity,
a hot gas by-pass valve cooperates with the
t he variable speed system.
5.2 Automatic Re-start After Power Outage
All D-IN/T dryers will automatically restart after power failure providing the dryer
dr yer was
running without a HTA, HT2 or ASt alarms. Please note there will be a two minute
delay before the dryer restart after power has be restored.
Attention: Automatic restart after power outage cannot be disabled from the con-
Attention:
troller, if it is a requirement for the dryer not to automatically re-start after power fail-
ure. The dryer must be connected to a suitable device with a manual reset that will
trip on power loss.
5.3 LED DISPLAY

DISPLAY DESCRIPTION
the unit is ON with low load and the measured temperature is

less than -1ºC
the unit is ON with normal load and the measured temperature is
between -1ºC and +4ºC
the unit is ON with normal-high load and the measured tempera-
ture is between +4ºC and +8ºC
the unit is ON with high load and the measured temperature is
above +8ºC
Dryer is turned off
LED STATUS DESCRIPTION
ON Compressor Is Energised
Flashing Programming Mode Activated
ON Condensate Drain Is Energised
ON Speed of The Fan = 100%
Flashing Speed Of The Fan < 100%

OFF Fan Not Running


5.4 FUNCTIONALITY OF THE KEYS
TEST:
When pressed for 3 sec. during normal operation, it will activate the condensate
drain.
SET:
When pressed
value in decimaland
thereleased during
default value normal(32.9ºF)
is 0.5ºC operation, it displays the evaporator set
When pushed for 10 seconds, it allows the user to change the C8 and C9 conden-
sate drain parameters programming menu (see relevant table).
When pushed after having set new configuration values, it stores the applied modifi-
cations.
DOWN:
When pressed while setting the drain set point, it decreases the displayed value of
one unit per second, during the first 10 seconds, then one unit every 0,1 sec.
When pushed for 10 seconds during normal operation, it starts an automatic test cy-
cle of the controller.
UP:
When pressed while setting the drain set point, it increases the displayed value of
one unit per second, during the first 10 seconds, then one unit every 0,1 sec.
ON / OFF:
When pressed for 1 second, it activates or deactivates the dryer. When the dryer is
deactivated, the LED display will read OFF.
NOTE:
When the controller is in the OFF position, some parts of the dryer
may still be energized. Therefore, for safety purposes, disconnect
the electrical power before performing any operation on the unit.
5.5 AUTOTEST FUNCTION
An auto test function allows the user to test the functionality of the controller and the
components connected to it, the test is performed by pressing the DOWN button for
10 seconds the testing procedure is as follows:-
f ollows:-
The controller will first test the small LED’s, then test in sequence outputs to the
compressor, condensate drain, condenser fan then the alarm output (if fitted). It will
then illuminate all the characters on the LED character display, and finally display
the firmware version of the controller. e.g. d10 = firmware version 1.0. If, whilst dis-
play the firmware a key is pressed then the display will show F1 through to F5 de-
pendant on which key is pressed. If after 5 seconds no key is pressed once the LED
has displayed the firmware version, the controller will revert back to standard opera-
tion.

5.6 CONDENSATE DISCHARGE PARAMETERS.
During normal operation only access to parameters C8 (Condensate close time) and
C9 (Condensate open time) is allowed, access to all other parameters is
i s disabled.
To change the condensate drain parameters push the SET key for 10 seconds to
enter the parameters configuration menu: the display will show in sequence the set
point value, the code of the first modifiable parameter (C8) and its value.
Only if strictly necessary, use the UP and/or DOWN keys to change the displayed
parameter value.
Press the SET key to store the previously changed parameter value or to browse
the parameters without changing them.
15 seconds after the last performed operation, the controller will return automatically
to the normal operation mode.
Parameter Description Range Default Value
C8 Condensate Drain Close 1 to 999 1

Time (minutes)
C9 Condensate Drain Open 1 to 999 D12-144IN D180IN D240-480IN
Time (seconds) 1 2 3
5.7 MODIFICATION OF THE PARAMETERS
To gain access to all parameters press the UP and DOWN keys together for 5 sec-
onds. The LED display will the flash POn for 3 seconds once the parameter pro-
gramming mode has been activated.
Once access is unlocked, it will be possible to enter programming mode by pressing

the SET key for 10 seconds the user should now be able to change all the
parameters of the controller.
After programming has been completed, the controller will again automatically block
access to the parameters except for C8 and C9.
To change any further parameters the programming mode will have to be re-
activated by following the procedure above.


Pos.
Pos. Par.
Par. Description
Description Range
Range
1 _C1
_C1 Setpoint -9.9…+10.0 °C
+14.0…+50.0 °F
2 _C2
_C2 High temperature differential alarm 0.0…30.0 °C °F
(In relation to C1) (0=exclude alarm)
3 _C3
_C3 High temperature alarm delay 0.…999 min
4 _C4
_C4 Low temperature differential alarm (ESA) 0.0…30.0 °C °F
(In relation to C1) (0= exclude alarm)
5 _C5
_C5 Restarting temperature differential from 0.0…30.0 °C °F
ESA
(In relation to C4)
6 _C6
_C6 Low temperature alarm delay 0…999 s
7 _C7
_C7 Fan stop temperature differential 0.0…30.0 °C o °F
(In relation to Setpoint C1)
8 _C8
_C8 Condensate valve close time 1…999 min
9 _C9
_C9 Condensate valve open time 1…999 s
10
10 _C10 Visualization in case of low temperature
_C10 t emperature 0=LtA
alarm 1=ESA
11
11 _C11 Temerature probe calibration (Offset)
_C11 -9.9…+10.0 °C o °F
12
12 _C12 Unit of temperature
_C12 0=°C
1=°F
13
13 _C13 Temperature Visualisation Resolution
_C13 0 = integer
1= decimal
14
14 _C14 Compressor Starting Delay
_C14 0…999 s
15
15 _C15 Fan starting delay after comp
_C15 compressor
ressor starting 0…999 s
16 _C16 The number of HtA or Ht2 alarms within 0…20

time C17 before ASt 0=Exclude Alarm ASt
17 _C17 Maximum time for Ast alarm
alarm 0…999min
0…999min
18 _tAt
_tAt Time the fan will run at minimum speed be- 0…999s
fore switching to logarithmic control,


19
19 _tSA
_tSA Time to wait for the temperature to stabilize 1…99 s
above the Setpoint before increasing fan
speed.
20 _tdI
_tdI Time to wait for the temperature to stabilize 1…99 s
below the Setpoint before decreasing fan
speed.
21
21 _dFI
_dFI Fan speed increment 0.1…20.0
22 _tEF
_tEF The time the fan will be supplied with a volt- 0.0 … 2.0 s
age signal on startup
(if parameter = 0 the function is disabled).
23
23 _MSP Minimum fan speed
_MSP 1…20
_CMI
_CMI Fan control constant. 1…10
24
24
25 _tES
_tES (Time Fan ESA) The time the fan will oper- 0…30 s
ate a 100 % before de-energizing the com-
pressor when the dryer goes to the state of
ESA
(If tES = 0 = the function is disabled)
26 _tE2
_tE2 ES2 temperature -20°C….-10°C
-4°F….+14°F
27 _Ast Mode of alarm ASt 0…1
0…1
If the parameter is set to 0. The user can
reset the alarm.
alarm.
If the parameter is set to 1. The user
cannot rest the alarm and the controller is
locked.
locked.
In this eventuality the parameter must be
set to ASt = 0 for the alarm to be reset
28 _dSP Visualisation Mode

Mode 0=OMI
If the parameter is set to OMI. The dew- 1=UtE
point will be displayed in decimal
decimal ºC or ºF
depending on the parameter C12
If the parameter is set to Ute (default) the
(default) the
dewpoint will be display as a bar graph
graph


5.8 DESCRIPTION OF THE PARAMETERS
1. C1
Setpoint. The setpoint value of the temperature of the evaporator, adjustable
between -9.9ºC to +10.0 °C (14.0 to 50 °F). This is the temperature that the
between
controller will vary the condensor fan speed to maintain. if temperature of the
evaporator rises above the Setpoint the controller will activate the fan and vary
its speedthe
Setpoint to controller
maintain the correct temperature,
will de-energize the fan. if the temperature fall below the
2. C2
High temperature differential alarm. The maximum increase in temperature
allowed above Setpoint C1. If the evaporator temperature is equal to or greater
than C1+C2 for the time specified in parameter C3 the controller will de-energize
the dryer compressor and fault HtA will be displayed on the LED display. Note
the fan output will remain energized and the drain cycle will remain as standard.
3. C3
High temperature alarm delay. The
delay. The maximum time allowable time in minutes
for the temperature of the evaporator to be equal to or above values C1+C2 be-
fore fault HtA.
4. C4
Low temperature alarm differential.
differential. The minimum temperature allowed below
Setpoint C1. If the evaporator temperature is equal to or less than C1-C4 for the
time specified in parameter C6 the controller will de-energize the dryer compres-
sor and condenser fan and fault ESA will be displayed on the LED display. Note
the drain cycle will remain as standard.
The warning will automatically be reset when the temperature of the evaporator
is equal to C1-C4+C5
5. C5
Restarting temperature differential from ESA. The temperature which the
dryer will automatically reset after an ESA alarm. The low temperature alarm will
reset when evaporator temperature exceeds C1-C4+C5.
6. C6
Low temperature alarm delay. The
delay. The maximum time allowable in minutes for the
temperature of the evaporator to be equal to or below the values C1-C4 before
the alarm ESA.
7. C7
Fan stop temperature differential If the temperature should fall bellow C1-C7
the controller will immediately de-energize the fan to stop freezing conditions.
8. C8
Condensate valve close time. Interval time in minutes that the condensate so-
lenoid will remain closed (de-energized) during the condensate drain cycle,
whilst in normal operation


9. C9
Condensate valve open time. time. Interval time in seconds that the condensate
valve will be energized (open) during the condensate drain cycle whilst in normal
operation.
10. C10
Visualization in case of low temperature alarm.
alarm . The controller LED is able to
show to different
perature Alarm and warning
ESA =messages in case
Energy Saving of low temperature
Activated. (Default). LtA = Low Tem-
0 = LtA 1=ESA
11. C11
Off Set. Used to calibrate the temperature sensor to the LED display (Sect. xx).
12. C12
Unit of Temperature.
Temperature.
0=Celsius
1=Fahrenheit
13. C13
Temperature Visualization Resolution. The controller can display the actual
evaporator temperature (see parameter 28). The number can be displayed a a
whole number rounded up or down accordingly, or to 1 decimal place.
0=Integer (whole number)
1=Decimal
14. C14
Compressor start delay. The minimum time allowable between stopping and
restarting the dryer compressor. A small time is not permitted in this parameter
as this would cause the compressor to over heat and not give time for the refrig-
erant pressures to equalize.
15. C15
Fan starting delay.
delay. The minimu time delay in seconds before the fan will start
after the dryer compressor has been activated.
16. C16
Nº of HtA or Ht2 alarms within time C17 before ASt. ASt . In order to protect the
dryer and the operator. If the dryer has repetitive alarms HtA or Ht2 the control-
ler will issue an alarm ASt. Adjustable between 0 and 20. If the parameter is set
to 0 ASt alarm will be disabled.
17. C17
Maximum time for Ast alarm.
alarm. The maximum time allowed that the programmed
number of HtA or Ht2 alarms (C16) will be issued before ASt.
18. tAt
Time before the fan switches to algorithmic control. When the fan switches
from 0 (fan stopped) to 1 MSP (Fan minimum speed) the fan will continue to run
at minimum speed for the time of tAt before switching to algorithmic control.
control.


19. tSA
Time to wait for the temperature to stabilize above the Setpoint before increas-
ing fan speed.
20. tdI
Time to wait for the temperature to stabilize below the Setpoint before decreas-
ing fan speed
6.0 REPLACING THE CONTROL

CONTROLLER
LER
In the event of failure the controller will need to replaced. All controllers are shipped
from aftermarket in a standard configuration, because of this some parameters on
the new controller may have to be changed to ensure correct dryer performance.
D-IN Units (D12IN - D180IN)
C8 Condensate Drain 1 to 999 1

Close Time (minutes)
C9 Condensate Drain 1 to 999 D12-144IN D180IN
Open Time (seconds) 1 2
C12 Unit of Temperature 0 - ºC 50Hz Models 60hz Models

1 - ºF 0 1
C11 Temperature probe -9.9 to D12- 180IN D240- 480IN
calibration +10 No Adjustment See page 29
D-IT Units (D25IT - D170IT)
C8 Condensate Drain 1 to 999 1

Close Time (minutes)
C9 Condensate Drain 1 to 999 D25- 60IT D102– 170IT

Open Time (seconds) 2 3
C12 Unit of Temperature 0 - ºC 1

1 - ºF
C11 Temperature probe -9.9 to -5.4
calibration +10


6.1 Calibration of the temperature probe D240IN - D480IN
For models fitted with a Hot Gas By-pass Valve, if the controller has to be replaced
the temperature probe must be calibrated to the suction pressure to ensure correct
dryer performance.
To perform this operation correctly you will need a digital or analogue refrigerant
charging
minimum)manifold preferably
and a Pressure with ball valve
Temperature (PT) hoses (toR134a
chart for keep refrigerant
refrigerant. losses to a
(See page
39).
1. Install the charging manifold hoses onto the Schrader valves on the high and
low pressure circuits. Attention must be paid to keep refrigerant losses to a
minimum..
minimum
2. Switch the dryer ON without any load.

load. Please note if the power the to dryer
has been removed there will be a 2 minute delay before the dryer starts.
starts.
3. Press the controller UP and DOWN keys together for 5 seconds. The LED dis-
play will the flash POn for 3 seconds to confirm that parameter programming
mode has been activated. Once access is unlocked, press the SET key for 10
seconds the user should now be able to change the parameters of the
controller.
4. Press the SET key until parameter C12 is displayed adjust this parameter us-
ing the UP or DOWN buttons to: 0 for 50hz models or 1 for 60hz models.
Not forgetting to press the SET key to confirm any changes.
changes.
5. Change parameter C13 to: 1 (Decimal).

Change parameter Dsp to: OMI (temperature visualisation).
Again not forgetting to press the SET key to confirm
confirm any changes.
changes.
6. If n
no
o further buttons are pressed the controller will save and exit from program-
ming mode. Note the main LED should now have changed and be displaying
the evaporator temperature in ºC for 50hz models (where 20 = 2.0ºC) or in ºF
for 60hz models.
7. Allow the dry

dryer
er to operate for a
att lea
least
st 5 m
minutes
inutes to allow the refrigerant tem-
peratures and pressures to stabilise.
8. If necessary adjust the Hot Gas By-pass Valve to obtain a suction pressure of
2.1 - 2.2 barg (30 - 32 psig), whilst the condensing pressure is approximately
13.5 - 13.9 barg (196 - 202 psig). Note: adjust the screw of HGBV by a maxi-
mum of 5° angle and wait each time a minimum of 2 minutes before making
further adjustments.
9. After completion of setting. Using the PT charts (see page 39) verify the read-
ing on the LED display is aligned with the suction pressure, otherwise using
the method described in step 3 modify parameter C11 so that the LED display
is equal to suction temperature.


10. Set the controller w

with
ith the parameters CC12=1,
12=1, C13
C13=0,
=0, dsp=U
dsp=UtE.
tE. Remove with
care the instruments from circuit without leakages.
7.0 WARNINGS
Low Evaporator Temperature Warnings
ESA
This occurs when the evaporator temperature drops below -1 °C (30.2°F) for a period
of 5 minutes. To prevent freezing of the evaporator this warning will de-energise the
refrigerant compressor and condenser fan, however will not issue a general alarm
and condensate drain cycle will remain as standard.
When the evaporator temperature rises to 6°C (42.8°F), the outputs to the compres-
sor and fan motor should be re–energised and the dryer will resume normal opera-
tion.
ES2
This occurs should the evaporator temperature drop below -18 °C (-0.4°F). This
alarm is immediate without any time delay. This warning will de-energise the refrig-
erant compressor and condenser fan, however will not issue a general alarm and
condensate drain cycle will remain as standard.
When the evaporator temperature rises to 6°C (42.8°F), the outputs to the compres-
sor and fan motor will be re–energised and the dryer will resume normal operation.
Probable Causes
No or low compressed air load.

Increase compressed air low through the dryer, the unit should automatically re-start
once evaporator temperature reaches 6°C (42.8°F).
Temperature probe incorrectly positioned.

Ensure that the temperature probe is correctly positioned under the insulation be-
tween the capillary device and evaporator.


Temperature probe incorrectly calibrated.

See page
page 29 for calibration procedure.
Low refrigerant charge.

Using a service manifold check the high and low refrigerant pressures. In case of
doubt contact your Ingersoll Rand service department.
8.0 ALARMS
High Evaporator Temperature Alarms
HtA
This alarm occurs when the evaporator temperature reaches 14.5°C (58.1°F) for a
period of 6 minutes. The controller w will
ill active the ge
general
neral alarm output
output and de-
energise the refrigerant compressor the condenser fan will be energised at full
speed for a period of 10 seconds, the condensate drain cycle will remain as stan-
dard.
As this is an alarm it must be reset manually
manually from the control panel by pressing ON
ON /
OFF button on the controller.
Ht2
This alarm occurs should the evaporator temperature reaches 45°C (113°F). This is
an immediate alarm without any delay. The controller will active the general alarm
output and de-energise the refrigerant compressor the condenser fan will be ener-
gised at full speed for a period of 10 seconds, the condensate drain cycle will re-
main as standard.
Reset manually from the control panel by pressing ON / OFF button on the control-
ler.
Probable Causes
High compressed air load.

Using the technical data sheets and the correction factor tables check the volume
flow, temperature
parameters of the and pressure of the incoming compressed air are with the working
dryer.
Condenser dirty
Check that the airflow through the condenser is not obstructed, clean if necessary.
High ambient temperature

t emperature
Check that the ambient conditions are not exceeding the working parameters of the
dryer. 50°C (122°F).
Temperature probe incorrectly positioned.

Ensure that the temperature probe is correctly positioned under the insulation be-
tween the capillary device and evaporator.
evaporator.


Temperature probe incorrectly calibrated.

See page 29 for calibration procedure.
High pressure switch tripped or defective.

All units are fitted with a 30 bar (435 psi) pressure switch fitted with a manual reset
button check if the switch has tripped and check wiring to and from the switch, if the
switch is defective it will need to be replaced care will need to be taken when remov-
ing the
keep switch from
refrigerant thetoSchrader
losses co
connection
a minimum. nnection to av
avoid
oid damage to pipe work and
Manual Reset
Defective Condenser Fan

Using the Autotest function (See page 22) carefully check the outputs from the con-
troller to the condenser fan. If the fan fails to operate check the wiring to the fan
from the controller if no loose wires are detected, remove the outputs plug on the
back of the controller and carefully check for a 230vac output for 50hz models or
115vac
and will for
need60hz models
to be on pin
replaced 5. ifcorrect
if the no voltage is detected
voltage thereplace
is detected controller
theiscondenser
defective
fan.
Pin 5


Low refrigerant charge.

Using a service manifold check the high and low refrigerant pressures. In case of
doubt contact your Ingersoll Rand service department.
Defective Refrigerant Compressor

Check the current draw and head temperature of the compressor if excessive the
compressor will need to be replaced. If replacing a refrigerant compressor it will be
necessary to relating
See page 35 replace to
theevacuation
drier filter also.
and recharging procedures.
Temperature Probe Error
PF1
This fault occurs when the controller cannot read a resistance within an acceptable
range from the PTC temperature probe.
Probable Causes
Loose connection
Check for loose connections between the controller and the PTC temperature
probe.
Temperature Probe
Connection
Incorrectly calibrated temperature probe

See page 29 for correct probe calibration procedures.
Defective temperature probe

Remove temperature probe from the dryer, using the resistance charts (See page
37) measure the resistance across the probe, if the resistance is not within the
range of the temperatures or the probe is open circuit, the probe is defective and will
need to be replaced.


Water in the system (High Pressure Dew Point)
Probable Causes
High compressed air load.

Using the technical data sheets and the correction factor tables check the volume
flow, temperature and pressure of the incoming compressed air are with the working
parameters of the dryer.

Condenser dirty
Check that the airflow through the condenser is not obstructed, clean if necessary.
High ambient temperature

t emperature
Check that the ambient conditions are not exceeding the working parameters of the
dryer. 50°C (122°F).
Condensate drain not functioning.

Clean the condensate drainage system pre-filter.
Coil
Pre-filter
Replace the coil of the drainage solenoid valve if burned.
Clean or replace the drainage solenoid valve if clogged/jammed.
Check the C8 and C9 parameters of the electronic control board (see section xx for
correct drain valve settings)
Carefully check for an output on Pin 1 on the controller outputs socket whilst activat-
ing the condensate drain test if no voltage is detected replace the controller.


ASt
An ASt alarm occurs when there are three HTA or HT2 alarms within a one hour pe-
riod. The alarm is to protect the operator from injury and equipment from damage. If
an ASt alarm occurs follow the troubleshooting proced
procedures
ures for Hta or HT2, in case
of doubt contact your Ingersoll rand service team. The Ast alarm is re-settable by
pressing the ON / OFF key.
9.0 DEHYDRATION AND EVACUATION PROCEDURE
This procedure describes the minimum operations that have to be done in order to
obtain a reliable dehydration and vacuum of the refrigeration system.
Dehydrate the circuit by pulling it under vacuum using the double vacuum proce-
dure.
First evacuation:
Fit the vacuum hose to vacuum pump and the refrigerant system and evacuate the
system until a minimum vacuum is reached of 1500 microns. Use a large diameter
hose to connect the vacuum pump to the system and keep it as short as possible.
Flush system by breaking the vacuum with dry nitrogen and bringing the system
pressure to 0.4 barg (5psi).
Second evacuation:
Pull down the entire system to 500 microns and hold for 10 minutes with minimal
rise in microns. A large rise would be a sign of a leak.
WARNING: Do not run compressor while under vacuum as it will cause the
compressor motor to burn out.
Refrigerant Charging:
This procedure describes the minimum operations that need to be completed to suc-
cessfully charge dryers with the correct quantity of refrigerant. These procedures
must only
dance withbe carried
local out by qualified personnel holding the correct licenses in accor-
legislation.
Equipment Required
-Filling cylinder R134a

-Service manifold with high and low pressure gauges
-Filling hoses (no loss fitting)
-Weight scale
-Micron gauge for testing vacuum
NOTE: Before charging, be sure that refrigeration system is dehydrated and

evacuated!
WARNING: Never exceed the normal charge. In cases of overcharging, the

compressor can be seriously damaged. For correct refrigerant charge see the
technical data sheets.


Charging Procedure
1. Connect the service manifold to the suction line on the compressor for low
pressure and to the discharge line for the high pressure, on units D12IN -
D180IN it will be necessary to remove the high refrigerant pressure switch to
gain access to the high pressure Schrader connector. This may already be
done during the evacuation process.
2. Connect the charging hose to the refrigerant-charging bottle, which should be

placed on a suitable scale for weighing the charge. Open the valve on the
charging bottle.
3. Establish the correct amount of R134a to be added to the system.
4. The ch
charging
arging hose should have no loss fittings. If the h
hose
ose does not have no
loss fittings, the hose will need to be purged first.
5. With the charging bottle o on

n the scale, open the h high
igh s side
ide ga
gauge
uge valve.
(Normally the refrigerant flows by itself into the system, if not, you can warm up
the charging bottle by using warm water)
WARNING: Do not use a blow torch or naked flames.
NOTE: If the flow of refrigerant stops before the unit is fully charged, follow
these next steps. You should have at least 90% of the full charge in the sys-
tem, if not, the system was not properly charge
charged
d or evacuated.
1. Close the high side valve.
2. Calculate how much more will be needed too fully charge the system.
3. Start the unit.
4. Open the suction-side valve and slowly weigh in the rest of the charge.
5. Once thebottle.
charging unit is fully charged, close the v
valves
alves on the ga
gauges
uges and on the
6. Start the unit if not already running.
8. Remove the gauges and refit the appropriate caps.
Compressor Oil:
For normal working conditions there is no need to remove or add oil to a compres-
sor. Remember, an excess of oil is as dangerous as a lack of oil. Where there has
been a severe oil leak, only add original polyolester compressor oil. Adding oil must
be done on the suction side with a special oil pump to overcome the refrigerant
pressure. Follow the pump directions or, or in case of doubt contact your Ingersoll
Rand service department.

10.0 KTY81-121 RESISTANCE

CHART


11.0 Pressure Temperature

emperature
Charts

R
1
3
4
a
P
r
e
s
s
u
r
e
T
e
m
p
e
rr
a
t
u
r
e
C
h
a
r
t
(
B
a
r
a
/
º
C
)
Note:
Pressures in bar are
Actual Not Gauge

P
r
e
s
s
u
r
e
T
e
m
p
e
r
a
t
u
r
e
C
h
a
r
t
(
p
s
i
g
/
º
F
)


12.0 Default Controller

Settings

D
e
f
a
u
l
t
C
o
n
t
r
o
l
e
r
P
a
r
a
m
e
t
e
r
s
5
0
h
z
M
o
d
e
l
s

D
e
f
a
u
l
t
C
o
n
t
r
o
l
e
r
P
a
r
a
m
e
t
e
r
s
6
0
h
z
M
o
d
e
l
s


13. Correction Factors
D12IN to D480IN
Inlet Temperature
Inlet Air Temperature (°F / °C) 86 / 30 95 / 35 104 / 40 113 / 45 122 / 50 131 / 55
Correction Factor 1.2 1 0.85 0.71 0.56 0.42
Ambient Temperature
45 /
Ambient Air Temperatu
Temperature
re (°C / °F) 25 / 77 30 / 86 35 / 95 40 / 104 42 / 108 113
Correction Factor 1 0.96 0.92 0.88 0.85 0.76
Inlet Pressure
Inlet Pres-
3/ 4/ 5/ 6/ 14 /
sure (barg / 7 / 102 8 / 116 9 / 131 10 / 145 12 / 174
44 58 78 87 203
psig)
Correction 0.7 0.78 0.85 0.93 1 1.06 1.11 1.15 1.2 1.24
Factor
How to use the factors:

To determine the capacity of a dryer at non standard conditions – take the nominal rated flow
and multiply by the appropriate correction factors.
Example: D300IN has nominal capacity of 300 m3/hr. At an inlet temperature of 40°C, ambi-
ent temperature of 35°C and pressure of 8 barg.
The new capacity of this dryer is 300 x .85 x .92 x 1.06 = 249 m3/hr
To select a dryer basis system flow – take the required system flow and divide by the appro-
priate factors.
Example: Requirement is 200 m3/min at inlet temperature of 45°C, ambient temperature of

30°C and pressure of 9 barg.
The corrected flow will be 200 / .71 / .96 / 1.11 = 264 m3/hr. Select the closest dryer rated
above 264: choose the D300IN.
Note: Correction factors are to be used for general sizing guidance. Dryer perform-
ance is guaranteed at nominal rating only.


14. TECHNICAL
DATA SHEETS
50hz Models














TECHNICAL
DATA SHEETS
60hz Models






D IN Dryers Service Manual Page 68












15.0 MATERIAL SAFETY

DATA SHEETS
R134a






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D-IN Dryers Service Manual Page 1

THIS PAGE IS LEFT INTENTIONALLY BLANK

D-IN Dryers Service Manual Page 2

D-IN Dryers Service Manual Page 3

Accidents can be avoided by recognizing that any machinery is potentially hazard-

BEFORE SERVICING OR DISMANTLING ALL PRESSURE MUST BE

D-IN Dryers Service Manual Page 4

D-IN Dryers Service Manual Page 5

Models D12IN to D180IN

Models D240IN to D480IN

D-IN Dryers Service Manual Page 6

3. COMPONENT REVIEW D12IN – D480IN

D-IN Dryers Service Manual Page 7

Air to Air and Refrigerant to Air Exchanger

Air to Air Heat

D-IN Dryers Service Manual Page 8

D-IN Dryers Service Manual Page 9

Models D12IN to D72IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Page 10

Models D108IN to D180IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Page 11

Models D240IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Page 12

Models D300IN to D380IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Page 13

Models D480 (230v/1Ph/50Hz

D-IN Dryers Service Manual Page 14

Models D12IN to D72IN (115v/1Ph/60Hz)

D-IN Dryers Service Manual Page 15

Models D108IN to D180IN (115v/1Ph/60Hz)

D-IN Dryers Service Manual Page 16

D-IN Dryers Service Manual Page 17

THIS PAGE IS LEFT INTENTIONALLY BLANK

D-IN Dryers Service Manual Page 18

D-IN Dryers Service Manual Page 19

Controller D12IN to D480IN

5.1 GENERAL DESCRIPTION

A patented microprocessor allows dryer’s cooling capacity

D-IN Dryers Service Manual Page 20

5.2 Automatic Re-start After Power Outage

5.3 LED DISPLAY

the unit is ON with low load and the measured temperature is

LED STATUS DESCRIPTION

Flashing Programming Mode Activated

ON Condensate Drain Is Energised

ON Speed of The Fan = 100%

Flashing Speed Of The Fan < 100%

D-IN Dryers Service Manual Page 21

5.4 FUNCTIONALITY OF THE KEYS

5.5 AUTOTEST FUNCTION

5.6 CONDENSATE DISCHARGE PARAMETERS.

Parameter Description Range Default Value

C8 Condensate Drain Close 1 to 999 1

5.7 MODIFICATION OF THE PARAMETERS

Once access is unlocked, it will be possible to enter programming mode by pressing

D-IN Dryers Service Manual Page 23

16 _C16 The number of HtA or Ht2 alarms within 0…20

D-IN Dryers Service Manual Page 24

(if parameter = 0 the function is disabled).

28 _dSP Visualisation Mode

D-IN Dryers Service Manual Page 25

5.8 DESCRIPTION OF THE PARAMETERS

D-IN Dryers Service Manual Page 26