Ingersoll Rand D12IN-A, D18IN-A, D25IN-A-SR, D42IN.A, D54IN.A Owners Manual

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Page 1

Page 2

- EN -

CONTENTS

1. GENERAL INFORMATION

1.1

1.2 Safe Use of the Dryer 3

2. INSTALLATION

2.1 Acceptance and Transportation 4

2.2 Installation Site 4

2.3 Installation 4

3. START UP

3.1

3.1.1 Keys function 6

3.1.2 Condensate discharge Parameters Programming 6

3.1.3 Anomaly Warning 7

3.1.4 Remote signalling Alarm 7

3.2 Before Start Up 8

3.3 Start Up 8

Functional Description 3

Control Panel 5

FR -

TABLE DES MATIERES

1. INFORMATIONS GENERALES

1.1

Description fonctionnelle 12

1.2 Utilisation du séchoir en toute sécurité 12

2. INSTALLATION

2.1 Réception et transport 13

2.2 Lieu d'installation 13

2.3 Installation

3. MISE EN SERVICE

3.1

Pupitre de commande 14

3.1.1 Fonction des touches 15

3.1.2 Programmation des paramètres 15

3.1.3 Signalisation des anomalies 16

3.1.4 Signalisation d’alarme a distance 16

3.2 Opérations préliminaires à la mise en marche 17

3.3 Mise en marche

4. MAINTENANCE, TROUBLESHOOTING AND DISMANTLING

4.1 Maintenance 8

4.2 Troubleshooting 8

4.3 Dismantling 10

ATTACHMENTS TO THIS MANUAL

A) Refrigerant Circuit 2 B) Electric Circuit Diagram 22 C) Technical Data Sheet 24 D) Correction Factors 25 E) Dryer Dimensions 26 F) Basic Spare Parts 28

4. ENTRETIEN, RECHERCHE DES PANNES ET DEMANTELEMENT

4.1

Entretien 17

4.2 Recherche des pannes 17

4.3 Démantèlement 19

ANNEXES AU MANUEL

A) Circuit Frigorifique 2 B) Schéma électrique 22 C) Caractéristiques Techniques 24 D) Facteurs de Correction 25 E) Dimensions Du Sécheur 26 F) Pièces De Rechange Essentielles 28

Cod. 710.0138.39.00 Rev03 – 02.2012 1 - 30

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- EN -

INTRODUCTION

This manual is an integral part of the dryer you bought, and must remain with the machine even if this will be resold.

t is highly recommended that the qualified*personnel for installation maintenance and/or control will fully comply with the

I contents of this manual and the prevention and safety rules in force in the country where the system will be used. In this way, not only the usage of the machine will be rational, but also the service will result cost effective.

In case your dryer will present any kind of problem, please contact your local authorized Ingersoll Rand distributor.

Please note that, when necessary, the use of original spare parts will ensure efficiency and long duration to your dryer.

Due to the continuous technological evolution, Ingersoll Rand reserves the right to modify the specifications contained in this manual without giving previous notice.

SYMBOLS AND LABELS USED IN THE MANUAL AND ON THE DRYER

or or or

Air inlet.

Read the Operators manual before attempt to start up the machine and to perform any service operation on the dryer.

Pay particular attention to the indications preceded by these symbols.

Installation, maintenance, and/or control operations preceded by these symbols must be performed exclusively by qualified personnel*.

Condensate drain point.

Pay particular attention to the risk of moving parts

Attention: Before performing any maintenance operation on this machine, do not forget to disconnect the electric supply, to completely discharge air pressure, and to refer to the Operators manual

or or or

Pay particular attention to components or

Air outlet.

systems under pressure.

Pay particular attention to hot surfaces.

Pay particular attention to the risk of electric shock.

Rotation direction of the fan.

* Qualified personnel must be trained and certified in accordance with local laws and regulations.

WARRANTY

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Company's prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Company's proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Company's obligation shall be to correct in the manner and for the period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HERBY DISCLAIMED.

Cod. 710.0138.39.00 Rev03 – 02.2012 2 - 30

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Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided a

bove, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on contract, warranty

negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The Purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at Purchaser's sole risk and liability.

Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the equipment or negotiated as part of the purchase order may take precedence over this warranty.

1. GENERAL INFORMATION

1.1 FUNCTIONAL DESCRIPTION

Ingersoll Rand refrigerated air dryers remove moisture from compressed air. Moisture is detrimental to pneumatically o

perated appliances, controls, instruments, machinery and tools.

Compressed air enters the patented aluminum heat exchanger where it is cooled down to the dew point temperature in two different stages: In the first air/air sector compressed inlet air is cooled thanks to the colder compressed air coming out counterflow from the condensate separator. In the second refrigerant / air sector, compressed air temperature is further lowered to the dew point temperature. During this two stages almost all the oil and water vapours contained in compressed air are condensed to liquid and successively be separated from the compressed air in the condensate separator and drained out by the automatic drain. At this point the obtained cold air re-enters counterflow the initial air / air exchanger and it is reheated by the inlet hot air with the consequence of energy recovering and also reduction of the relative humidity contained in the outflowing air.

This dryer can be easily installed into various pneumatic systems in which dry air is required or desired. Please refer to Start up chapter for complete operating details.

The dryer comes provided with all the control, safety and adjustment devices, therefore no auxiliary devices are needed.

A system overload not exceeding the maximum operative limits can worsen the operational performance of the dryer (high dew point), but it will not affect its safety.

The electric diagram (attachment B) shows the minimum protection degree IP 42. Improper grounding can result in electrical shock and can cause severe injury or death. This product must be connected to a grounded, metallic, permanent wiring system or an equipment-grounding terminal or lead on the product. All grounding must be performed by a qualified electrician and comply with national and local electrical codes. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. Ground must be established with a bare grounding wire sized according to the voltage and minimum branch circuit requirements. Ensure good bare metal contact at all grounding connection points, and ensure all connections are clean and tight. Check grounding connections after initial installation and periodically thereafter to ensure good contact and continuity has been maintained. Check with a qualified electrician or service technician if the grounding instructions are not completely understood, or if in doubt as to whether the product is properly grounded.

1.2 USE OF THE MACHINE IN SAFE CONDITIONS

This system has been designed and manufactured in compliance with the European safety directive in force and U

L/ULC, therefore any installation, use and maintenance operations must be performed respecting the instructions

contained in this manual.

Because an air dryer is pressurized and contains rotating parts, the same precautions should be observed as with any piece of machinery of this type where carelessness in operation or maintenance could be hazardous to personnel. In addition to obvious safety rules that should be followed with this type of machinery, safety precautions as listed below must be observed.

1. Only qualified personnel shall be permitted to adjust, perform maintenance or repair this air dryer.

Cod. 710.0138.39.00 Rev03 – 02.2012 3 - 30

2. Read all instructions completely before operating unit.

3. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to work or perform maintenance on the unit.

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

5. Do not attempt to remove any parts without first relieving the entire air system of pressure.

6. Do not attempt to remove any part of the refrigeration system without removing and containing refrigerant in accordance with the EPA and local regulations.

7. Do not operate the dryer at pressures in excess of its rating.

8. Do not operate the dryer without guards, shields and screen in place.

9. Inspect unit daily to observe and correct any unsafe operating conditions.

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2. INSTALLATION

2.1 ACCEPTANCE, UNPACKING AND HANDLING

Upon receiving your Ingersoll Rand air dryer, please inspect the unit closely. If rough handling is detected, please note it on your delivery receipt, especially if the dryer will not be uncrated immediately. Obtaining the delivery person's signed agreement to any noted damages will facilitate any insurance claims by the customer.

It is mandatory to keep the dryer always in vertical position, as indicated by the symbols present on the packaging. For handling, use devices having sufficient capacity for the weight of the machine.

Remove the packaging after having positioned the dryer in the installation site. Dispose the various packaging materials in compliance with the relevant rules locally in force.

If not in use, the dryer can be stored in its packaging in a dust free and protected site between 32°F (0°C) and 120 °F (50 °C), and a specific humidity not exceeding 90 %. Should the stocking time exceed 12 months, please contact your local Ingersoll Rand authorized distributor.

Under no circumstances should any person attempt to lift heavy objects without proper lifting equipment (i.e., crane, hoist, slings or fork truck). Lifting any unit without proper lifting equipment, may cause serious injury. Use fork lift channels where provided.

2.2 INSTALLATION SITE

While preparing a proper site for the installation of the dryer, please take into account the following requirements

 The machine must be protected from atmospheric agents and not directly exposed to sun light.  A seating base flat and capable to hold the weight of the machine.  Ambient temperature complying with the nominal data of the dryer.  The dryer should be located in a clean area, without forced air draft that can affect the fan control

system.

 Make sure to leave sufficient clearance (20 inches, 500 mm) around the dryer in order to allow an

adequate cooling of the machine and for maintenance and/or control operations.

The incoming air must be free from smoke or flammable vapours which could lead to explosion or fire risks.

2.3 INSTALLATION

Before attempting any installation operation, make sure that

 No parts of the air system are under pressure.  No parts of the system are electrically powered.  Tubing to be connected to the dryer are free of impurities.  All interconnecting piping has been tightened.

After having verified the points listed above, you can proceed to the installation of the machine.

1. Connect the dryer to the compressed air lines. If not already existing, we suggest to install a by-pass allowing to isolate the machine from the plant, thus to facilitate eventual maintenance operations.

2. Perform the electrical connection in accordance with any local laws and regulations after reviewing the dryer electrical specifications and wiring diagram.

3. Check the condensate drainage assembly, and connect the drain flexible hose to the draining line, keeping in mind that the condensate separated by the dryer may contain oil, therefore, in order

to dispose of it in compliance with the local rules in force, we suggest installing a water-oil separator having adequate capacity.

4. Power the dryer after having checked that the nominal voltage and line frequency are constant and matching the nominal values of the machine. The user must provide the installation with an

adequate line protection and a ground terminal complying with the electrical rules locally in force.

In order to optimise the use of the dryer, we suggest to place it in such a way that all the control instruments of the machine will result easily visible.

A suitably sized prefilter must be installed before the dryer. Failure to install and maintain a proper prefilter will void the dryer warranty. The rating for this filter must be at least 10 micron.

Cod. 710.0138.39.00 Rev03 – 02.2012 4 - 30

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3. START UP

Ensure that the dryer is by−passed, or there is no load on the cooler. Switch on the main electrical isolation switch (if present). The control panel will show the message OFF, indicating that the line and control voltages are available.

Start sequence

The dryer will initially start by pressing the local ON/OFF button for 1 second. The start sequence will progress only if there are no active alarms. The compressor motor will start AFTER 120 SECONDS. The fan motor will start simultaneously with the compressor for D300-360IN models, after 30 seconds for smaller models.

Stop sequence

The dryer can be stopped locally from the control panel. After having pressed the ON/OFF switch for 1 second, the compressor and the fan motor keep on running for further 10 seconds in order to re-balance the internal pressures. The dryer can be also stopped due to an alarm or energy saving condition (ESA or ES2). Any alarm will de−energize the compressor, fan motor can still running, it depends on the type of alarm (see Display indications chapter). If the shutdown is due to an alarm, a message will blink on display indicating the reason for the shutdown. Energy saving condition (ESA or ES2) occurs when the dew point stands below the set value for a long time in order to save energy and avoid heat exchanger freezing. This situation can happen when ambient temperature is low and there is no compressed air load.

Variable speed fan control

A patented microprocessor allows to adjust dryer’s cooling capacity by changing the fan motor speed. If the dew point is greater than the set value, the fan speed is increased, if the dew point is smaller than the set value, the fan velocity is decreased. The range can be from 0 to 100% and the higher is the fan speed, the faster the fan LED blinks, you can read the exact value by pressing the UP button. If the velocity is 100% you will read FL (Full Load). Under load standard condition the fan speed is usually at 100%, if there is no load the fan velocity can oscillate between 0 and 20%. In models D300-360IN, in order to adjust the greater dryer’s cooling capacity, a hot gas by-pass valve cooperates with the variable speed system.

3.1 CONTROL PANEL

The dryers are provided with an electronic control system. All adjustments and resets can be performed by means of the d

igital panel located on the front of the dryer. The control panel is composed of 5 keys (ON/OFF, TEST, SET, DOWN and UP) and a 3 digit display, with three signalling LEDs indicated by icons (PIC 1)

DISPLAY VISUALIZATION A

DISPLAY DESCRIPTION

Cod. 710.0138.39.00 Rev03 – 02.2012 5 - 30

the unit is ON with low load

the unit is ON with normal load

the unit is ON with normal-high load

the unit is ON with high load

ND SIGNALLING LEDS

LED STATUS DESCRIPTION

Compressor energized

Programming mode activated

Condensate drain energized

Speed of the fan = 100% Speed of the fan < 100%

Blinking

ON ON

OFF

PIC. 1

Fan not running

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TEST:

.1.1 KEYS FUNCTION

SET: When pushed and released during normal operation, it displays the dew point set value (decimal).

When pushed for 10 seconds, it allows to enter the C8 and C9 condensate drain parameters programming menu (see relevant table). When pushed after having set new configuration values, it stores the applied modifications.

When pushed for 3 sec. during normal operation, it activates the condensate drain.

DOWN: W

hen pushed while setting the drain set point, it decreases the displayed value of one unit per second, during the first 10 seconds, than of one unit every 0,1 sec. When pushed for 10 seconds during normal operation, it starts an automatic test cycle of the controller.

UP: When pushed while setting the drain set point, it increases the displayed value of one unit per second, during the first 10 seconds, than of one unit every 0,1 sec.

ON / OFF: Pushed for 1 second, it activates or deactivates the dryer. When the dryer is deactivated, the display shows 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 machine.

3.1.2 CONDENSATE DISCHARGE PARAMETERS PROGRAMMING

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 SET VALUE

Delay between condensate

discharges

1 ÷ 999 (min)

Time required for condensate

discharge

1 ÷ 999 (sec)

D12-144IN-A D180IN-A D300-360IN-A

1 2 3

NOTE: Changes entered for timing values will be effective only after exiting the programming, while changes to other variables will be immediately effective. Please remember that eventual changes to the configuration parameters of the machine could negatively affect its efficiency. Thus, changes have to be performed by a person familiar with the operation of the dryer.

WARNING FOR USER:

IT’S FORBIDDEN TO ATTEMPT TO MODIFY THE OTHER CONFIGURATION PARAMETERS OF THE ELECTRONIC CONTROLLER WITHOUT AUTHORIZATION AND COLLABORATION OF INGERSOLL RAND’S AUTHORIZED DISTRIBUTOR.

Cod. 710.0138.39.00 Rev03 – 02.2012 6 - 30

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3.1.3 DISPLAY INDICATIONS

he controller is capable of recognizing certain types of anomalies in the drying circuit. In such cases, a message will

T blink on the display, alternated to the current dew point value.

MESSAGE

(BLINKING)

CAUSE OUTPUTS ACTIONS

HtA

Ht2

LtA

PF1

ESA

ES2

ASt

High dew point value

(delayed alarm)

Very high dew point value

(immediate alarm)

Low dew point value

Interruption or short circuit on

the PTC probe input line

The automatic Energy saving

mode activated due to low

load

Activated after repeated

larms

Alarm output ON Refrig. Compressor output OFF Fan output ON Drain cycle standard

Alarm output ON Refrig. Compressor output OFF Fan output OFF Drain cycle standard

Alarm output OFF Refrig. Compressor output OFF Fan output OFF Drain cycle standard

Alarm output ON Refrig. Compressor output OFF Fan output ON Drain cycle standard

Resettable by switching off the dryer. If problem persists call your local Ingersoll Rand distributor.

Automatic reset when dew point returns to preset range. If problem persists call your local Ingersoll Rand distributor.

Resettable by switching off the dryer. May require replacing the faulty probe. If problem persists call your local Ingersoll Rand distributor.

No action necessary. Automatic Reset

Call your local Ingersoll Rand distributor.

Note: PF1 has priority on all other messages.

3.1.4 REMOTE SIGNALING ALARM

The dryer control board is equipped with a dry contact for a remote alarm signal. This is normally open contact: when an alarm is detected, this contact is closed. Proceed as follows to activate a remote alarm output:

1. The User must review the diagram below.

2. Disconnect the dryer from electrical power supply, remove cover and left side panel.

3. Connect the alarm circuit to the terminal blocks (See PIC.2).

4. Replace cover, left side panel and reconnect power.

Alarm Output relays electric features:

Max. 250VAC / 3A – AC 15 (Amp. Inductive)

PIC.2

The activation of the above function is at the User’s discretion. The User will purchase all necessary installation material. Any operation which needs access to the dryer must be carried out by qualified personnel.

Cod. 710.0138.39.00 Rev03 – 02.2012 7 - 30

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3.2 BEFORE START UP

Before starting the machine, make sure that all operating parameters correspond to the nominal data. The dryer is supplied already tested and preset for normal operation, and it doesn’t require any calibration.

Nevertheless, it’s necessary to check the operating performances during the first working hours.

3.3 START UP

The operations specified below must be performed after the first start up and at each start up after a prolonged inactive period of time due to maintenance operations, or any other reason.

1. Make sure that all instructions contained in chapters INSTALLATION SITE and INSTALLATION have been observed.

2. Ensure dryer by-pass is open and air inlet/outlet valves closed. (if existing).

3. Activate power supply and press the ON/OFF switch on the control panel for at least 1 second. (note there is a 2 minute delay before the dryer will start after the dryer is turned on).

4. Wait 5 to 10 minutes until machine has achieved its standard operating parameters.

5. Slowly open the air outlet valve and successively open the air inlet valve.

6. If existent, close the air by-pass valve.

7. Check if the condensate drain is working properly.

8. Check if all connecting pipes are properly tightened and fixed.

Before disconnecting the dryer from electrical power supply, use ON/OFF switch to stop the dryer. Otherwise wait 10 minutes before switching the dryer on again, in order to allow freon pressure to rebalance.

4. MAINTENANCE, TROUBLESHOOTING AND DECOMMISSIONING

4.1 MAINTENANCE

Before attempting any maintenance operation, make sure that:

1. No parts of the system are under pressure.

2. No parts of the system are electrically powered.

 WEEKLY OR EVERY 40 HOURS OF OPERATION

 Verify the temperature on the control panel display is acceptable.  Visually check if the condensate is drained regularly.

 MONTHLY OR EVERY 200 HOURS OF OPERATION

 Clean the condenser with compressed air, taking care not to damage the condenser fins..  At the end of the above mentioned operations, check if the dryer is working properly.  Check the condition of any filters installed with the dryer. Replace elements as needed.

 YEARLY OR EVERY 2000 HOURS OF OPERATION

 Check if the flexible tube used for condensate drainage is damaged and replace it if necessary.  Check if all connecting pipes are properly tightened and fixed.  At the end of the above mentioned operations, check if the dryer is working properly.

4.2 TROUBLESHOOTING

NOTE: FOLLOWING BEHAVIORS ARE NORMAL CHARACTERISTIC OF OPERATION AND NOT TROUBLES

• Variable speed of the fan.

• Display of message ESA and ES2 in case of operation without load or low load.

• A 2 minute delay for dryer to start after pressing the on/off switch.

Troubleshooting and eventual control and/or maintenance operations must be performed by qualified personnel.

For maintaining the refrigerating circuit of the machine, contact a refrigeration engineer.

Cod. 710.0138.39.00 Rev03 – 02.2012 8 - 30

Page 10

TROUBLE

DISPLAY

POSSIBLE CAUSE REMEDY

Control

panel

display is

blank

No power in the line. Restore the power in the line. Problems with cabling. Check cabling; if the trouble persists, replace it.

Problems with the electronic control board.

The dryer is off. Dryer in stand-by. Wait 2 minutes after the dryer is switched on.

Compressed air inlet/outlet inverted. The flow rate and/or temperature of the

air entering the dryer are higher than the nominal values. The ambient temperature is higher than the nominal values.

The condenser is dirty. Clean the condenser.

Condensate drain is not functioning.

The temperature control probe is positioned improperly or faulty.

Problems with cabling or with the electronic control board.

Activation of compressor’s internal thermal protection.

Problems with the electrical components of the compressor.

Check the electronic control board; if the trouble persists, replace it.

Turn it on by pressing the ON/OFF switch for 1 second.

Check if the compressed air inlet/outlet is connected properly.

Restore the nominal conditions.

Clean the condensate drainage system pre-filter. (Pic.3) 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; if the trouble persists, replace it.

Check the probe; if the trouble persists, replace it. Check the cabling and the electronic control board, if

the trouble persists, replace them. Wait one hour and check again. If the fault persists: stop dryer and call your local Ingersoll Rand distributor.

Check the electrical components of the compressor.

Defective compressor. Replace the compressor.

WATER IN THE SYSTEM

The flow rate and/or temperature of the air entering the dryer are higher than the nominal values. The ambient temperature is higher than the nominal values.

The condenser is dirty. Clean the condenser. The temperature control probe is

positioned improperly or faulty. Fan pressure switch defective or burned out (if present). High pressure switch defective or burned out (if present).

Gas leakage in the refrigerating circuit. Defective fan. Replace the fan.

Protection fuse burned out (if present). Replace the fuse. The temperature control probe is

positioned improperly or faulty. Gas leakage in the refrigerating circuit

without load. The temperature control probe is

positioned improperly or faulty. Series of alarms very close to each

other.

Restore the nominal conditions.

Check the probe; if the trouble persists, replace it. Turn off the dryer and call your local Ingersoll Rand

distributor. Turn off the dryer and call your local Ingersoll Rand distributor. Turn off the dryer and call your local Ingersoll Rand distributor.

Check the probe; if the trouble persists, replace it.

Turn off the dryer and call your local Ingersoll Rand distributor.

Check the probe; if the trouble persists, replace it.

Call your local Ingersoll Rand distributor.

Cod. 710.0138.39.00 Rev03 – 02.2012 9 - 30

Page 11

in compli

ance with the

TROUBLE

DISPLAY

POSSIBLE CAUSE REMEDY

Ice formation in the evaporator.

Clog.

LOW PRESSURE IN THE LINE

Air flows continuously through the condensate drainage.

Check the probe; if the trouble persists, replace it. Check the electronic control board; if the trouble

persists, replace it. Contact our Service Centre to check the gas charge.

Check if the compressed air inlet/outlet is connected properly. Check if the connecting tubing is clogged; in case proceed accordingly.

Check if any valves are closed. Check the condition of any filter.

Drainage solenoid valve jammed, clean or replace it. Verify the condensate drainage times set on the

electronic control board (C8 and C9). Check the signal from the control board: if it is continuous, replace the control board.

IMPORTANT:

The temperature control probe is extremely delicate. Do not remove the probe from its position. In case of any kind of problem, please contact your local Ingersoll Rand distributor

Pic.3

4.3 DECOMMISSIONING

In case of necessity, decommission the machine and the relevant packaging

rules locally in force.

Pay particular attention to the refrigerant, as it contains part of the refrigerating compressor lubricating oil.

Always contact a waste disposal and recycling facility.

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Page 12

ATTACHMENTS TO THIS MANUAL - ANNEXES AU MANUEL

1A1

1B1

1M1

1M2

1P1

1P2

1Q1

1Q2

1S1

1S2

1T1

1V1

CBL

CND

CNV

CPL

EVA

F1 – F2

PCP

PSC

RBF

RT1

SCO

SLI

SSC

STC

TEMP

TLT

VNR

X1-X2

Legend - Légende:

Pos. -

GB - DESCRIPTION - F - DESCRIPTION

Electronic Controller Contrôleur électronique

Drain solenoid valve coil Bobine électrovalve de décharge

Refrigerant compressor Compresseur réfrigérant

Fan Motor Ventilateur

High pressure Switch Pressostat haute pression

Fan pressure Switch Pressostat de ventilation

Compressor circuit breaker Interrupteur automatique de compresseur

Fan circuit breaker Interrupteur automatique de ventilation Main power switch Interrupteur général

Plug Fiche

Transformer Transformateur

Solenoid drain Valve Purge de condensants

Compressor box Boîte de compresseur

Cables câbles

Condenser Condenseur Fan capacitor Condenseur de ventilation Capillary tube Tubo capillaire Electrical box Boîte électrique

10 micron filter element Cartouche 10 micron

0.01 micron filter element Cartouche 0.01 micron 1 micron filter element Cartouche 1 micron 5 micron filter element Cartouche 5 micron

Evaporator Evaporateur

Fuses Fusibles

Air filter 10 micron Filtre à air 10 micron

Filter dryer Filtre déshydrateur

Air filter 0.01 micron Filtre à air 0.01 micron

Air filter 1 micron Filtre à air 1 micron Air filter 5 micron Filtre à air 5 micron

Drain screen Filtro a red

Fan motor fuse Fusible de ventilateur

Grid Grille

Moisture indicator Indicateur d'humidité

Contactor switch Commutat. de conjoncteur

Fan contactor switch Commutat. de conjoncteur de ventilateur

Thermal protection Protection thermique

Air-air heat exchanger Echangeur air-air

Air-air heat exchanger (D__IT) Echangeur air-air (D__IT)

Tap with strainer Valve à bille avec le tamis

Rotalock cock Robinet rotalock

Temperature probes Sondes de température

Heat exchanger base Base de l’échangeur de chaleur

Condensate separator Séparateur de condensants

Liquid separator Liquide séparateur

Condensate drain Purge de condensants

Control panel cover Couverture de panneau de commande

Time setter Temporisateur Thermostat Thermostat

Remote cont. Thermostat Tele Thermostat digital

By-pass hot gas valve Vanne de fréon

Expansion valve Soupape d’ expansion

One way valves with strainer Soupape unidirection. / filtre

Fan blade Ventilateur

X3-XM

Terminal blocks Boîte terminale électrique

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Page 13

A) REFRIGERANT CIRCUIT - CIRCUIT FRIGORIFÉRIQUE

Cod. 713.0048.04.00 – Rev. 00

Models D12IN-A to D180IN-A

od. 713.0057.06.00 – Rev. 00

Models D300IN-A to D360IN-A

Condensate drain Purge de condensant Air inlet Entrée de l'air Air outlet Sortie de l'air

Cod. 710.0138.39.00 Rev03 – 02.2012 21 - 30

Refrigerant line Ligne réfrigérant Compressed air line Ligne de l'air comprimé Condensate drain line Ligne de drainage Equalization line Ligne de égalisation

Page 14

B) WIRING DIAGRAM - SCHEMA ÉLECTRIQUE

Cod. 714.0164.01.00 – Rev. 00

Models D12IN-A to D72IN-A (115V/1Ph/60Hz)

Cod. 714.0165.01.00 – Rev. 00

Models D108IN-A to D180IN-A (115V/1Ph/60Hz)

Cod. 710.0138.39.00 Rev03 – 02.2012 22 - 30

Page 15

Cod. 714.0168.03.00 – Rev. 00

Models D300IN-A to D360IN-A (230V/1Ph/60Hz)

Cod. 710.0138.39.00 Rev03 – 02.2012 23 - 30

Page 16

MODEL

D25IN

-A-

+ / - 5%

AIR FLOW

RATE*

POW SUPPLY

1M1

COMPRESSOR

1M2

FAN MOTOR

TOTAL A A

CONNECTION NPT

AIR T

AIR T MAX

AMB T

AMB T MIN-MAX

AIR W PRESS

AIR PRESS MAX

DEW POINT*

REFRIGERANT

CFM M3/h

VOLT/

PH/HZ

HP kW

Max kW

RLA

FLA LRA QTY

HP RLA LRA

psi

bar

psi

bar

TYPE

LB OZ KG

°F °C °F °C °F °C °F °C

°F °C

C) D

ATA SHEET - CARACTERISTIQUES TECHNIQUES

12IN-A D18IN-A

7 11 15 25 32 42 64 85 106 176 212

12 18 25 42 54 72 108 144 180 300 360

1/10 1/10 1/10 1/6 1/3 1/3 1/3+ 1/2 2/3 1 1

0.14 0.14 0.14 0.20 0.37 0.37 0.49 0.61 0.71 1.34 1.34

0.20 0.20 0.20 0.31 0.49 0.49 0.77 0.81 1.14 1.55 1.55

1.83 1.83 1.83 2.6 4.23 4.23 6.05 7.93 8.16 6.5 6.5

2.5 2.5 2.5 3.5 4.10 4.10 8.10 9.23 11.6 7.35 7.35

14.5 14.5 14.5 23 32.5 32.5 43 44 46 35 35 1 1 1 1 1 1 1 1 1 1 1

1/80 1/80 1/80 1/80 1/80 1/80 1/46 1/46 1/46 2/5 2/5

0.58 0.58 0.58 0.58 0.58 0.58 1.00 1.00 1.00 1.04 1.04

0.76 0.76 0.76 0.76 0.76 0.76 1.36 1.36 1.36 1.35 1.35

2.8 2.8 2.8 3.6 6 6 8 9 12.6 8 8

3/8" 3/8" 3/8" ½" ½" ½" ¾" ¾" ¾" 1½" 1½"

0.31 0.31 0.31 0.62 0.57 0.57 0.77 0.84 0.99 1.98 1.98

4.94 4.94 4.94 9.88 9.17 9.17 12.35 13.40 15.87 32 32

0.14 0.14 0.14 0.28 0.26 0.26 0.35 0.38 0.45 0.9 0.9

D42IN-A D54IN-A D72IN-A D108IN-A D144IN-A D180IN-A D300IN-A D360IN-A

115/1/60 230/1/60

100

140

100

36 - 122

2 - 50

100

203 174

14 12

< 50 (ISO CLASS 6) < 10 (ISO CLASS 6)

R134a R407C

MAX FUSE A Not present – Pas présent

MIN CIRCUIT

AMPACITY

WEIGHT

EVAP. TEMP.*

SUCTION

TEMP.*

DISCH. PRESS.*

HP SWITCH

SETTING

Rating conditions of: 38°C (100°F) and 100 psig Ai r Inlet, 38°C (100°F) Ambient

* *Conditions de fonctionnement de: 38°C (100°F) et 100 psig air en entrée, 38°C (100°F) température am bient

Performance and specifications - Performances et caractéristiques techniques

Cod. 710.0138.39.00 Rev03 – 02.2012 24 - 30

A Not present – Pas présent

°F °C °F °C

psig

Bar

psig

Bar

39.7 39.7 39.7 77.2 61.7 61.7 77.2 81.6 103.6 191.8 191.8

18 18 18 27 28 28 35 37 47 87 87

37 – 41 37 – 41

3 – 5 3 – 5

39 – 43 39 – 50

4 – 6 4 – 10

170 – 230 180 – 246

12 – 16 13 – 17

435 435

30 3

15 15 10 10

Page 17

Legend - Légende:

Pos. - GB - DESCRIPTION - F - DESCRIPTION

POW SUPPLY

Max kW

RLA

FLA

LRA

TOTAL A

CONNECTION

AIR T

AIR T MAX

Air flow rate Performances

Power supply Alimentation

Nominal power Puissance nom.

Nominal consumption Consommation nom.

Full load consumption Cons. pleine charge

Nominal Current Ampère nominale

Full load current Ampère pl. charge

Locked rotor current Ampère max.

Total current A

Air connections Connexion aircomp.

Air inlet temperature Temp. entrée d’air

Max. air inlet temperature

mpère total

Temp. entrée d’air

max.

AMB T MIN-

MAX

AIR W PRESS

AIR PRESS

MAX

DEWP

REF

MAX FUSE

MIN CIRCUIT

AMPACITY

EVAP. TEMP

SUCTION TEMP

DISCH. PRESS.

HP SWITCH

SETTING

Min-Max. ambient

temperature

Air working pressure Pression travail d’air

Max. air pressure Pression max. d’air

Pressure dew point Pression pt de rosée

Refrigerant Réfrigérant

Max fuse size Maximum fusibles

Minimum circuit

ampacity

Weight Poids

Evaporation

Temperature

Suction Temperature

Discharge Pressure Pression de décharge

High pressure switch

setting

Temp. Ambiante min-

max.

Minimum courant

électrique

Température

d'évaporation

Température

d'aspiration

Réglage du pressostat

de haute pression

AMB T

Ambient temperature Temp. ambiante

) CORRECTION FACTORS - FACTEURS DE CORRECTION

Correction factor for working pressure - Facteur de correction pour la pression du travail

bar psi 73 87 102 116 131 145 160 174 188,5 203

FC1

Correction factor for inlet air temperature - Facteur de correction pour la température de l'air d'entrée

°C °F 80 90 100 110 120 130 140

FC3

Correction factor for ambient temperature- Facteur de correction pour la température ambiante

°C °F 80 90 100 105 110 122

FC2

Calculation of the dryer REAL FLOW RATE = nominal dryer flow rate x FC1 x FC2 x FC3 Calcul du DÉBIT RÉEL du séchoir = débit nominal du séchoir x FC1 x FC2 x FC3

Calculation of the GIVEN FLOW RATE to select a suitable dryer = given flow rate ÷ FC1 ÷ FC2 ÷ FC3 Calcul du DÉBIT DONNÉ pour sélectionner un séchoir approprié = débit donné ÷ FC1 ÷ FC2 ÷ FC3

5 6 7 8 9 10 11 12 13 14

0,85 0,93 1 1,06 1,11 1,15 1,18 1,2 1,22 1,24

26,5 32 37,8 43,5 49 54,5 60

1,3 1,18 1 0,8 0,6 0,42 0,25

26,5 32 37,8 40,5 43,5 50

1,1 1,05 1 0,93 0,83 0,65

Cod. 710.0138.39.00 Rev03 – 02.2012 25 - 30

Page 18

E) DRYER DIMENSIONS - DIMENSIONS DU SECHEUR

Models D12IN-A to D25IN-A-SR

A B C D E F G H

inches

305 360 408 51 40 50 332 24

12"

14"

3/16

16"

1/16

Power supply Alimentation

9/16

Models D42IN-A to D180IN-A

3/8"

13"

1/16

15/16"

Air flow Circulation de l'air

NPT

3/8"

NPT Ø 6mm

115/1/60

V/ph/Hz

D42IN-A

D72IN-A

D108IN-A

D180IN-A

Cod. 710.0138.39.00 Rev03 – 02.2012 26 - 30

mm 390 432 441 100 85 65 45 65 12

inches

mm 420 516 551 100 85 80 44 63 12

inches

B C D E F G H L

15" 3/8

16"

9/16

17" 17"

20"

5/16

3/8

21"

11/16

15/16

3/8

9/16

3/16

3/4

9/16

1/2

7/16"

1/2"

NPT

3/4"

NPT

1/2"

NPT

3/4"

NPT

6mm

115/1/60

V/ph/Hz

115/1/60

V/ph/Hz

Page 19

Models D300IN-A to D360IN-A

B C D E F G H

inches

500 679 980 157 254 99.5 114 40 19"

11/16

26"

38"

3/4

9/16

Power supply Alimentation

3/16

10"

15/16

1/2

Air flow Circulation de l'air

9/16

1/2

NPT

1/2

NPT

Ø 6mm

230/1/60

V/ph/Hz

Cod. 710.0138.39.00 Rev03 – 02.2012 27 - 30

Page 20

F) BASIC SPARE PARTS - PIÈCES DE RECHANGE ESSENTIELLES

Model

Pos

1A1 RT1 1M1 1M2

G 1P1 1S1

1V1

1B1

CND

FF FR K1 SC

STC

Element

Electronic Controller 38457404 38457404 38457404 38457404 38457404 38457404 38457404 38457404 38457404

Temperature probe 38457412 38457412 38457412 38457412 38457412 38457412 38457412 38457412 38457412

Refrigerant compressor

Fan Motor 38457768 38457768 38457768 38457768 38457768 38457768 38457776 38457776 38457776

Fan blade 38457784 38457784 38457784 38457784 38457784 38457784 38457792 38457792 38457792

Grid - - 38457800 38457800 38457800 38457800 38457818 38457818 38457818

High pressure Switch 38457511 38457511 38457511 38457511 38457511 38457511 38457511 38457511 38457511

Main power switch - - - - - - 38457826 38457826 38457826

Complete solenoid drain

valve

Drain solenoid valve coil 38457545 38457545 38457545 38457545 38457545 38457545 38457545 38457545 38457545

Condenser 38457834 38457834 38459087 38457859 38457859 38457859 38457867 38457867 38457875

Filter dryer 38457594 38457594 38457594 38457594 38457594 38457594 38457602 38457602 38457602

Drain screen 38457891 38457891

Contactor switch - - - - - - 38457644 38457644 38457644

Heat exchanger base 38457909 38457909 38457909 38457651 38457651 38457651 38457669 38457677 38457677

Control panel cover 38457883 38457883 38457883 38457917 38457917 38457917 38457917 38457917 38457917

D12IN-A D18IN-A

24062093 24062093 24062093 24062101 24062135 24062135 24062119 24062127

38457537 38457537 38457537 38457537 38457537 38457537 38457537 38457537 38457537

D25IN-A-

38457891 38457891 38457891 38457891 38457636 38457636 38457636

D42IN-A D54IN-A D72IN-A D108IN-A D144IN-A D180IN-A

38457461

1M2

STC

RT1

1P1

1M1

1B1

1V1

1S1

1A1

CND

DETAIL A

Cod. 710.0138.39.00 Rev03 – 02.2012 28 - 30

Page 21

Model

Pos

1A1

RT1

1M1

1M2

1P1

1S1

1V1

1B1

CND

RBF

STC

Element

Electronic

Controller

Temperature

probe

Refrigerant

compressor

Fan Motor Fan blade

Grid

High pressure

Switch

Main power

switch

Complete

solenoid drain

valve

Drain solenoid

valve coil

Condenser 38459681 38459699

Filter dryer 38459707 38459707

Drain screen 38457636 38457636

Contactor switch 38459723

Heat exchanger

base

Control panel cover 38457917 38457917

By-pass hot gas

valve

300IN-A

38459608 38459608

38459616 38459616

24044976 24044976

38459632

38457511

38459657

38459665

38459673

23516370

23716095

D360IN-A

38459632

38457511

38459657

38459665

38459673

38459723 23516370

23716095

1P1

Cod. 710.0138.39.00 Rev03 – 02.2012 29 - 30

Page 22

DICHIARAZIONE CE DI CONFORMITA'

-PL-

DECLARATION OF CONFORMITY

EC DECLARATION DE CONFORMITE’ CEE KONFORMITATSERKLARUNG GEMASS EG-RICHTLINIE ∆ΗΛΩΣΗ ΣΥΜΜΟΡΦΩΣΗΣ CE

NOI - WE - NOUS - WIR - ΕΜΕΙΣ - NOSOTROS - NOS - WIJ - VI - MY

DECLARATION DE CONFORMIDAD CEE DECLARACAO DE CONFORMIDADE CEE OVEREENKOMSTVERKLARING EG-RICHTLIJN EEG EC DECLARATION EEG DEKLARACJA ZGODNOŚCI CE

-I- Dichiariamo sotto la nostra esclusiva responsabilità che il prodotto al quale questa dichiarazione si riferisce, è conforme alle seguenti Direttive, nonché norme armonizzate. Fascicolo tecnico disponibile presso il costruttore.

-UK- Declare under our sole responsibility that the product which this declaration relates is in conformity with the following standards and other normative documents. Technical file is available at the offices of the manufacturer.

-F- Déclarons sous notre entière responsabilité que le produit auquel cette déclaration se réfère, est conforme aux normes suivantes et aux autres règlementations CEE. Le dossier technique est disponible aux bureaux du fabricant.

- Wir Erklären,daß das Produkt,für welches diese Erklärung gilt,unter unserer alleiniget Verantwortung in Übereinstimmung mit den nachfolgenden EG-Richtlinien und anderen Normen gefertigt wurde. Die Technisches Heft ist in den Büros des Herstellers vorhanden.

-GR- ∆ηλώνουµε µε αποκλειστική µας ευθύνη ότι το προϊόν που

αναφέρεται στην παρούσα συµµορφώνεται µε τα ακόλουθα πρότυπα και οδηγίες της Ε.Ε. . Τεχνικό φάκελο είναι διαθέσιµο στα γραφεία του κατασκευαστή.

2006/42/CE : UNI EN ISO 12100/1-2:2005

97/

23/CE : EN 13445-3 ; 2006/95/CE : EN60204-1 :2006

2004/108/CE : EN50081-2/92, EN50082-2/95

-E- Declaramos bajo nuestro unica responsabilidad que el producto al cual esta declaracion se refiere,es conforme a las siguientes normas y otros documentos normativos. El archivo técnico está disponible en las oficinas del fabricante.

- Declaramos sob nossa exclusiva responsabilidade que o produto a que se refere esta declaraçào està conforme as seguientes normas e/ou documentos normativos. O fasciculo técnico está disponível nos escritórios do fabricante.

- Verklaren dat onder onze volledige verantwoording de volgende producten warrop deze verklarimg betrekking heeft,met de volgende richtlijnen en andere normatieve documenten overeenkomen. Het technische boekje is beschikbaar op de kantoren van de fabrikant.

-S- Förklarar härmed som ensam ansvarig för tillverkning av produkten vilken detta intyg gäller,att denna produkt överensstämmer med följande standard och andra normativa dokument. Teknisk dokumentation finns tillgängliga hos tillverkaren.

Deklarujemy, na naszą wyłączną odpowiedzialność, że wyrób, którego niniejsza deklaracja dotyczy, jest zgodny z następującymi normami i innymi dokumentami normującymi. Stosowne dane techniczne jest dostępny w urzędy producenta.

Nome, Name, Name, Όνοµα, Imię, /

Cognome, Surname, Nachname, Nazwisko

Giovanni Capellari

................................................................

Posizione, Position, Stellung, Θ

Stanowisko

General Manager

.................................................................

έση,

Data, Date, Datum

.................................................................

Firma - Signature - Unterschrift - Υ

Firma - Assinatura - Ondertekening -

underskrift - Podpis

πογραφή -

.................................................................

Cod. 710.0138.39.00 Rev03 – 02.2012 30 - 30