Ingersoll-Rand NVC 200, NVC 300, NVC 400 Operator's Manual
Nirvana Cycling Refrigerated Dryer
ENGLISH
PORTUGUESE
PRINT LANGUAGE
FRENCH
SPANISH
Models 200-400
Operator’s Manual
EN
Operator’s Manual
ES
Manual Del Operador
FR
Manuel De L’opérateur
PT
Manual do Operador
80442775
Revision E
July 2012
Save These Instructions
1.0 CONTENTS
CONTENTS PAGE CONTENTS PAGE
1.0 CONTENTS 2
2.0 INTRODUCTION 3
3.0 WARRANTY 3
4.0 REFRIGERATED DRYER NOMENCLATURE 3
5.0 RECEIVING AND INSPECTION 4
5.1 INSPECTION 4
5.2 UNPACKING AND HANDLING 4
6.0 SAFETY AND OPERATION PRECAUTIONS 4
7.0 PRINCIPLES OF OPERATION 6
7.1 INTRODUCTION 6
7.2 AIR SYSTEM 6
7.3 MOISTURE REMOVAL SYSTEM 6
7.3.1 SOLENOID DRAIN STANDARD 6
7.3.2 NO AIR LOSS DRAIN OPTIONAL 7
7.4 REFRIGERATION SYSTEM 7
7.5 THERMAL MASS CIRCULATING
SYSTEM 7
7.6 CONTROLS 7
7.6.1 BASIC USER INTERFACE 8
7.6.2 EXCHANGER TEMPERATURE SET
POINT AND ALARMS 8
7.6.3 ADJUSTING SET POINTS 9
7.6.4 ALARMS AND THEIR FUNCTIONS 9
7.6.5 ALERT MESSAGES 9
7.6.6 START MODES 9
7.6.6.1 MANUAL MODE 9
7.6.6.2 REMOTE MODE OPTIONAL 9
7.6.6.3 AUTO RESTART 10
8.0 INSTALLATION AND INITIAL STARTUP 10
8.1 LOCATION AND MOUNTING 10
8.2 PIPING AND VALVES 10
8.3 FILTRATION 10
8.4 ELECTRICAL CONNECTION 11
8.5 INITIAL STARTUP 11
8.5.1 START UP SEQUENCE 11
9.0 SCHEDULED MAINTENANCE 12
9.1 INTRODUCTION 12
9.2 REFRIGERANT CONDENSER 12
9.3 CONDENSATE DISCHARGE SYSTEM 12
9.3.1 SOLENOID DRAIN STANDARD 12
9.3.1.1 CLEANING INSTRUCTIONS
SOLENOID DRAIN 12
9.3.2 NO AIR LOSS DRAIN OPTIONAL 13
9.4 PANEL FILTER ELEMENT 13
9.5 PREFILTERS AND POSTFILTERS 13
10.0 TROUBLESHOOTING 14
10.1 INTRODUCTION 14
10.2 PROBLEM / ACTION GUIDE 14
11.0 WIRING DIAGRAMS 17
12.0 GENERAL ARRANGEMENT 21
13.0 REPLACEMENT PARTS 22
13.0 REPLACEMENT PARTS 23
14.0 ENGINEERING SPECIFICATIONS 23
2 NIRVANA CYCLING REFRIGERATED DRYER MODELS 200-400
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2.0 INTRODUCTION
Ingersoll Rand Nirvana™ Cycling refrigerated air dryer
removes moisture, oil vapor, and other contaminants from
compressed air. These contaminants are detrimental to
pneumatically operated appliances, controls, instruments,
machinery and tools. This removal is accomplished by
cooling the air with a refrigeration unit to a temperature
at which moisture in the air is condensed and separated
3.0 WARRANTY
The Company warrants that the equipment manufactured
by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months
from the date of placing the Equipment in operation or
eighteen months from the date of shipment from the
factory, whichever shall rst occur. The Purchaser shall
be obligated to promptly report any failure to conform
to this warranty, in writing to the Company in said
period, whereupon the Company shall, at its option,
correct such nonconformity, by suitable repair to such
equipment or, furnish a replacement part F.O.B. point of
shipment, provided the Purchaser has stored, installed,
maintained and operated such Equipment in accordance
with good industry practices and has complied with
specic 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 eects of corrosion, erosion and normal wear and
tear are specically excluded. Performance warranties are
limited to those specically stated within the Company’s
proposal. Unless responsibility for meeting such
from the air stream. The temperature the air is cooled to,
normally between 34° and 38°F (1° and 3°C), is known as
dew point. This dryer can be easily installed into various
pneumatic systems in which dry air is required or desired.
Please refer to Principles of Operation for complete
operating details.
performance warranties are limited to specied tests, the
Company’s obligation shall be to correct in the manner and
for the period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR
REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED
OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, ARE HERBY DISCLAIMED.
Correction by the Company of nonconformities whether
patent or latent, in the manner and for the period of time
provided above, shall constitute fulllment of all liabilities
of the Company for such nonconformities whether
based on contract, warranty negligence, indemnity, strict
liability or otherwise with respect to or arising out of such
Equipment.
The Purchaser shall not operate Equipment which is
considered to be defective, without rst notifying the
Company in writing of its intention to do so. Any such use
of Equipment will be at Purchaser’s sole risk and liability.
Note that this is Ingersoll Rand standard warranty. Any
warranty in force at the time of purchase of the equipment
or negotiated as part of the purchase order may take prec-
edence over this warranty.
4.0 REFRIGERATED DRYER NOMENCLATURE
PREFIX NOMINAL*
FLOW
NVC 200-400 A = AIR
* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 100 psig compressed air
pressure.
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CONDENSER
TYPE
W = WATER
POWER RATING
2 = 230-1-60
4 = 460-3-60
5 = 230-3-60
6 = 575-3-60
7 = 380-3-50
8 = 220-3-50
0 = NEMA 1
H = NEMA 4
5.0 RECEIVING AND INSPECTION
5.1 INSPECTION
Upon receiving your Ingersoll Rand air dryer, please
inspect the unit closely. If rough handling has been
detected, please note it on your delivery receipt, especially
if the dryer will not be uncrated immediately. Obtaining the
delivery person’s signed agreement to any noted damages
will facilitate any insurance claims.
5.2 UNPACKING AND HANDLING
WARNING
Under no circumstances should any person
attempt to lift heavy objects without proper lifting
equipment (i.e., crane, hoist, slings or fork truck).
Lifting any unit without proper lifting equipment,
may cause serious injury.
6.0 SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating
parts, the same precautions should be observed as with
any piece of machinery of this type where carelessness in
operation or maintenance could be hazardous to personnel.
In addition to obvious safety rules that should be followed
with this type of machinery, safety precautions as listed
below must be observed:
Only qualied personnel shall be permitted to adjust,
1.
perform maintenance or repair this air dryer.
To facilitate handling during shipment, all dryer packages
have been mounted on a base that provides for forklifting
between two base channels. Forks should extend all the
way through forklift channels to reduce unnecessary forces
to the dryer during moving. Slings can be used to lift the
crates, but spreader bars must be used to prevent the slings
from exerting a force against the sides of the crates or the
dryer.
OSHA Heading Descriptions
WARNING
“Warning” is used to indicate a hazardous
situation which has some probability of death or
severe injury. Warning should not be considered
for property damage accidents unless personal
injury risk is present.
Read all instructions completely before operating
2.
unit.
Pull main electrical disconnect switch and
3.
disconnect any separate control lines, if used, before
attempting to work or perform maintenance on the
unit.
Do not attempt to service any part while machine is
4.
in an operational mode.
Do not attempt to remove any parts without rst
5.
relieving the entire air system of pressure.
Do not attempt to remove any part of the
6.
refrigeration system without removing and
containing refrigerant in accordance with the EPA
and local regulations.
Do not operate the dryer at pressures in excess of its
7.
rating.
Do not operate the dryer without guards, shields and
8.
screen in place.
Inspect unit daily to observe and correct any unsafe
9.
operating conditions.
CAUTION
“Caution” is used to indicate a hazardous situation
which may result in minor or moderate injury.
NOTICE
“Notice” is used to indicate a statement of company
policy as the message relates directly or indirectly
to the safety of personnel or protection of
property. Notice should not be associated directly
with a hazard or hazardous situation and must
not be used in place of “Danger,” “Warning,” or
“Caution.”
NOTICE
The user of any air dryer manufactured by Ingersoll
Rand, is hereby warned that failure to follow the
above Safety and Operation Precautions may result
in personal injury or equipment damage. However,
Ingersoll Rand does not state as fact, nor does it
mean to imply, that the preceding list of Safety and
Operating Precautions is all inclusive, and further,
that the observance of this list will prevent all
personal injury or equipment damage.
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6.0 SAFETY AND OPERATION PRECAUTIONS
Air Under Pressure Will Cause
Injury, Death Or Property Damage.
• Do Not Exceed Pressure Rating.
• Relieve Press. Before Servicing.
• Do Not Modify/Repair/Rework
ASME Coded Pressure Vessels
As Insurance Rating Aected.
READ TECHNICAL MANUAL
ELECTRICAL CONNECTION BOX
All Customer Connections To Be Made At This Location.
See Terminal Connection Diagrams, below.
Be Certain To Follow All NEC, State, Local and Other Applicable
Codes During Installation.
1
2
3
4
5
6
GRN
WHT
BLK
G
N
L1
FACTORY
WIRING
INCOMING
LINE VOLTAGE
100-125VAC
1PH/50-60HZ
(BY OTHERS)
(REFER TO UNIT
NAMEPLATE FOR
POWER
REQUIREMENTS)
100-125VAC / 1 PH
1
2
3
4
5
6
GRN
BLK
G
L1
RED
L2
FACTORY
WIRING
INCOMING
LINE VOLTAGE
200-240VAC
1PH/50-60HZ
(BY OTHERS)
(REFER TO UNIT
NAMEPLATE FOR
POWER
REQUIREMENTS)
200-240VAC / 1 PH
1
2
3
4
5
6
GRN
RED
WHT
G
L1
L2
BLK
L3
FACTORY
WIRING
INCOMING
LINE VOLTAGE
200-575VAC
3PH/50-60HZ
(BY OTHERS)
(REFER TO UNIT
NAMEPLATE FOR
POWER
REQUIREMENTS)
200-575VAC / 3 PH
•
•
•
ELECTRICAL CONNECTION BOX
CONTAINS HIGH VOLTAGE
• Turn O 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 Cause
Injury, Death Or Property Dam age.
• Relieve Press. Before Servicing.
• Condensate Drain Discharges
Under Pressure.
• Drain Requires Periodic
Cleaning (Service).
READ TECHNICAL MANUAL
Removing fuses will not disconnect
power from dryer. Always disconnect
power from ALL sources before
performing service.
READ TECHNICAL MANUAL
HIGH VOLTAGE
This unit is charged with
refrigerant under high pressure.
FAN MAY AUTOMATICALLY
START AT ANY TIME
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7.0 PRINCIPLES OF OPERATION
7.1 INTRODUCTION
Ingersoll Rand Nirvana™ Cycling dryers remove moisture
from compressed air by cooling the air temperature to
between 34° and 38°F (1 and 3°C). This causes vapors to
condense into liquid droplets which can then be easily
removed from the air. The major systems of the dryer which
contribute to its operation are the Air System, the Moisture
Removal System, the Refrigeration System, the Thermal
Mass Circulating System and the Controls. The following
paragraphs describe each of the systems in greater detail.
7.2 AIR SYSTEM
The air system consists of the dryer components which are
in contact with the compressed air. Referring to
Figure 1 and following the bold “AIR FLOW,” hot saturated
air from the compressor enters the precooler/reheater
where the air temperature is reduced prior to entering the
chiller by the cool air exiting the air/moisture separator.
This precooling allows for the use of a smaller refrigeration
system. The air then goes into the chiller section where
it is further cooled to the desired dew point by a thermal
mass uid. The temperature of the thermal mass uid is
maintained by the refrigeration circuit and controls. The
air continues to the separator where moisture is removed,
thereby, allowing the cool, dry air to return back to the
precooler/reheater to be heated by the incoming moist
hot air. The air exiting the “reheater” portion of the dryer
should be approximately 15°- 20°F lower than the inlet air
temperature based on standard conditions at full rated ow.
FAN MOTOR
AIR INLET
PRECOOLER / REHEATER
CHILLER
EVAPORATOR
CONDENSATE
DRAIN
LEGEND
AIR OUTLET
SEPARATOR
AIR FLOW
REFRIG (R404A) FLOW
THERMAL MASS FLUID
CONDENSATE LINE
WATER FLOW
CHILLER (EXCHANGER) TEMPERATURE
DIGITAL DISPLAY
CONTROL ENCLOSURE
FIGURE 1 FLOW DIAGRAM
7.3 MOISTURE REMOVAL SYSTEM
Ingersoll Rand condensate drains discharge condensed
moisture and lubricants (condensate) from compressed air
equipment.
Liquid droplets are removed from the air stream in the
separator. As the air and liquid mixture passes through the
separator it spins, slows down and then changes direction.
This causes condensate to fall out of the air stream and
collect in the bottom of the separator. The collected
liquid is removed from the separator by a timed electric
drain(standard) which is controlled by the Controller OR an
optional No-Air Loss drain.
WATER-COOLED CONDENSER
WATER IN
WATER OUT
CIRCULATING PUMP
WATER
REGULATING
VALVE
FILTER
DRYER
AIR COOLED
CONDENSER
THERMAL MASS RESERVOIR
REFRIGERANT MATERING
DEVICE
REFRIG
COMPRESSOR
PROCESS AND
INSTRUMENTATION
DIAGRAM
NVC200-400
AIR AND
WATERCOOLED
550032-D
7.3.1 SOLENOID DRAIN (STANDARD)
The Drain Open time and Drain Closed time are accessed
by depressing the appropriate button and using the up and
down arrows to change the value. The Drain Open value is
seconds; the Drain Closed value is minutes.
To obtain the optimum time values for operation of
•
the electric drain valve, set the drain closed time to
ve minutes and the open time to ten seconds.
After running the unit under full rated ow for
•
approximately 30 minutes, verify that when the
electric drain opens, all of the accumulated liquid is
discharged and then followed by a small burst of air.
6 ingersollrandproducts.com
7.0 PRINCIPLES OF OPERATION
If a small amount of liquid and a large amount of
•
air is discharged, decrease the on-time setting or
increase the o-time setting. If there is all liquid and
no air has been discharged, increase the on-time
setting or decrease the o-time setting.
The on/o-time settings will vary accordingly to
•
seasonal conditions. During the summer when
more moisture is present in the air system, a shorter
ontime that increases the valve opening frequency is
required. A longer o-time may be used during the
winter months when moisture levels are lower.
7.3.2 NO AIR LOSS DRAIN (OPTIONAL)
The condensate drain operates as a zero-air-loss drain,
returning air that is displaced in the drain bowl back into
the compressed air system. Consistent discharging of
condensate from compressed air equipment is essential for
proper equipment operation and performance.
The condensate drain uses a unique sensing method to
determine the level of condensate in the drain bowl. A
transducer located in the drain bowl continuously sends
out a signal 50 times per second. Once the transducer
determines that the level of condensate has reached a
predetermined level within the drain bowl, a signal is sent
to the no-loss drain valve to open. This operation permits
removal of condensate of up to 80 gallons per hour.
tube (expansion valve on water-cooled dryers) meters
the refrigerant for introduction into the evaporator.
The refrigerant pressure is reduced upon entering the
evaporator where as it evaporates, removes heat from the
thermal mass uid.
7.5 THERMAL MASS CIRCULATING SYSTEM
The thermal mass uid in a Ingersoll Rand Nirvana™
Cycling dryer is continuously circulated in a closed pump
loop system. Referring to Figure 1 and following the dashed
“THERMAL FLUID” line, the heat is removed from the uid
in the evaporator by the refrigeration system. The thermal
mass reservoir is sized to minimize refrigeration cycles
during reduced air load periods. The thermal mass uid
is pulled from the bottom of the reservoir and pumped
through the chiller, removing heat from the air and then
returned to the evaporator. The pump utilized on the
Ingersoll Rand Nirvana™ Cycling dryer is a maintenancefree, quiet cartridge circulator pump similar to those
used in residential water systems. While the refrigeration
system cycles on and o based on loading conditions,
the circulating pump runs continuously to maintain ow
through the chiller at all times. Note that when the power
switch is set to the o position, the circulating pump will
not operate.
7.6 CONTROLS
The drain also features a test button that permits manual
operation of the no-loss drain valve. Depressing the test
button illuminates the LED and energizes the solenoid
valve. The LED illuminates to indicate “POWER ON” and
goes o when the no-loss drain valve is operated by the
transducer or manual test button.
The condensate ows through the feed line into the drain
unit and accumulates in the container. A capacitive sensor
continuously registers the liquid level and passes a signal
to the electronic control as soon as the container is lled.
The pilot valve is then activated and the diaphragm opens
the outlet line for discharging the condensate. When the
drain unit has been emptied, the outlet line is closed again
quickly and tightly without wasting compressed air.”
7.4 REFRIGERATION SYSTEM
The Refrigeration System consists of all the components
which handle R-404A. This is a hermetically sealed closedloop system. Referring to Figure 1 and following the
phantom “REFRIG(R-404A) FLOW,” refrigerant is shown
leaving the evaporator section where, in the process of
removing heat, it is changed from a low pressure liquid into
a low pressure gas. This gas enters the suction side of the
compressor where it is compressed into a high pressure gas.
The high pressure gas is cooled in the condenser section
until it becomes a high pressure liquid. It then goes through
a permanent lter dryer that ensures the refrigeration
system is free of contaminants. A small diameter capillary
The Ingersoll Rand NVC200-400 Series dryers incorporate
automatic controls for proper operation. The thermal mass
uid temperature is maintained by a microprocessor control
that monitors the temperature and cycles the refrigeration
system in response to varying air ow and temperature.
Upon an increase in the temperature of the thermal mass
uid, the refrigeration compressor is cycled on. When the
uid is cooled to two deg.F below its control set point, the
refrigerant compressor is cycled o. The thermal mass uid
functions as a thermal storage mass in the NVC Series dryer.
A low pressure cut out (LPCO) switch is provided for all NVC
series dryers. This switch is factory set to open at 20 psig. If
the refrigerant suction pressure draws below 20 psig, the
LPCO opens to shut o the refrigerant compressor. Once
the switch has opened, it will prevent the compressor from
running until the suction pressure rises above 60 psig and
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. To compensate for water temperature
variation, it may be necessary to adjust the water
regulating valve to maintain a 250 psig discharge pressure.
Adjustment can be done by rotating the adjusting screw
counterclockwise for an increase in discharge pressure.
For conditions where low water temperature and/or high
water pressure are expected it is advisable to install a water
pressure regulator ahead of the condenser.
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