Manual de Secadoras Nirvana 200 - 400 NVC400A400

NIRVANA CYCLING REFRIGERATED DRYERMODELS 200-400

OPERATORS MANUAL

C.C.N. : 80442775 DATE : APRIL 2007REV. : B

Ensure that the operator reads and understands thedecals and consults the manuals before maintenanceor operation.

Ensure that the Operation and Maintenance manual isnot removed permanently from the machine.

Ensure that maintenance personnel are adequatelytrained, competent and have read the MaintenanceManuals.

a

1Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

CONTENTS PAGE

1.0 CONTENTS 12.0 INTRODUCTION 23.0 WARRANTY 24.0 REFRIGERATED DRYER

NOMENCLATURE 25.0 RECEIVING AND INSPECTION 35.1 INSPECTION5.2 UNPACKING AND HANDLING6.0 SAFETY AND OPERATION

PRECAUTIONS 37.0 PRINCIPLES OF OPERATION 57.1 INTRODUCTION7.2 AIR SYSTEM7.3 MOISTURE REMOVAL SYSTEM7.4 REFRIGERATION SYSTEM7.5 THERMAL MASS CIRCULATING

SYSTEM7.6 CONTROLS7.6.1 BASIC USER INTERFACE7.6.2 EXCHANGER TEMPERATURE

SET POINT AND ALARMS7.6.3 ADJUSTING SET POINTS7.6.4 ALARMS AND

THEIR FUNCTIONS7.6.5 ALERT MESSAGES7.6.6 START MODES7.6.6.1 Manual Mode7.6.6.2 Remote Mode (Optional)7.6.6.3 Auto Restart

CONTENTS PAGE

8.0 INSTALLATION AND INITIAL START-UP 8

8.1 LOCATION AND MOUNTING8.2 PIPING AND VALVES8.3 FILTRATION8.4 ELECTRICAL CONNECTION8.5 INITIAL START-UP8.5.1 START- UP SEQUENCE9.0 SCHEDULED MAINTENANCE 109.1 INTRODUCTION9.2 REFRIGERANT CONDENSER9.3 CONDENSATE DISCHARGE

SYSTEM9.4 PANEL FILTER ELEMENT9.5 PRE-FILTERS AND

POST-FILTERS9.5.1 THREADED FILTERS10.0 TROUBLESHOOTING 1310.1 INTRODUCTION10.2 PROBLEM / ACTION GUIDE11.0 WIRING DIAGRAMS 1512.0 GENERAL ARRANGEMENT 1713.0 REPLACEMENT PARTS 1814.0 ENGINEERING

SPECIFICATIONS 19

CONTENTS

Ingersoll Rand Nirvana Cycling refrigerated air dryer removesmoisture, oil vapor, and other contaminants from compressed air. Thesecontaminants are detrimental to pneumatically operated appliances,controls, instruments, machinery and tools. This removal isaccomplished by cooling the air with a refrigeration unit to a temperatureat which moisture in the air is condensed and separated from the air

2 Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

stream. The temperature the air is cooled to, normally between 34 and38F (1 and 3C), is known as dew point. This dryer can be easilyinstalled into various pneumatic systems in which dry air is required ordesired. Please refer to Principles of Operation for complete operatingdetails.

The Company warrants that the equipment manufactured by it anddelivered hereunder will be free of defects in material and workmanshipfor a period of twelve months from the date of placing the Equipment inoperation or eighteen months from the date of shipment from the factory,whichever shall first occur. The Purchaser shall be obligated to promptlyreport any failure to conform to this warranty, in writing to the Companyin said period, whereupon the Company shall, at its option, correct suchnonconformity, by suitable repair to such equipment or, furnish areplacement part F.O.B. point of shipment, provided the Purchaser hasstored, installed, maintained and operated such Equipment inaccordance with good industry practices and has complied with specificrecommendations of the Company. Accessories or equipment furnishedby the Company, but manufactured by others, shall carry whateverwarranty the manufacturers have conveyed to the Company and whichcan be passed on to the Purchaser. The Company shall not be liable forany repairs, replacements, or adjustments to the Equipment or any costsof labor performed by the Purchaser or others without Company's priorwritten approval.

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

THE COMPANY MAKES NO OTHER WARRANTY ORREPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED ORIMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, ARE HERBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent,in the manner and for the period of time provided above, shall constitutefulfillment of all liabilities of the Company for such nonconformitieswhether based on contract, warranty negligence, indemnity, strict liabilityor otherwise with respect to or arising out of such Equipment.

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

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

2.0 INTRODUCTION

3.0 WARRANTY

4.0 REFRIGERATED DRYER NOMENCLATURE

NOMINAL*FLOW CONDENSER

PREFIX (SCFM) TYPE POWER RATINGNVC 200-400 A = AIR 2 = 230-1-60 0 = NEMA 1

W = WATER 4 = 460-3-60 H = NEMA 45 = 230-3-606 = 575-3-607 = 380-3-508 = 220-3-50

* Nominal Flows indicated are for 100F inlet temperature, 100F ambient temperature and 100 psig compressed air pressure.


5.1 INSPECTIONUpon receiving your Ingersoll Rand air dryer, please inspect the unitclosely. If rough handling has been detected, please note it on yourdelivery receipt, especially if the dryer will not be uncrated immediately.Obtaining the delivery persons signed agreement to any noteddamages will facilitate any insurance claims.

5.2 UNPACKING AND HANDLING

a WARNINGUnder no circumstances should any person attempt to lift heavyobjects without proper lifting equipment (i.e., crane, hoist, slings or forktruck). Lifting any unit without proper lifting equipment, may causeserious injury.

5.0 RECEIVING AND INSPECTION

To facilitate handling during shipment, all dryer packages have beenmounted on a base that provides for forklifting between two basechannels. Forks should extend all the way through forklift channels toreduce unnecessary forces to the dryer during moving. Slings can beused to lift the crates, but spreader bars must be used to prevent theslings from exerting a force against the sides of the crates or the dryer.

6.0 SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, thesame precautions should be observed as with any piece of machineryof this type where carelessness in operation or maintenance could behazardous to personnel. In addition to obvious safety rules that shouldbe followed with this type of machinery, safety precautions as listedbelow must be observed:

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

2. Read all instructions completely before operating unit.3. Pull main electrical disconnect switch and disconnect any separate

control lines, if used, before attempting to work or performmaintenance on the unit.

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

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

6. Do not attempt to remove any part of the refrigeration system withoutremoving and containing refrigerant in accordance with the EPA andlocal regulations.

7. Do not operate the dryer at pressures in excess of its rating.8. Do not operate the dryer without guards, shields and screen in place.9. Inspect unit daily to observe and correct any unsafe operating

conditions.

OSHAHeading Descriptions

a WARNINGWarning is used to indicate a hazardous situation which has someprobability of death or severe injury. Warning should not be consideredfor property damage accidents unless personal injury risk is present.

a CAUTIONCaution is used to indicate a hazardous situation which may result inminor or moderate injury.

a NOTICENotice is used to indicate a statement of company policy as themessage relates directly or indirectly to the safety of personnel orprotection of property. Notice should not be associated directly with ahazard or hazardous situation and must not be used in place ofDanger, Warning, or Caution.

a NOTICEThe user of any air dryer manufactured by Ingersoll Rand, is herebywarned that failure to follow the above Safety and OperationPrecautions may result in personal injury or equipment damage.However, Ingersoll Rand does not state as fact, nor does it mean toimply, that the preceding list of Safety and Operating Precautions is allinclusive, and further, that the observance of this list will prevent allpersonal injury or equipment damage.

Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

4

6.0 SAFETY AND OPERATION PRECAUTIONS

Air Under Pressure Will CauseInjury, Death Or Property Damage. Do Not Exceed Pressure Rating. Relieve Press. Before Servicing. Do Not Modify/Repair/Rework ASME Coded Pressure Vessels As Insurance Rating Affected.

READ TECHNICAL MANUAL

ELECTRICAL CONNECTION BOXAll Customer Connections To Be Made At This Location.See Terminal Connection Diagrams, below.Be Certain To Follow All NEC, State, Local and Other ApplicableCodes During Installation.

1

2

3

4

5

6

GRNWHT

BLK

GN

L1

FACTORYWIRING

INCOMINGLINE VOLTAGE

100-125VAC1PH/50-60HZ(BY OTHERS)

(REFER TO UNITNAMEPLATE FOR

POWERREQUIREMENTS)

100-125VAC / 1 PH

1

2

3

4

5

6

GRN

BLK

G

L1

RED L2

FACTORYWIRING




POWERREQUIREMENTS)

200-240VAC / 1 PH

1

2

3

4

5

6

GRNRED

WHT

GL1

L2

BLK L3

FACTORYWIRING




POWERREQUIREMENTS)

200-575VAC / 3 PH

ELECTRICAL CONNECTION BOXCONTAINS HIGH VOLTAGE

Turn Off Power And Lock Out At ALL Sources Before Opening To Perform Service. Remote Alarm Contact Wiring Has Control Power From Separate Source.


Air Under Pressure Will CauseInjury, Death Or Property Damage. Relieve Press. Before Servicing. Condensate Drain Discharges Under Pressure. Drain Requires Periodic Cleaning (Service).


Removing fuses will not disconnectpower from dryer. Always disconnectpower from ALL sources beforeperforming service.


HIGH VOLTAGEThis unit is charged withrefrigerant under high pressure.

FAN MAY AUTOMATICALLYSTART AT ANY TIME

Alternate three-phase wiring may be black / black / black.


5

7.1 INTRODUCTIONIngersoll Rand Nirvana Cycling dryers remove moisture fromcompressed air by cooling the air temperature to between 34 and 38F(1 and 3C). This causes vapors to condense into liquid droplets whichcan then be easily removed from the air. The major systems of the dryerwhich contribute to its operation are the Air System, the MoistureRemoval System, the Refrigeration System, the Thermal MassCirculating System and the Controls. The following paragraphsdescribe each of the systems in greater detail.

7.0 PRINCIPLES OF OPERATION

7.2 AIR SYSTEMThe air system consists of the dryer components which are in contactwith the compressed air. Referring to Figure 1 and following the boldAIR FLOW, hot saturated air from the compressor enters theprecooler/reheater where the air temperature is reduced prior toentering the chiller by the cool air exiting the air/moisture separator. Thisprecooling allows for the use of a smaller refrigeration system. The airthen goes into the chiller section where it is further cooled to the desireddew point by a thermal mass fluid. The temperature of the thermal massfluid is maintained by the refrigeration circuit and controls. The aircontinues to the separator where moisture is removed, thereby, allowingthe cool, dry air to return back to the precooler/reheater to be heated bythe incoming moist hot air. The air exiting the reheater portion of thedryer should be approximately 15- 20F lower than the inlet airtemperature based on standard conditions at full rated flow.

FLOW DIAGRAMFIGURE 1

7.3 MOISTURE REMOVAL SYSTEMIngersoll Rand condensate drains discharge condensed moisture andlubricants (condensate) from compressed air equipment. Thecondensate drain operates as a zero-air-loss drain, returning air that isdisplaced in the drain bowl back into the compressed air system.Consistent discharging of condensate from compressed air equipmentis essential for proper equipment operation and performance.

The condensate drain uses a unique sensing method to determine thelevel of condensate in the drain bowl. A transducer located in the drainbowl continuously sends out a signal 50 times per second. Once thetransducer determines that the level of condensate has reached apredetermined level within the drain bowl, a signal is sent to the no-lossdrain valve to open. This operation permits removal of condensate of upto 80 gallons per hour.

The drain also features a test button that permits manual operation ofthe no-loss drain valve. Depressing the test button illuminates the LEDand energizes the solenoid valve. The LED illuminates to indicate"POWER ON" and goes off when the no-loss drain valve is operated bythe transducer or manual test button.

The condensate flows through the feed line into the drain unit andaccumulates in the container. A capacitive sensor continuously registers

the liquid level and passes a signal to the electronic control as soon asthe container is filled. The pilot valve is then activated and thediaphragm opens the outlet line for discharging the condensate. Whenthe drain unit has been emptied, the outlet line is closed again quicklyand tightly without wasting compressed air."

7.4 REFRIGERATION SYSTEMThe Refrigeration System consists of all the components which handleR-404A. This is a hermetically sealed closed-loop system. Referring toFigure 1 and following the phantom REFRIG(R-404A) FLOW, refrigerantis shown leaving the evaporator section where, in the process ofremoving heat, it is changed from a low pressure liquid into a lowpressure gas. This gas enters the suction side of the compressor whereit is compressed into a high pressure gas. The high pressure gas iscooled in the condenser section until it becomes a high pressure liquid.It then goes through a permanent filter dryer that ensures therefrigeration system is free of contaminants. A small diameter capillarytube (expansion valve on water-cooled dryers) meters the refrigerant forintroduction into the evaporator. The refrigerant pressure is reducedupon entering the evaporator where as it evaporates, removes heat fromthe thermal mass fluid.

PROCESS ANDINSTRUMENTATION

DIAGRAMNVC200-400

AIR ANDWATERCOOLED



7.5 THERMAL MASS CIRCULATING SYSTEMThe thermal mass fluid in a Ingersoll Rand Nirvana Cycling dryer iscontinuously circulated in a closed pump loop system. Referring toFigure 1 and following the dashed THERMAL FLUID line, the heat isremoved from the fluid in the evaporator by the refrigeration system.The thermal mass reservoir is sized to minimize refrigeration cyclesduring reduced air load periods. The thermal mass fluid is pulled fromthe bottom of the reservoir and pumped through the chiller, removingheat from the air and then returned to the evaporator. The pump utilizedon the Ingersoll Rand Nirvana Cycling dryer is a maintenance-free,quiet cartridge circulator pump similar to those used in residential watersystems. While the refrigeration system cycles on and off based onloading conditions, the circulating pump runs continuously to maintainflow through the chiller at all times. Note that when the power switch isset to the off position, the circulating pump will not operate.

7.6 CONTROLSThe Ingersoll Rand NVC200-400 Series dryers incorporate automaticcontrols for proper operation. The thermal mass fluid temperature ismaintained by a microprocessor control that monitors the temperatureand cycles the refrigeration system in response to varying air flow andtemperature. Upon an increase in the temperature of the thermal massfluid, the refrigeration compressor is cycled on. When the fluid is cooledto two deg.F below its control set point, the refrigerant compressor iscycled off. The thermal mass fluid functions as a thermal storage massin the NVC Series dryer.

A low pressure cut out (LPCO) switch is provided for all NVC seriesdryers. This switch is factory set to open at 20 psig. If the refrigerantsuction pressure draws below 20 psig, the LPCO opens to shut off therefrigerant compressor. Once the switch has opened, it will prevent thecompressor from running until the suction pressure rises above 60 psigand the LPCO has been manually reset.

All water cooled units come with a high pressure cut out (HPCO) switch.This switch is set to open at 320 psig and close at 270 psig. Tocompensate for water temperature variation, it may be necessary toadjust the water regulating valve to maintain a 250 psig dischargepressure. Adjustment can be done by rotating the adjusting screwcounterclockwise for an increase in discharge pressure. For conditionswhere low water temperature and/or high water pressure are expectedit is advisable to install a water pressure regulator ahead of thecondenser.

7.6.1 BASIC USER INTERFACEThe Controller provides the user with information about thedryers operation and alarms.

The following illustration summarizes the keypad functions.

BUTTONS

ON / OFF Toggles the dryer operation between "On Line" and Off Line status;Energizes glycol pump. Note that the refrigeration system will operate basedon temperature.

EXCH SETWhen depressed, will display the current exchanger set point in the LCDwindow. While the exchanger set point is displayed, the up and down arrowsmay be used to increase or decrease the exchanger set point temperature.

ALARM RESETPressing once clears the local alarm indication and de-energizes the remotealarm contact. Should the alarm condition persist, the alarm will return afterthe alarm inhibit time has expired.

% SAVINGSDepressing once changes LCD display to indicate ratio of refrigeration systemrunning time vs. total dryer ON time.

F / CToggles the LED temperature indicators between Fahrenheit and Celsius unitsof measure.

+ / -Allows user to modify set point values. Set point values cycle through a fixedrange.

LIGHTS

LCD DisplayDisplays exchanger temperature during normal operation. Also used todisplay exchanger temperature set point, alarm condition and timing functions.

SYSTEM ENERGIZED Indicates when power is applied to unit.

DRYER ONIlluminated when the On/Off switch has been pressed to place the unit inoperation. The refrigerant system may start at any time when the light is on.

REFRIGERATION COMPRESSOR ONIndicates that the refrigeration system is operating.

DEGREES F / DEGREES CIndicates the temperature units of measure.

HIGH TEMP ALARMIndicates that the exchanger temperature has risen to 10F or 5C above theexchanger temperature set point.

LOW TEMP ALARMWhen activated, indicates that the exchanger temperature has dropped below29F or -2C. This condition stops the compressor. The compressor will notrestart until the temperature has risen two degrees above exchanger set point.

ADJUSTMENTSCREW

FIGURE 2WATER REGULATING VALVE

7.6.2 EXCHANGER TEMPERATURE SET POINT AND ALARMSThe Controller allows the user to configure the dryersExchanger Temperature Setpoint to operate according to siteconditions. The Controller is shipped from the factory with theexchanger temperature having a default value of 38 deg.

7.6.3 ADJUSTING SET POINTSAccessing and manipulating the Exchanger TemperatureSetpoint is accomplished as follows.



The alarm names and a brief description of each are described indetail below.

HIGH TEMPERATURE ALARMWhen the thermal mass (glycol) temperature reaches the alarm setpoint, the alarm will be activated. This alarm condition may notnecessarily damage the dryer when subjected to long-term exposure.It may, however, have a significant impact on downstream processesand thus should be investigated upon detection. Note that this alarmwill not shut down the dryer. This alarm will activate the remote alarmcontact and reset automatically once the alarm condition is rectified.

LOW TEMPERATURE SAFETY ALARMIf the dryer chiller temperature falls below the factory set point, thealarm routine will activate. This alarm condition may cause damage tothe dryer when subjected to continuous or long-term exposure. Notethat this alarm will shut down the dryer after a response time delay.This alarm will activate the remote alarm contact and resetautomatically once the alarm condition is rectified.

7.6.5 ALERT MESSAGESThe Controller features the following readouts to communicate thestatus of the dryers operation.

EXCH.SET

Pressing EXCHANGER SETPOINT button will change the display toshow the current setpoint.

36

Pressing the UP or DOWN arrows modifies the EXCHANGERSETPOINT in one degree increment.

37

Pressing the UP or DOWN arrows modifies the EXCHANGERSETPOINT in one degree increment.

38

The Controller accepts the last setpoint. After 5 seconds, the readoutwill return to displaying the current Exchanger Temperature.

38

a CAUTIONDo not set the Exchanger Temperature greater than 50 deg.F. Runningdryer at an Exchanger Temperature higher than 50 deg.F may damagerefrigeration system.

7.6.4 ALARMS AND THEIR FUNCTIONSThe Controller indicates critical alarms to alert the user of anout of tolerance condition. Once each alarm condition isdetected, the appropriate LED indicator will illuminate and theremote alarm contact will close.

Alarm Display Alarm Set Point

HIGH TEMPERATURE ALARM HI TEMP ALARM EXCH SETPOINT + 10 F

LOW TEMPERATURE ALARM LOW TEMP ALARM 28 F

Indicates a probe failure. This conditionis usually caused by a probe beingunplugged, damage to the probe lead ora defective probe.

P F

Indicates that the refrigerant compressorwill not start until the end of a threeminute safety delay. The display of cd isimmediately followed by the number ofminutes left in the delay. This is a normalfunction of the controller and not a faultindication.

c d

7.6.6 START MODESThe NCV200-400 dryers are capable of starting in one of thefollowing start modes:

7.6.6.1 Manual ModeAfter power is supplied to the dryer, the LCD display willindicate the chiller temperature as well as the time remainingfor the safety delay. Once the delay has timed out,depressing the On/Off button will permit the refrigerationsystem to operate. Should the chiller temperature be greaterthan the set point, the refrigeration system will energize.Should the chiller temperature be below the set point, therefrigeration system will remain off until the chiller temperaturerises to the setpoint.

7.6.6.2 Remote Mode (Optional)This mode of operation allows the user to control the dryerremotely and requires the installation of a customer-suppliedcontact. With power applied to the dryer and once the safetydelay has timed out, the dryer will start once the remote switchis closed. In addition, this mode of operation still permitsmanual control of the dryer via the On/Off pushbutton on thelocal control panel. Note that if the dryer was turned "On"from the remote switch and then turned "Off" via the localcontrol panel, the remote switch must be turned "Off" and then"On" to reinstate the dryer.



7.6.6.3 Auto RestartShould the dryer lose power while in the "On" mode, the dryerwill revert to the "On" mode once power is restored. Similarly,should power be removed from the dryer while the dryer is inthe "Off" mode, the dryer will remain in the "Off" mode oncepower is restored until the On/Off switch is depressed or theremote switch is closed.

8.0 INSTALLATION AND INITIAL START-UP

8.1 LOCATION AND MOUNTINGThe dryer should not be located in an area where ambient temperatureis likely to exceed 113F (45C) or be less than 50F (10C). The dryermust be located in an area that provides sufficient clearance from wallsand other adjoining equipment to allow easy access for servicing andmaintenance requirements. A minimum of 18 inches is required to allowfree flow of air to the condenser inlet.

On installations with a relatively steady flow rate, the dryer is normallyconnected after the air receiver. If loads fluctuate widely, the dryershould be positioned ahead of the receiver and sufficient storagecapacity downstream is necessary to prevent excessive air flow throughthe dryer.

When installed after any compressor that causes significant vibration orair pulsation, such as reciprocating compressors, proper vibrationisolation and pulsation dampening devices should be added to protectthe dryer.

a NOTICEFailure to comply to the above instructions may result in equipmentmalfunction and will void warranty.

a NOTICEAlways use a backup wrench when making any threaded connectionto the dryer. Failure to use a backup wrench may result in damagedtubing and components internal to the cabinet.

8.2 PIPING AND VALVESInstall piping, fittings and accessories as required for specific siteconditions and requirements. Figure 3 indicates a typical pipingarrangement for a refrigerated dryer, including dryer and filter bypasses.This figure can be used as a guide for valve and accessory placementin the system.

Ingersoll Rand NVC200-400 models come factory installed with a drainisolation valve (D). The isolation valve permits maintenance of theautomatic drain without isolating air flow to the dryer. To operate dryer,all valves shown in Figure 3 are to be closed except valves (B), (C) and(D). Valve (A) is used for bypass purposes and valve (E) is for test andmanual drain purposes.

8.3 FILTRATIONTo protect the air dryer from gross contamination associated withcompressor oil and debris and ensure maximum dryer performance, apre-filter is recommended. Pre-filters and post-filters sized to your dryingapplication can be provided by Ingersoll Rand and are available factoryinstalled. Call your local distributor to select the filter that best suits yourfiltration requirements. In addition to air filtration, condensate dischargeoil/water separators are also available to address stringent EPAregulations.


8.0 INSTALLATION AND INITIAL START-UP

FIGURE 3

TYPICAL PIPING ARRANGEMENT

8.4 ELECTRICAL CONNECTIONEquipment is available in various electrical configurations. All customerconnections can be made at the terminal connections located in thecustomer electrical connection box on the rear of the dryer. (Refer toGeneral Arrangement and appropriate Wiring Diagrams.)

A suitable fused disconnect switch or circuit breaker, in accordance withnational and local code requirements, is recommended for all IngersollRand equipment. Refer to Section 13 for voltage requirements andload.

a CAUTIONNever wire directly or connect any additional wires to the compressorjunction box. This will cause severe system malfunction.

8.5 INITIAL START-UP

a NOTICEFor water cooled models, the water valve must be manually opened toensure that the condenser is full of water prior to start-up.

8.5.1 START- UP SEQUENCE Apply power to dryer. LCD Panel will illuminate. The Anti-

Short Cycle delay will commence counting down.

a NOTICEAfter installation or a prolonged shutdown, start the dryer with no airload (no air flow). This enables the dryer to reach its proper operatingtemperature in the shortest time possible (typically within 30 minutesfor Nirvana Cycling dryers).

Start Dryer, using one of the following methods, dependingon Start Mode setting:

Manual Mode - Press the ON pushbutton.

Auto Restart Mode - No additional action required

Remote Automatic Mode - Close the remote contact.

AIRDRYER

OILSEPARATOR

DRAINVALVE

CHECKVALVE

CHECKVALVE

CHECKVALVE

DRAINVALVE

CHECKVALVE

PREFILTER

B

A

CAIR OUTAIR IN

UNIT AS DELIVERED

OPTIONAL ACCESSORY ITEMS

NOTE: DRAIN TUBE MUST NOT RISE OR BE CONNECTED TOEXCESSIVELY LONG PIPE WHICH MAY CREATE BACK PRESSUREA CONNECTION TO OPEN FLOOR DRAIN IS REQUIRED

DE

PRE-FILTER


10

9.0 SCHEDULED MAINTENANCE

9.1 INTRODUCTIONIngersoll Rand Nirvana Cycling refrigerated air dryers require littlemaintenance. These dryers utilize hermetically sealed compressorswhich do not require any lubrication. Fan motors require lubrication atboth oil ports every six months. Ingersoll Rand recommends componentinspection and service at regular intervals to obtain maximumperformance from your dryer.

9.2 REFRIGERANT CONDENSERFor standard dryers, regular inspection and cleaning of the condenser isrecommended. Ingersoll Rand dryers may be equipped with an optionalambient air filter designed to protect the condenser from dirt and debristhat can accumulate on the condenser. For proper operation with thisoption, it is imperative that this filter be inspected and cleaned on aregular basis. Annual replacement of the filter is recommended. Forapplications where excessive dirt, dust or debris is encountered, morefrequent inspection and cleaning may be required.

8 9

9

5 6 7

1

6

2

4

1

3

108 9

5

7

1

3

24

9.3 CONDENSATE DISCHARGE SYSTEM

a WARNINGBefore drain maintenance work, always close the drain isolation ballvalves and ensure that the device is pressureless and de-energized.

Maintenance recommendations

Replace service unit (5) annually.

Remove control unit (1) by pressing latching hook (2).

Detach Drain from outlet (3).

Remove design shell (4) (where applicable) using a screw driver (10).

Remove service unit (5) from pipe at inlet by undoing union nut

or by undoing screws (6) at elbow connector (7)

orby undoing screws (8) at intermediate adapter (9) which is then detached from the service unit by downward movement.

Check if new service unit (5) matches control unit (1)- type designation and colour of latching hook (2)

Fit new service unit (5) in reverse order

Open drain isolation ball valve. Press drain test button to verify properdrain operation.

2

1

3

4

567


9.4 PANEL FILTER ELEMENTAnnual replacement of the panel filter element is recommended. Toreplace the panel filter element, remove the panel filter by pulling up andout of its slots, then fit the new element in.

9.5 PRE-FILTERS AND POST-FILTERS

a WARNINGDepressurize the system before disassembling filters. Failure to do somay result in injury or death.

Filter elements should be changed as indicated on the pressuredifferential gauge. Change carbon elements when hydrocarbons arefirst detected downstream or every six months, whichever comes first.

Certain filters contain multiple elements. When replacing filter elements,all elements should be replaced simultaneously. Mixing new and oldelements can result in reduced air quality.

9.5.1 THREADED FILTERS:

NO-LOSS DRAIN VALVE

GP,HE,DP 19-1380

?

2

5

4

3

2

1

6

43

1 Assembly Control unit onto service unit:

Check if service unit (3) matches control unit (1) (type designation andcolour of latching hook)

Check if sensor tube plate (5) with contact springs (4) is clean, dry and free from foreign matter.

Insert sensor (2) into sensor tube plate (5).

Fit latching hook (6) of control unit (1) into sensor tube plate (5).

Press control unit (1) against service unit (3) and snap into place

Open drain isolation ball valve. Press drain test button to verify properdrain operation.

2

1

3

4


20(68)

30(86)

40(104)

50(122)

1,000

10,000

CF

`

AC19-1380

hrs



1 2

1

11

2

4

5

67

1

23

34

21

3a 3b

1

21

2

5

2

1

3

4

16mm(5/8)

1

4

6 7

8 9

1

13

1

2 2

2


PROBLEM

Moisture down stream

Moisture down stream

SYMPTOM(S)

Dryer is properly cooling airstream (Check Chiller. Tempon controller)

Inlet and outlet temperaturesare the same.

Inlet and outlet temperaturesare the same.

Compressor and fan arerunning, exchanger temphigh, pump not running.

POSSIBLE CAUSE

Condensate drain failurecaused by defective serviceunit.

Excessive flow

Dryer by-pass valve notclosed

No power to the dryer

High suction pressure

Refrigerant leak

Compressor not running andfan is running

Compressor and fan notrunning.

Compressor and fan notrunning. Controller indicatescompressor is ON.

Defective Pump

CORRECTIVE ACTION

Replace service unit.

Check inlet and outlet pressure and systemdesign capacity. Correct cause of excessive flow.

Close by-pass valve

Check power supply and fuses/circuitbreakers

Check and clean condenser.

Check suction pressure gauge if reading is 0 psig, turn dryer off and contact yourdistributor

Check and clean condenser.

Check ambient temperature and reducebelow 113F

Check Chiller Temperature

Check MAIN CONTROL fuse.

Compressor relay may be bad, replace relay

Check for loose wire connections atcontactor or loss of power at control board

Defective control board - replace asnecessary

Contact your local distributor for furtherassistance.


a WARNINGAn air dryer always operates under pressure. Any maintenanceprocedure that involves disassembly of pipe fittings, valves or anyother components requires the dryer be isolated from the compressedair stream and fully depressurized.

a WARNINGPrior to working on the unit, make sure that all circuit breakers ordisconnected switches are tagged Out of Service.

10.2 PROBLEM / ACTION GUIDE

10.0 TROUBLESHOOTING

10.1 INTRODUCTIONIngersoll Rand Nirvana Cycling dryers are designed for reliable, trouble-free operation. In the event of any dryer malfunction, the guide belowhas been developed to facilitate problem identification and corrective actions.


10.0 TROUBLESHOOTING

PROBLEM

Apparent controller displaymalfunction

High pressure drop acrossdryer

Condensate drain does not fire

Condensate drain LED is off

Air bleed from condensatedrain outlet port

Condensate drain bowl doesnot seem to fill withcondensate, drain does notseem to work due to airlocking

SYMPTOM(S)

Display Blank

Unrealistic temperaturedisplayed

Erratic or inaccuratetemperature readings

Unrealistic pressuredisplayed

Outlet pressure substantiallylower than inlet pressureSystem operatingtemperature is above 32F

Outlet pressure substantiallylower than inlet pressureSystem operatingtemperature is below 32F

POSSIBLE CAUSE

Blown Fuse

Board Failure

Probe loose,off connection ordefective probe

Probe not completely inthermal well

Defective probe

Transducer loose, offconnection or defectivetransducer

Inlet and outlet valves notcompletely open

Inlet and outlet filters blockedup

Compressor relay / contactorstuck.

Microprocessor Control relaybad

Probe not completely inthermal well

Problem persists

Inlet / outlet pipe internaldiameter too small causingair-lock or back pressure.

Excessive use of bends /elbows in inlet / outlet pipework causing air-lock/ backpressure.

Outlet pipe too long / toohigh causing back pressure.

More than one condensatesource connected providingalternative path forcondensate.

Debris trapped under seal.Damage to seal.

CORRECTIVE ACTION

Check Fuses


Inspect probe cable and terminal connectionReplace probe

Inspect probe and check readings againstindependent source (eg. temperatureanalyzer/pyrometer/ice bath) both intemperature well and to ambient

Replace probe

Inspect transducer cable and terminalconnection

Replace transducer

Open valves

Change filter elements

Replace relay / contactor.

Replace relay

Inspect probe and check readings againstindependent source (eg. temperatureanalyzer/pyrometer/ice bath) both inexchanger well and to ambient

Turn dryer off and consult your localdistributor for further assistance

Check installation is in accordance with thismanual. Revise installation accordingly.

Replace with larger diameter piping.

Reduce the amount of bends and elbows.

Reconfigure condensate piping.

Reroute condensate to eliminate secondarypath. Install check valves as required.

Check power supply. Press test button forminimum 2 seconds and observe. Locateand eliminate supply fault.

Press and hold the test button to clear (drainvalve will open). Replace seal with ServiceKit.

If bottom inlet is used, top port must be usedas air bleed. Make sure Connect the topinlet to a higher point in system, which willfunction as an air bleed for the drain.


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18

13.0 REPLACEMENT PARTS

Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for maintenance or repair. The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.Class Quantity Suggested for1 Minimum Domestic service where interruptions in service are acceptable.2 Average Domestic service where some interruptions in service are acceptable.3 Maximum Export service or for domestic service where interruptions in service are unacceptable.

QTY/ SPARES

CCN DESCRIPTION UNIT 1 2 3

38052197 BOARD, CONTROL 1 1 1 1

38052718 CONTACTOR, COMPRESSOR 1 1 1 1

22719421 DRAIN, CONDENSATE 1

38448239 DRAIN, SERVICE UNIT 1

38052916 DRYER, REFRIGERANT FILTER 1

38052437 PANEL FILTER ELEMENT 1

38054268 FUSE, TRANSFORMER PRIMARY 2 2 2 4

38052361 FUSE, TRANSFORMER SECONDARY (EXCEPT NVC200) 1 1 1 2

38052676 OVERLAY, CONTROL BOARD 1

38052908 PROBE, EXCHANGER TEMPERATURE 1 1 1 1

38052171 SWITCH, LOW REFRIGERANT PRESSURE 1

38053252 TRANSFORMER, CONTROL - 0.15 KVA (EXCEPT NVC200) 1

38052148 VALVE, DRAIN 1

38052320 VALVE, GLYCOL PUMP ISOLATION 1

MISCELLANEOUS PARTS

PARTS FOR AIR COOLED DRYERS

FAN MOTORSNVC NEMA 1 NEMA 4 NEMA 1 NEMA 4

MODEL CONDENSERS 230V 230V 460V 460V200 38053104 38053229 3854789 38446498 38446498300 38052700 38053229 3854789 38446498 38446498400 38052700 38053229 3854789 38446498 38446498

PARTS FOR WATER COOLED DRYERS

NVCMODEL CONDENSERS VALVES

200 38054581 38054623300 38450029 38054631400 38450029 38054631

COMPRESSORS

NVCMODEL 230/1/60 230/3/60 230/3/50 380/3/50 460/3/60 575/3/60

200 38446746 38054649 38054672 38450003 38450003 38450003300 - 38054656 38054680 38052288 38052270 38052270400 - 38054664 38054698 38054706 38052288 38052288


MAXIMUM ALLOWABLE WORKING PRESSURE: 230 psig

a NOTICESpecification information above accurate at time of publication. Refer to equipment serial labelfor actual refrigerant charges and specifications for units.

14.0 ENGINEERING SPECIFICATIONS

AIR COOLED CONDENSERSWEIGHT R-404A MAX. FUSE

SIZEMIN. CIRCUIT

AMPACITYCOMPRESSOR RATINGS FAN RATINGS

MODEL NO. VOLTS/PH/HZ LBS. KG. LB-OZ KG. HP RLA LRA QTY HP RLA LRANVC200 230/1/60 540 245 2-4 1.02 20 13.7 1 9.7 40 1 1/6 1 3NVC200 460/3/60 540 245 2-4 1.02 6 3.9 1 2.4 13 1 1/6 0.5 1.2NVC200 230/3/60 540 245 2-4 1.02 12 7.7 1 4.8 25 1 1/6 1 3NVC200 575/3/60 540 245 2-4 1.02 5 3.0 1 2.4 13 1 1/6 0.5 1.2NVC250 460/3/60 570 259 3-8 1.588 8 5.3 11/2 3.6 16 1 1/6 0.5 1.2NVC250 230/3/60 570 259 3-8 1.588 15 9.6 11/2 6.4 38 1 1/6 1 3NVC250 575/3/60 570 259 3-8 1.588 7 4.3 11/2 3.6 16 1 1/6 0.5 1.2NVC300 460/3/60 630 286 4-0 1.814 10 6.2 2 4.3 16 1 1/6 0.5 1.2NVC300 230/3/60 630 286 4-0 1.814 18 11.5 2 7.9 38 1 1/6 1 3NVC300 575/3/60 630 286 4-0 1.814 8 4.9 2 4.3 16 1 1/6 0.5 1.2NVC400 460/3/60 670 304 4-0 1.814 12 7.6 2 1/2 5.4 23 1 1/6 0.5 1.2NVC400 230/3/60 670 304 4-0 1.814 25 15.9 2 1/2 11.4 57 1 1/6 1 3NVC400 575/3/60 670 304 4-0 1.814 10 6.0 2 1/2 5.4 23 1 1/6 0.5 1.2

SECADORA REFRIGERANTE NIRVANA CYCLINGMODELOS 200-400

MANUAL DEL OPERADOR

C.C.N. : 80442775 FECHA : ABRIL DE 2007MOD. : B

Asegrese de que el operador lea y comprenda lascalcomanas y consulte los manuales antes delmantenimiento o la operacin.

Asegrese de que el manual de operacin ymantenimiento no se saque de la mquina.

Asegrese de que el personal de mantenimiento estadecuadamente capacitado, sea competente y hayaledo los manuales de mantenimiento.

a

1Secadora refrigerante Nirvana Cycling Modelos 200-400http://air.irco.com

NDICE PGINA

1.0 NDICE 12.0 INTRODUCCIN 23.0 GARANTA 24.0 NOMENCLATURA DE LA

SECADORA REFRIGERANTE 25.0 RECEPCIN E INSPECCIN 35.1 INSPECCIN5.2 DESEMBALAJE Y MANIPULACIN6.0 PRECAUCIONES DE

SEGURIDAD Y OPERACIN 37.0 PRINCIPIOS DE

FUNCIONAMIENTO 57.1 INTRODUCCIN7.2 SISTEMA DE AIRE7.3 SISTEMA DE ELIMINACIN

DE LA HUMEDAD7.4 SISTEMA DE REFRIGERACIN7.5 SISTEMA DE CIRCULACIN

DE MASA TRMICA7.6 CONTROLES7.6.1 INTERFAZ DE USUARIO BSICA7.6.2 PUNTO DE REFERENCIA Y

ALARMAS DE TEMPERATURADEL INTERCAMBIADOR

7.6.3 AJUSTE DE LOS PUNTOS DE REFERENCIA

7.6.4 ALARMAS Y SUS FUNCIONES7.6.5 MENSAJES DE ALERTA7.6.6 MODOS DE INICIO7.6.6.1 Modo manual7.6.6.2 Modo remoto (opcional)7.6.6.3 Reinicio automtico

NDICE PGINA

8.0 INSTALACIN Y PUESTAEN MARCHA INICIAL 8

8.1 UBICACIN E INSTALACIN8.2 TUBERAS Y VLVULAS8.3 FILTRACIN8.4 CONEXIN ELCTRICA8.5 PUESTA EN MARCHA INICIAL8.5.1 SECUENCIA DE PUESTA

EN MARCHA9.0 MANTENIMIENTO

PROGRAMADO 109.1 INTRODUCCIN9.2 CONDENSADOR

DEL REFRIGERANTE9.3 SISTEMA DE DESCARGA

DE CONDENSADO9.4 ELEMENTO DE FILTRO

DEL PANEL9.5 PREFILTROS Y POSTFILTROS9.5.1 FILTROS ROSCADOS10.0 LOCALIZACIN DE FALLAS 1310.1 INTRODUCCIN10.2 GUA DE PROBLEMAS/

MEDIDAS11.0 DIAGRAMAS DE CABLEADO 1512.0 DISPOSICIN GENERAL 1713.0 PIEZAS DE REPUESTO 1814.0 ESPECIFICACIONES

DE INGENIERA 19

NDICE

La secadora de aire refrigerante Nirvana Cycling de Ingersoll Randelimina la humedad, el vapor de aceite y otros contaminantes del airecomprimido. Estos contaminantes provocan efectos adversos en losaparatos, controles, instrumentos, mquinas y herramientas operadosneumticamente. Esta eliminacin se logra mediante el enfriamiento delaire con una unidad de refrigeracin a una temperatura a la que la

2 Secadora refrigerante Nirvana Cycling Modelos 200-400http://air.irco.com

humedad en el aire se condensa y separa del flujo de aire. Latemperatura a la que se enfra el aire, normalmente entre 34 y 38 F(1 y 3 C), se conoce como el punto de condensacin. Esta secadorase puede instalar fcilmente en varios sistemas neumticos en loscuales se requiere o desea aire seco. Consulte los Principios defuncionamiento para obtener todos los detalles de funcionamiento.

Ingersoll-Rand Company Limited garantiza que los equipos que fabricay distribuye conforme a este documento estarn libres de defectos tantode materiales como de mano de obra, durante un perodo de docemeses desde la fecha en que los Equipos se ponen en funcionamientoo de dieciocho meses desde la fecha de envo desde la fbrica, lo quesuceda primero. El Comprador estar obligado a informaroportunamente y por escrito a la Compaa de cualquier tipo deincumplimiento de las condiciones de esta garanta dentro de dichoperodo, y la Compaa corregir, a su discrecin, dicho incumplimientoreparando el equipo en forma apropiada, o proporcionar una pieza derepuesto F.O.B. en el punto de embarque, siempre y cuando elComprador haya almacenado, instalado, mantenido y operado dichosEquipos en conformidad con las buenas prcticas industriales y hayacumplido con las recomendaciones especficas de la Compaa. Losaccesorios o equipos que proporcione la Compaa pero que fabriquenterceros, mantendrn cualquier garanta que los fabricantes hayantraspasado a la Compaa y que se pueda transferir al Comprador. LaCompaa no ser responsable de reparaciones, reemplazos o ajustesa los Equipos ni de ningn tipo de costo por mano de obra en queincurra el Comprador u otras personas que no cuenten con la previaautorizacin por escrito de la Compaa.

Se excluyen especficamente de esta garanta los efectos de lacorrosin, erosin y del desgaste normal. Las garantas decumplimiento se encuentran limitadas a las que se indicanespecficamente dentro de la propuesta de la Compaa. A menos quela responsabilidad de cumplir tales garantas de rendimiento se

encuentre limitada a pruebas especficas, la obligacin de la Compaaser corregirla de la manera y dentro del plazo estipuladoanteriormente.

LA COMPAA NO OTORGA NINGN OTRO TIPO DE GARANTA NIREALIZA NINGUNA DECLARACIN, EXPRESA O IMPLCITA, SALVOLA DEL TTULO, Y POR MEDIO DE ESTE DOCUMENTO SE NIEGANTODAS LAS GARANTAS IMPLCITAS DE COMERCIABILIDAD EIDONEIDAD PARA UN FIN EN PARTICULAR.

La correccin de los incumplimientos por parte de la Compaa, seanpatentes o latentes, en la forma y el plazo estipulado anteriormente,debern constituir el cumplimiento de todas las responsabilidades de laCompaa, para aquellos incumplimientos que se basen ya sea en elcontrato, negligencia de la garanta, indemnizacin, responsabilidadabsoluta u otros relativos a o que se deriven de dichos Equipos.

El Comprador no operar los Equipos que se consideren defectuosos,sin notificar por escrito primeramente a la Compaa de su intencin dehacerlo. Cualquier uso tal de los Equipos ser bajo el riesgo yresponsabilidad exclusivos del Comprador.

Observe que sta es una garanta estndar de Ingersoll Rand.Cualquier garanta vigente al momento de la compra del equipo o quese haya negociado como parte de la orden de compra podr tenerprecedencia sobre esta garanta.

2.0 INTRODUCCIN

3.0 GARANTA

4.0 NOMENCLATURA DE LA SECADORA REFRIGERANTE

FLUJO NOMINAL * TIPO DE

PREFIJO (SCFM) CONDENSADOR ENERGA CLASIFICACINNVC 200-400 A = AIRE 2 = 230-1-60 0 = NEMA 1

W = AGUA 4 = 460-3-60 H = NEMA 45 = 230-3-606 = 575-3-607 = 380-3-508 = 220-3-50

* Los flujos nominales que se indican son para una temperatura de entrada de 100 F, una temperatura ambiente de 100 F y una presin deaire comprimido de 100 psig.


5.1 INSPECCINAl recibir su secadora de aire Ingersoll Rand, revise la unidaddetenidamente. Si detecta una manipulacin descuidada, haga laobservacin en su recibo de entrega, especialmente si la secadora nose desembalar inmediatamente. Es recomendable obtener la firma dela persona que entregue el producto por cualquier dao que puedaobservar a fin de facilitar cualquier reclamacin de seguros.

5.2 DESEMBALAJE Y MANIPULACIN

a ADVERTENCIANinguna persona debe tratar de levantar objetos pesados sin losequipos adecuados para este fin (es decir, gras, montacargas,eslingas u horquillas elevadoras) bajo ninguna circunstancia. Ellevantamiento de cualquier unidad sin los equipos adecuados puedecausar lesiones graves.

5.0 RECEPCIN E INSPECCIN

Para facilitar la manipulacin durante el envo, todos los paquetes desecadoras se han instalado sobre una base que proporciona ranuraspara montacargas de horquilla entre dos canales base. Las horquillasse deben extender a lo largo de los canales para montacargas dehorquilla a fin de reducir las fuerzas innecesarias en la secadoradurante su traslado. Se pueden usar eslingas para levantar las cajas detransporte, pero se deben usar barras separadoras para evitar que laseslingas ejerzan fuerza contra los costados de las cajas de transporte ola secadora.

6.0 PRECAUCIONES DE SEGURIDAD Y OPERACIN

Debido a que una secadora de aire est presurizada y contiene piezasgiratorias, se deben tomar las mismas precauciones como concualquier maquinaria de este tipo, ya que el descuido en la operacin yel mantenimiento puede ser peligroso para el personal. Adems de lasnormas lgicas de seguridad que se deben seguir con este tipo demaquinaria, se deben tomar las siguientes precauciones de seguridad:

1. Slo se permitir que personal calificado ajuste, realicemantenimiento o repare esta secadora de aire.

2. Lea todas las instrucciones completamente antes de operar launidad.

3. Accione el interruptor principal de desconexin elctrico ydesconecte todas las lneas de control separadas, si se usan, antesde trabajar en la unidad o realizar mantenimiento en ella.

4. No intente realizar mantenimiento en ninguna pieza mientras lamquina est en funcionamiento.

5. No intente sacar ninguna pieza sin antes aliviar la presin de todo elsistema de aire.

6. No intente sacar ninguna pieza del sistema de refrigeracin sineliminar y almacenar el refrigerante en conformidad con lasnormativas de EPA y locales.

7. No opere la secadora con presiones superiores a su rgimen.8. No opere la secadora sin las protecciones, blindajes y rejillas en su

lugar.9. Inspeccione la unidad a diario para observar y corregir cualquier

condicin de funcionamiento insegura.

OSHADescripciones del encabezado

a ADVERTENCIA"Advertencia" se usa para indicar una situacin peligrosa con algunaprobabilidad de muerte o lesin grave. Advertencia no debeconsiderarse para accidentes que provoquen daos a la propiedad, amenos que exista riesgo de lesin personal.

a PRECAUCION"Precaucin" se usa para indicar una situacin peligrosa que puedeprovocar lesiones menores o moderadas.

a AVISO"Aviso" se usa para indicar una declaracin de la poltica de lacompaa, si el mensaje tiene relacin directa o indirecta con laseguridad del personal, o la proteccin de la propiedad. Aviso no sedebe asociar directamente con un peligro o una situacin peligrosa yno se debe usar en lugar de "Peligro", "Advertencia" o "Precaucin".

a AVISOPor medio de este documento se le advierte al usuario de cualquiersecadora de aire fabricada por Ingersoll Rand que el incumplimientode las Precauciones de seguridad y operacin anteriores puedeprovocar lesiones personales o daos a los equipos. Sin embargo,Ingersoll Rand no declara como hecho ni pretende implicar que la listaanterior de Precauciones de seguridad y operacin sea exhaustiva, nitampoco que su cumplimiento evitar todas las lesiones personales ylos daos a los equipos.

Secadora refrigerante Nirvana Cycling Modelos 200-400http://air.irco.com

4

6.0 PRECAUCIONES DE SEGURIDAD Y OPERACIN

El aire bajo presin provocar lesiones, la muerte o daos a la propiedad. No exceda la capacidad nominal de presin. Libere la presin antes de realizar mantenimiento. No modifique/repare/reprocese recipientes a presin con cdigo ASME ya que eso afecta la tarificacin de seguros.

LEA EL MANUAL TCNICO

ADVERTENCIA

CAJA DE CONEXIONES ELCTRICASTodas las conexiones del cliente se deben realizar en esta ubicacin.Consulte los diagramas de conexin del terminal que se encuentran a continuacin.Asegrese de respetar todos los cdigos NEC, estatales, locales y otros cdigos correspondientes durante la instalacin.

1

2

3

4

5

6

VERDE

BLANCONEGRO

GN

L1

CABLEADO DE FBRICA

VOLTAJE DE LNEA

DE ENTRADA100 a 125 V CA1 PH/50 a 60 HZ(DE TERCEROS)

(CONSULTE LA PLACA DE

IDENTIFICACIN PARA CONOCER LOS REQUISITOS

DE POTENCIA)

100-125 V CA/1 PH

1

2

3

4

5

6

VERDE

NEGRO

G

L1

ROJO L2

CABLEADO DE FBRICA

200-240 V CA/1 PH

1

2

3

4

5

6

VERDE

ROJOBLANCO

GL1

L2

NEGRO L3

CABLEADO DE FBRICA

200-575 V CA/3 PH

CAJA DE CONEXIONES ELCTRICASCONTIENE ALTO VOLTAJE

Corte la energa y bloquee TODAS las fuentes antes de abrirla para realizar mantenimiento. El cableado de contacto de la alarma remota posee control de encendido de una fuente separada.


ADVERTENCIA

VOLTAJE DE LNEA

DE ENTRADA200 a 240 V CA

1 PH/50 a 60 HZ(DE TERCEROS)



DE POTENCIA)

VOLTAJE DE LNEA

DE ENTRADA200 a 575 V CA3 PH/50 a 60 HZ(DE TERCEROS)



DE POTENCIA)

El aire bajo presin provocar lesiones, la muerte o daos a la propiedad. Libere la presin antes de realizar mantenimiento. El drenaje del condensado se descarga bajo presin. El drenaje requiere de limpieza (mantenimiento) peridica.


ADVERTENCIA

Si se quitan los fusibles no se desconectar la energa de la secadora. Desconecte siempre la energa desde TODAS las fuentes antes de realizar el mantenimiento.


ADVERTENCIA

ALTO VOLTAJEADVERTENCIA

Esta unidad est cargada con refrigerante bajo alta presin.

ADVERTENCIA

EL VENTILADOR SE PUEDE ENCENDER AUTOMTICAMENTE

EN CUALQUIER MOMENTO

ADVERTENCIA

El cableado trifsico alterno puede ser negro/negro/negro.

Secadora refrigerante Nirvana Cycling Modelos 200-400http://air.irco.com

5

7.1 INTRODUCCINLas secadoras Nirvana Cycling de Ingersoll Rand eliminan la humedaddel aire comprimido enfriando la temperatura del aire a entre 34 y 38 F (1y 3 C). Esto provoca que los vapores se condensen en gotitas de lquidoque se pueden eliminar fcilmente del aire. Los principales sistemas de lasecadora que contribuyen a su funcionamiento son el sistema de aire, elsistema de eliminacin de la humedad, el sistema de refrigeracin, elsistema de circulacin de masa trmica y los controles. Los siguientesprrafos describen cada uno de los sistemas con mayor detalle.

7.2 SISTEMA DE AIREEl sistema de aire est constituido por los componentes de la secadora queestn en contacto con el aire comprimido. De acuerdo con la Figura 1 y con

7.0 PRINCIPIOS DE FUNCIONAMIENTO

la leyenda "FLUJO DE AIRE" en negrita, el aire saturado caliente queproviene del compresor ingresa al preenfriador/recalentador, en donde latemperatura del aire se reduce antes de ingresar al refrigerador mediante elaire fro que sale del separador de aire/humedad. Este preenfriamientopermite el uso de un sistema de refrigeracin ms pequeo. El aire pasaluego a la seccin del refrigerador en donde se enfra ms hasta alcanzar elpunto de condensacin que desee mediante un lquido de masa trmica. Latemperatura del lquido de masa trmica se mantiene mediante el circuito derefrigeracin y los controles. El aire sigue hasta el separador en donde seelimina la humedad, lo que permite que el aire fro y seco vuelva alpreenfriador/recalentador para que reciba calor del aire caliente hmedoentrante. El aire que sale de la parte del "recalentador" de la secadora debetener aproximadamente 15 a 20 F menos que la temperatura de aire deentrada basado en las condiciones estndar a un flujo de velocidad mxima.

DIAGRAMA DE FLUJOFIGURA 1

7.3 SISTEMA DE ELIMINACIN DE LA HUMEDADLos drenajes de condensado Ingersoll Rand descargan humedadcondensada y lubricantes (condensado) de compresores de aire. Eldrenaje de condensado funciona como un drenaje de cero prdida deaire, lo que devuelve el aire que se desplaza en el recipiente de drenajeal sistema de aire comprimido. La descarga adecuada del condensadode los compresores de aire es esencial para el funcionamiento yrendimiento correcto del equipo.

El drenaje de condensado usa un mtodo de deteccin exclusivo paradeterminar el nivel de condensado en el recipiente de drenaje. Untransductor que se ubica en el recipiente de drenaje envaconstantemente una seal 50 veces por segundo. Luego de que eltransductor determine que el nivel de condensado ha alcanzado unnivel predeterminado dentro del recipiente de drenaje, se enva unaseal a la vlvula de drenaje sin prdidas para que se abra. Esteproceso permite la eliminacin de condensado en hasta 80 galones porhora.

El drenaje tambin cuenta con un botn de prueba que permite laoperacin manual de la vlvula de drenaje sin prdidas. Al presionar elbotn de prueba se enciende el LED y se activa la vlvula solenoide. ElLED se enciende para indicar "ENCENDIDO" y se apaga cuando lavlvula de drenaje sin prdidas se acciona mediante el transductor o elbotn de prueba manual.

El condensado circula por la tubera de alimentacin hacia la unidad dedrenaje y se acumula en el contenedor. Un sensor capacitivo registraconstantemente el nivel de lquido y enva una seal al controlelectrnico, tan pronto se llena el contenedor. Luego se activa la vlvulapiloto y el diafragma abre la tubera de salida para descargar elcondensado. Cuando se ha vaciado la unidad de drenaje, la tubera desalida se cierra de nuevo rpida y hermticamente sin desperdiciar airecomprimido.

7.4 SISTEMA DE REFRIGERACINEl sistema de refrigeracin se compone de todos los componentes quemanejan R-404A. ste es un sistema de ciclo cerrado hermticamentesellado. De acuerdo con la Figura 1 y siguiendo el circuito fantasma"FLUJO DE REFRIG. (R-404A)," el refrigerante se muestra saliendo de laseccin del evaporador, en donde, en el proceso de eliminacin delcalor, cambia de un lquido de baja presin a un gas de baja presin.Este gas ingresa al lado de succin del compresor en donde secomprime en un gas de alta presin. El gas de alta presin se enfra enla seccin del condensador hasta que se convierte en un lquido de altapresin. Luego pasa por una secadora con filtro permanente quegarantiza que el sistema de refrigeracin est libre de contaminantes.Un tubo capilar de dimetro pequeo (vlvula de expansin ensecadoras enfriadas por agua) mide el refrigerante para introducirlo enel evaporador. La presin del refrigerante se reduce al ingresar alevaporador a medida que se evapora y elimina el calor del lquido demasa trmica.

DIAGRAMA DEPROCESOS E

INSTRUMENTACINNVC200-400

ENFRIADO POR AIRE Y AGUA

6 Secadora refrigerante Nirvana Cycling Modelos 200-400http://air.irco.com


7.5 SISTEMA DE CIRCULACIN DE MASA TRMICAEl lquido de masa trmica de una secadora Nirvana Cycling deIngersoll Rand circula continuamente en un sistema de bomba decircuito cerrado. De acuerdo con la Figura 1 y con la lnea a rayas"LQUIDO TRMICO", se elimina el calor del lquido en el evaporador pormedio del sistema de refrigeracin. El tamao del depsito de masatrmica est diseado para minimizar los ciclos de refrigeracin duranteperodos de carga de aire reducida. El lquido de masa trmica seextrae de la parte inferior del depsito y se bombea por el refrigerador,lo que elimina el calor del aire y luego regresa al evaporador. La bombaque se utiliza en la secadora Nirvana Cycling de Ingersoll Rand esuna bomba de circulacin de cartucho silencioso que no requieremantenimiento similar a las que se usan en redes hidrulicasresidenciales. Si bien el sistema de refrigeracin realiza ciclos deencendido y apagado basndose en las condiciones de carga, la bombade circulacin funciona de manera continua para mantener el flujo porel refrigerador en todo momento. Observe que cuando el interruptor deencendido se ajuste en la posicin de apagado, no funcionar la bombade circulacin.

7.6 CONTROLESLas secadoras Ingersoll Rand de la serie NVC200-400 incorporancontroles automticos para su funcionamiento adecuado. Latemperatura del lquido de masa trmica se mantiene mediante uncontrol de microprocesador que controla la temperatura y realiza losciclos del sistema de refrigeracin en respuesta al flujo y la temperaturavariables del aire. Al aumentar la temperatura del lquido de masatrmica, el compresor de refrigeracin realiza un ciclo de encendido.Cuando el lquido se enfra a dos grados F menos de su punto dereferencia de control, el compresor refrigerante realiza un ciclo deapagado. El lquido de masa trmica funciona como una masa dealmacenamiento trmico en la secadora de la serie NVC.

Se proporciona un interruptor de desconexin por baja presin (LPCO,por sus siglas en ingls) para todas las secadoras de la serie NVC. Esteinterruptor est ajustado en fbrica en 20 psig. Si la presin de succinde refrigerante consume menos de 20 psig, el LPCO se abre para cerrarel compresor refrigerante. Luego de que se haya abierto el interruptor,impedir que funcione el compresor hasta que la presin de succinaumente a ms de 60 psig y se haya reiniciado manualmente el LPCO.

Todas las unidades enfriadas por agua vienen con un interruptor dedesconexin por alta presin (HPCO, por sus siglas en ingls). Esteinterruptor est ajustado para que se abra a 320 psig y se cierre a 270psig. Para compensar la variacin de la temperatura del agua, esposible que sea necesario ajustar la vlvula de regulacin de agua paramantener una presin de descarga de 250 psig. El ajuste se puederealizar girando el tornillo de ajuste en el sentido contrario al de lasagujas del reloj para aumentar la presin de descarga. Paracondiciones en donde se espere una baja temperatura del agua o unaalta presin del agua, se aconseja instalar un regulador de presin deagua delante del condensador.

7.6.1 INTERFAZ DE USUARIO BSICAEl controlador proporciona al usuario informacin sobre elfuncionamiento y las alarmas de la secadora.

La siguiente ilustracin resume las funciones del teclado.

BOTONES

ON / OFF (Encendido/Apagado)Alterna el funcionamiento de la secadora entre los estados "en lnea" y "fuerade lnea"; activa la bomba de glicol. Observe que el sistema de refrigeracinfuncionar basndose en la temperatura.

EXCH SET (Punto de referencia del intercambiador)Cuando se presiona, mostrar el punto de referencia actual delintercambiador en la ventana LCD. Mientras se muestre el punto dereferencia del intercambiador, las flechas hacia arriba y hacia abajo sepueden usar para aumentar o disminuir la temperatura del punto de referenciadel intercambiador.

ALARM RESET (Reinicio de la alarma)Si se presiona una vez, elimina la indicacin de alarma local y desactiva elcontacto de la alarma remota. Si la condicin de alarma persiste, la alarmavolver a aparecer luego de que expire el tiempo de inhibicin de la alarma.

% SAVINGS (% de ahorro)Si se presiona una vez, cambia la visualizacin del LCD para indicar larelacin del tiempo de funcionamiento del sistema de refrigeracin con eltiempo de encendido total de la secadora.

F / CAlterna los indicadores de temperatura del LED entre unidades de medidaFahrenheit y Celsius.

+ / -Permiten que el usuario modifique los valores de punto de referencia. Losvalores de punto de referencia varan dentro de un rango fijo.

LUCES

Pantalla LCDMuestra la temperatura del intercambiador durante el funcionamiento normal.Tambin se usa para mostrar el punto de referencia de temperatura delintercambiador, la condicin de alarma y las funciones de sincronizacin.

SYSTEM ENERGIZED (Sistema activado)Indica que se alimenta energa a la unidad.

DRYER ON (Secadora encendida)Se enciende cuando se ha presionado el interruptor de encendido/apagadopara poner la unidad en funcionamiento. El sistema refrigerante se puedeiniciar en cualquier momento cuando la luz est encendida.

REFRIGERATION COMPRESSOR ON (Compresor de refrigeracinencendido)Indica que est en funcionamiento el sistema de refrigeracin.

DEGREE F/DEGREE C (Grados F/Grados C)Indica las unidades de medida de temperatura.

HIGH TEMP ALARM (Alarma de alta temperatura)Indica que la temperatura del intercambiador ha subido a 10 F o 5 C porsobre el punto de referencia de temperatura del intercambiador.

LOW TEMP ALARM (Alarma de baja temperatura)Cuando se activa, indica que la temperatura del intercambiador ha bajado amenos de 29 F o -2 C. Esta condicin detiene el compresor. El compresorno se reiniciar hasta que la temperatura haya subido dos grados por sobreel punto de referencia del intercambiador.

TORNILLO DE AJUSTE

FIGURA 2VLVULA DE REGULACIN

DE AGUA

7.6.2 PUNTO DE REFERENCIA Y ALARMAS DETEMPERATURA DEL INTERCAMBIADOREl controlador permite al usuario configurar el punto dereferencia de temperatura del intercambiador de la secadorapara funcionar de acuerdo con las condiciones del lugar. Elcontrolador se enva desde fbrica con la temperatura delintercambiador en un valor predeterminado de 38 grados.

7.6.3 AJUSTE DE LOS PUNTOS DE REFERENCIAEl acceso y la manipulacin del punto de referencia detemperatura del intercambiador se hacen de la siguientemanera.



Los nombres de las alarmas y una descripcin breve de cada una deellas se indican a continuacin.

ALARMA DE ALTA TEMPERATURACuando la temperatura de la masa trmica (glicol) alcance el punto dereferencia de la alarma, se activar la alarma. Puede que estacondicin de alarma no dae necesariamente la secadora cuando estsujeta a una exposicin prolongada. Sin embargo, puede tener unimpacto significativo en los procesos descendentes, por lo que sedebe investigar en el momento de detectarla. Observe que estaalarma no apagar la secadora. Esta alarma activar el contacto de laalarma remota y se reiniciar automticamente luego de que serectifique la condicin de la alarma.

ALARMA DE SEGURIDAD DE BAJA TEMPERATURASi la temperatura del refrigerador de la secadora baja a menos delpunto de referencia de fbrica, se activar la rutina de alarma. Puedeque esta condicin de alarma dae la secadora cuando est sujeta auna exposicin prolongada o continua. Observe que esta alarmaapagar la secadora despus de un retardo de tiempo de respuesta.Esta alarma activar el contacto de la alarma remota y se reiniciarautomticamente luego de que se rectifique la condicin de la alarma.

7.6.5 MENSAJES DE ALERTAEl controlador cuenta con las siguientes lecturas para comunicar elestado de funcionamiento de la secadora.

EXCH.SET

Si se presiona el botn EXCHANGER SETPOINT, cambiar lapantalla para mostrar el punto de referencia actual.

36

Si se presionan las flechas HACIA ARRIBA o HACIA ABAJO semodifica el PUNTO DE REFERENCIA DEL INTERCAMBIADOR enincrementos de un grado.

37

Si se presionan las flechas HACIA ARRIBA o HACIA ABAJO semodifica el PUNTO DE REFERENCIA DEL INTERCAMBIADOR enincrementos de un grado.

38

El controlador acepta el ltimo punto de referencia. Despus de 5 segundos, la lectura volver a mostrar la temperatura actual del intercambiador.

38

a PRECAUCIONNo ajuste la temperatura del intercambiador a ms de 50 grados F. Sise hace funcionar la secadora con una temperatura del intercambiadormayor que 50 grados F puede daar el sistema de refrigeracin.

7.6.4 ALARMAS Y SUS FUNCIONESEl controlador indica las alarmas crticas que deben alertar alusuario de una condicin fuera de tolerancia. Luego de quese detecte cada condicin de alarma, se encender elindicador LED correspondiente y se cerrar el contacto de laalarma remota.

Alarma Pantalla Punto de referencia de alarma

ALARMA DE ALTATEMPERATURA HI TEMP ALARM

PTO. DE REF. DELINTERCAMBIADOR + 10 F

ALARMA DE BAJATEMPERATURA LOW TEMP ALARM 28 F

Indica una falla de la sonda. Esta condicinnormalmente se produce cuando sedesenchufa una sonda, se daa elconductor de la sonda o una sondapresenta defectos.

P F

Indica que el compresor refrigerante no seiniciar hasta el final de un retardo deseguridad de tres minutos. Aparece "cd" enpantalla e inmediatamente despus, elnmero de minutos que quedan del retardo.sta es una funcin normal del controlador yno una indicacin de falla.

c d

7.6.6 MODOS DE INI

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Manual de Secadoras Nirvana 200 - 400 NVC400A400

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