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Nirvana Cycling Refrigerated Dryer Models 3250-8000

Operator’s Manual

Manual Del OperadorES

Manual do OperadorPT

Manuel De L’opérateurFR

Operator’s ManualEN

September 2014

1Nirvana Cycling Refrigerated Dryer Models 3250-8000

ingersollrandproducts.com

CONTENTS PAGE

1.0 CONTENTS 1

2.0 INTRODUCTION 2

3.0 WARRANTY 2

4.0 REFRIGERATED DRYER

NOMENCLATURE 2

5.0 RECEIVING AND INSPECTION 3

5.1 UNPACKING

5.2 HANDLING

6.0 SAFETY AND OPERATION

PRECAUTIONS 3

7.0 PRINCIPLES OF OPERATION 5

7.1 INTRODUCTION

7.2 AIR SYSTEM

7.3 MOISTURE REMOVAL SYSTEM

7.4 REFRIGERATION SYSTEM

7.5 THERMAL MASS CIRCULATING

SYSTEM

7.6 CONTROLS

7.6.1 BASIC USER INTERFACE

7.6.2 DISPLAY PARAMETERS

7.6.3 DRYER SET POINTS

AND ALARMS

7.6.4 ADJUSTING CHILLER

TEMPERATURE SET POINTS

7.6.5 ALARMS AND

THEIR FUNCTIONS

7.6.6 START MODES

7.6.6.1 AUTO Mode

7.6.6.2 REMOTE Mode

7.6.6.3 MANUAL Mode

8.0 INSTALLATION AND

INITIAL START-UP 13

8.1 LOCATING EQUIPMENT

8.2 OFFLOADING / LIFTING

THE DRYER (NVC4000 -

NVC19200 ONLY)

CONTENTS PAGE

8.3 INSTALLATION OF AIR PIPING

8.4 PIPING AND VALVES

8.5 FILTRATION

8.6 ELECTRICAL CONNECTION

8.7 PRE START-UP AND SYSTEM

LEAK CHECK

8.8 INITIAL START-UP

8.9 GENERAL START-UP

8.9.1 GENERAL START-UP -

AUTO MODE

(LOCAL OPERATION)

8.9.2 GENERAL START-UP -

REMOTE MODE

9.0 SCHEDULED MAINTENANCE 17

9.1 INTRODUCTION

9.2 REFRIGERANT CONDENSER

9.3 CONDENSATE DISCHARGE

SYSTEM

9.4 PRE-FILTERS AND

POST-FILTERS

9.4.1 FLANGED FILTERS

10.0 TECHNICIAN MODE 18

10.1 ENTERING TECHNICIAN

MODE

10.2 ALARM LIST

11.0 TROUBLESHOOTING 20

11.1 INTRODUCTION

11.2 PROBLEM / ACTION GUIDE

12.0 WIRING DIAGRAMS 22

13.0 GENERAL ARRANGEMENT 32

14.0 REPLACEMENT PARTS 44

15.0 ENGINEERING

SPECIFICATIONS 47

CONTENTS

The Ingersoll Rand multiple module 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 is accomplished by

cooling the air with a refrigeration unit to a temperature at which

moisture in the air is condensed and separated from the airstream. The

temperature the air is cooled to, normally between 36 and 40°F, is

2 Nirvana Cycling Refrigerated Dryer Models 3250-8000


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.

Ingersoll Rand recommends that this technical manual be thoroughly

reviewed prior to start up.

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.

Correction by the Company of nonconformities whether patent or latent,

in the manner and for the period of time provided above, 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.

2.0 INTRODUCTION

3.0 WARRANTY

4.0 REFRIGERATED DRYER NOMENCLATURE

NOMINAL*

FLOW CONDENSER

PREFIX (SCFM) TYPE POWER RATING

NVC 3250-8000 A = AIR 4 = 460-3-60 1 = NEMA 1

W = WATER 6 = 575-3-60 H = NEMA 4

7 = 380-3-50

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



The unit should be thoroughly inspected immediately upon delivery by

the carrier. The unit should be placed in an open area to allow inspection

from all sides. Examine the unit for physical signs of damage or

mishandling such as bent support members, misaligned piping or

control components. Report all discrepancies on shipping documents.

Any indication of potentially rough handling by the carrier should be

noted on the delivery receipt especially if the dryer will not be

immediately uncrated. Obtaining the delivery man’s signed agreement

to any noted damages will facilitate any future insurance claims.

5.1 UNPACKING

All models are wrapped in protective plastic to protect fragile

components. Carefully remove the protective wrap from the dryer,

paying particular attention not to damage dryer components during the

removal process.

5.0 RECEIVING AND INSPECTION

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:

1. Only qualified personnel shall be permitted to adjust, perform

maintenance 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 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.

OSHA

Heading Descriptions

A 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.

A CAUTION

“Caution” is used to indicate a hazardous situation which may result in

minor or moderate injury.

A 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.”

A 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.

5.2 HANDLING

All uncrated multiple module refrigerated air dryer units should be

moved with great care. Be sure the lifting equipment and hoists are rated

to lift and move such weight. Slings can be used as long as those safety

features mentioned above are abided by. Rigging holes are provided for

hoist and spreader bar transporting as well as crane movement. Do not

allow chains and slings to bear on sheet metal.

A WARNING

Multiple module refrigerated air dryers require specific offloading

procedures to avoid damage to the dryer or personal injury. Before

offloading dryer, refer to Section 8.2.

A 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, can cause

serious injury.



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

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 VOLTAGE

This unit is charged withrefrigerant under high pressure.

FAN MAY AUTOMATICALLYSTART AT ANY TIME

5

7.1 INTRODUCTION

Ingersoll Rand multiple module dryers remove moisture from

compressed air by cooling the air to a low temperature ( adjustable

between 32 and 50°F). This causes water vapor to condense into water

droplets which can then be easily removed from the air. The multiple

module design consists of two (2) or more Air / Refrigeration Modules.

All modules are connected by common Inlet and Outlet Headers. The

major systems of the dryer are: Air System, Moisture Removal System,

Refrigeration System and the Controls System The following sections

describe each of the systems in greater detail.

7.2 AIR SYSTEM

The Air System for each module consists of the dryer components which

are in contact with the compressed air. Referring to the Flow Diagram

and following the bold “AIR FLOW,” hot saturated air from the air

compressor enters the inlet header and then the precooler/reheater

where the air temperature is reduced prior to entering the chiller by the

cool air exiting the air/moisture separator. The air then goes into the

chiller section where it is further cooled to the desired dew point by a

thermal mass fluid. The temperature of the thermal mass fluid 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 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 flow. Air from each module is collected

in the outlet header and exits the dryer.

7.3 MOISTURE REMOVAL SYSTEM

Ingersoll Rand condensate drains discharge condensed moisture and

lubricants (condensate) from compressed air equipment. 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 drain valve is designed for trouble-free and maintenance free

draining of unwanted accumulations of condensation and other foreign

matter from any collection point in a compressed air system without the

need for electricity.

7.4 REFRIGERATION SYSTEM

The Refrigeration System consists of all the components in each module

that handles the R-404A refrigerant. This is a hermetically sealed

closed-loop system. Referring to Figure 1 and following the phantom

“REFRIGERANT” line, refrigerant for each module is shown leaving its

respective 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 air cooled or

water cooled condenser section until it becomes a high pressure liquid.

It then goes to a liquid receiver and through a permanent filter dryer that

ensures the refrigeration system is free of contaminants.

7.0 PRINCIPLES OF OPERATION

A thermostatic expansion valve meters the refrigerant for introduction

into the evaporator. The refrigerant pressure is reduced upon entering

the evaporator where as it evaporates, heat is removed from the thermal

mass fluid.

Heavy-duty hermetic compressors are standard on multiple module

dryers. These compressors are equipped with an oil sight glass and

internal overload controls.

7.5 THERMAL MASS CIRCULATING SYSTEM

The heat is removed from the fluid in the evaporator by the refrigeration

system. The thermal mass holding tank is sized to minimize refrigeration

cycles during reduced air load periods. The thermal mass fluid is pulled

from the bottom of the holding tank and pumped through the chiller,

removing heat from the air and then returned to the evaporator. While

the individual refrigeration systems cycle on and off based on loading

conditions, the circulating pump runs continuously to maintain flow

through the chiller at all times.

7.6 CONTROLS

Ingersoll Rand Refrigerated Compressed Air Dryers are equipped with

the Microprocessor Control on each module. This advanced

microprocessor-based controller has been engineered by Ingersoll

Rand exclusively for use with Ingersoll Rand Compressed Air Dryers.

The Microprocessor Control cycles the refrigeration system based on

the dryer's Chiller Temperature. A temperature sensor samples the

thermal mass temperature as it enters the chiller exchanger. The

Chiller Temperature Set point is a user adjustable set point that is used

to set the Refrigeration Compressor Off temperature. Once the Chiller

Temperature has fallen below the Chiller Temperature Set point, the

refrigeration compressor will de-energize. The Operating Temperature

Differential is factory set at 3°F above the Chiller Temperature Set point.

Therefore, if a user adjusts the Chiller Temperature at 36°F, the

Refrigeration Compressor On temperature will be 39°F.

The Microprocessor Control features three levels of access. The default

level CUSTOMER MODE permits adjustment of dryer parameters to

address seasonal variations for drain timing and pressure dew point

temperature. A protected TECHNICIAN MODE permits access to and

manipulation of additional parameters. A password protected

FACTORY MODE is also included for use with Ingersoll Rand Service

Personnel for troubleshooting the dryer.



6 Nirvana Cycling Refrigerated Dryer Models 3250-8000ingersollrandproducts.com


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The microprocessor controller includes a digital readout for monitoring

the discharge pressure of the refrigerant gas exiting the compressor.

This reading will vary dependent upon condenser type as indicated

below:

• For air-cooled applications, condensing fans are cycled on and off by

the Microprocessor Control based on the refrigerant discharge pressure.

Primary fan is cycled on at 275 psig and off at 195 psig. Should the

discharge pressure continue to climb above 335 psig, the secondary

condensing fan will cycle on. As discharge pressure is reduced below

235 psig, the secondary fan will cycle off.

• Water cooled condensers utilize a water regulating valve (Note Figure

2). The water regulating valve comes pre-adjusted from the factory at

260 psig discharge pressure. To compensate for water temperature

variation, it may be necessary to adjust the water regulating valve to

maintain a 260 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.

Multiple module dryers come standard with individual glycol circulating

pumps on each module. This design permits inherent redundancy, as

the loss of a single pump will not degrade the performance of the dryer.

Ingersoll Rand recommends servicing the dryer at the first available

opportunity should a modules pump require servicing.

ADJUSTMENT

SCREW

FIGURE 2

WATER REGULATING VALVE

A NOTICE

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.

A NOTICE

Verify that there is an adequate volume of water for dryer demand.


7.6.1 BASIC USER INTERFACE

The Microprocessor Control display provides the user with the

operating parameters and their corresponding values. When

power is supplied to the dryer, the Microprocessor Control will

illuminate and default to the “Standby” mode, displaying the

“Press ON” prompt.

The following illustration summarizes the keypad functions.

CHLLR TEMP: 37

BUTTONS

• ON

Places the dryer "On Line"; Energizes glycol pump on Nirvana™ Cycling

dryers. For Nirvana™ Cycling models, the compressor will operate based on

temperature;

• OFF

Places the dryer "Off Line"; Stops all automatic functions, including circulating

pump operation on Nirvana™ Cycling dryers.

• SELECT DISPLAY

Allows the user to cycle through the available displays. The last display

selected will remain displayed as the default display.

• + / -

Allows user to modify set point values. Set point values cycle through a fixed

range. Also allows entering negative numbers in FACTORY MODE.

• TEST

Allows user to manually activate the drain no-loss drain valve.

• RESET

Pressing once clears the local alarm indication and de-energizes the remote

alarm contact. Should the alarm condition persist, the alarm will return after

the alarm inhibit time has expired.

• SET

Permits the adjustment of parameters in TECHNICIAN and FACTORY

MODES. In CUSTOMER MODE, allows user to back through displays,

• ENTER

Used to accept changed parameters and set point values.

• i

Restricted Level access for factory use only. Not used for basic dryer

functions. Not to be used by customer or service technician.



7.6.2 DISPLAY PARAMETERS

The Microprocessor Control is capable of displaying a number

of system parameters. For NVC dryers, Module #1 is

supplied with a Deluxe Microprocessor Controller. The

remaining modules feature a Microprocessor Controller. The

following summarizes the parameters that can be accessed

by the user from the Microprocessor Controller:

• Chiller Temperature (CHLLR TEMP): For Nirvana Cycling

Dryers, the Chiller Temperature is the temperature, in

degrees Fahrenheit, of the thermal mass fluid.

• Compressor Status (CMPRSSR): Displays whether the

refrigeration compressor is “ON” or “OFF”.

• Discharge Pressure (P disch): Displays the discharge

pressure of the refrigeration system.

• Suction Temperature (T suction): Displays the suction

temperature, in deg. F, of the refrigeration system. This

value is useful in determining superheat of the refrigerant.

• Suction Pressure (P suction): Displays the suction pressure,

in psig, of the refrigeration system.

• Inlet Air Pressure and Temperature (P AIR IN / T AIR IN):

Displays the temperature, in °F and pressure, in psig, of the

inlet compressed air.

• Outlet Air Pressure and Temperature (P AIR OUT / T AIR

OUT): Displays the temperature, in °F and pressure, in psig,

of the outlet compressed air.

• Drain Interval (DRN INT): Displays the length of time, in

minutes, between operation of the no-loss drain valve.

• Drain On (DRN ON): Displays the length of time, in seconds,

that the no-loss drain valve is open.

• Percent Savings (% SVGS): Displays the length of time the

compressor has been operating versus the length of time

the dryer has been on.

• Cumulative Dryer Hours (CUM DRYER HR): Displays the

length of time, in hours, that the dryer has been operational.

• Cumulative Compressor Operating Hours (CUM CMP HR):

Displays the length of time, in hours, that the refrigeration

compressor has been energized.

Depressing the SELECT DISPLAY button repeatedly scrolls

through the above non-adjustable displays. The Customer

Set Points appear at the end of the list and may be adjusted

by the end user to match seasonal refrigeration and drain

operation. These settings are as follows:

• Chiller Temperature (CHLLR TEMP)


7.6.3 DRYER SET POINTS AND ALARMS

The Microprocessor Controller permits adjustment of each

module’s Chiller Temperature set point. This adjustment

allows the user to configure the dryer to operate according to

site conditions or to equalize run time of the compressors. The

controller is shipped from the factory with the Chiller

Temperature of each module preset as follows:Press SELECT DISPLAY as necessary to display the End

Customer Set points Screen.

End Cust Set PtsSELECTDISPLAY

SELECTDISPLAY

Press SELECT DISPLAY until the Customer Set point screen is

displayed. The parameters that follow are the User Adjustable

Parameters for the controller.

Cust Set Points

ENTER

Pressing “ENTER“ saves the set point.

CHLLR TEMP: 36

SELECTDISPLAY

Pressing SELECT DISPLAY until the CHLLR TEMP parameter is

displayed.

CHLLR TEMP: 34

Depress “ + / -“ as required to change the Chiller Temperature to

36 °.F.

CHLLR TEMP: 36+-

Press SELECT DISPLAY as necessary to return the

Microprocessor Control to the desired display parameter.

This display shows the actual chiller temperature.

SELECTDISPLAY CHLLR TEMP: 39

NVC4000 34 35

NVC4800 34 35

NVC6000 34 35 36

NVC7200 34 35 36

NVC8000 33 34 35 36

NVC9600 33 34 35 36

NVC12000 34 35 36 34 35

NVC14400 34 35 36 34 35 36

NVC16800 33 34 35 36 33 34 35

NVC19200 33 34 35 36 33 34 35 36

Module

#1

Module

#2

Module

#3

Module

#4

Module

#5

Module

#6

Module

#7

Module

#8

To equalize the runtime of the compressors, the user may

“shift” the setpoints above to other modules. For example, on

a NVC6000, Module #2 can be set to 34°F, Module #3 to 35°F

and Module #1 to 36°F. Additionally, to address seasonal

drying needs, the user may adjust the Chiller Temperatures in

a range of up to 43°F - 47°F max, with the modules adjusted

in 1°F increments as shown above.

7.6.4 ADJUSTING CHILLER TEMPERATURE SET POINTS

Accessing the Chiller Temperature parameter in the

CUSTOMER MODE is accomplished by entering the

Customer Set Point routine as described below. Once the

user changes the CHLLR TEMP parameter to a new value,

the value is confirmed and the user exits the Customer Set

Point routine. The following example illustrates the keystrokes

required to change the Chiller Temperature from the default

value of 34°F to 36°F:




7.6.5 ALARMS AND THEIR FUNCTIONS

There are several alarms detected by the Microprocessor

Control to alert the user of an out of tolerance condition. Once

each alarm is detected, a description of the alarm will appear

in the screen and the remote alarm contact will close. Note

that during the alarm condition, the SELECT DISPLAY button

may be depressed to scroll through the available parameters.

After approximately 30 seconds, the alarm screen will

reappear, provided the alarm condition persists.

The alarm names and a brief description of each are described in

detail below. Note that some alarms will enunciate only after a

prescribed alarm delay.

HIGH TEMPERATURE ALARM (HITEMP ALARM)

When the thermal mass (glycol) temperature reaches the factory alarm

set point, after an alarm delay, the module’s alarm will be activated.

This alarm condition that may not necessarily damage the dryer when

subjected to long-term exposure. It may, however, have a significant

impact on downstream processes and thus should be investigated

upon detection. Note that this alarm will not shut down the dryer. This

alarm will reset automatically once the alarm condition is rectified.

LOW TEMPERATURE SAFETY ALARM (LOWTEMP ALARM)

If the dryer chiller temperature falls to or below the factory set point and

remains at or below this set point for the factory delay time, the alarm

routine will activate. This alarm condition may cause damage to the

dryer when subjected to continuous or long-term exposure. Note that

this alarm will shut down the dryer after a response time delay. This

alarm will activate the remote alarm contact and reset automatically

once the alarm condition is rectified.

HIGH PRESSURE CUTOUT ALARM (HPCO ALARM)

If the discharge pressure of the refrigerant is determined to be above

the set point, the alarm routine will activate. This alarm condition may

cause damage to the dryer when subjected to continuous or long-term

exposure. Note that this alarm will shut down the dryer after a

response time delay. The operator must depress the RESET button in

order to clear the alarm and restart the refrigeration system.

LOW PRESSURE CUTOUT ALARM (LPCO ALARM)

If the suction pressure of the refrigerant is determined to be below the set

point of the LPCO alarm, the Microprocessor Control alarm routine will

activate. This alarm condition may cause damage to the dryer when

subjected to continuous or long-term exposure. Note that once cleared,

the compressor will restart automatically. However, if two successive low-

pressure conditions are determined, this alarm will shut down the dryer

after a response time delay and will display the alarm condition. The

operator must depress the RESET button in order to reinstate the

compressor.

Alarm Display Alarm Set Point

HIGH PRESSURE CUTOUT HI PRESS CO See Table 1

LOW PRESSURE CUTOUT LO PRESS CO See Table 1

HIGH TEMPERATURE ALARM HITEMP ALRM 55 °F

LOW TEMPERATURE ALARM LOTEMP ALRM 30 °F

TABLE - 1

7.6.6 START MODES

Ingersoll Rand dryers are capable of starting in several start

modes.

7.6.6.1 AUTO Mode

After power is supplied to the dryer and once the Crankcase

Heater Delay has timed out, the Microprocessor Control will

display the ASC delay, followed by the “PRESS ON BUTTON”

display. Provided the thermal mass temperature is above the

set point, turning the Dryer Operation Switch on the Main

Power Enclosure to the “AUTO” position will start all the

refrigeration systems simultaneously.

7.6.6.2 REMOTE Mode

This mode of operation allows the user to turn the dryer on

and off remotely and requires the installation of a customer-

supplied switch (see Wiring Diagram). For this mode, the

Dryer Operation Switch is placed in the REMOTE position.

With power applied to the dryer and once the ASC and

Crankcase Heater Delays have timed out, the dryer will start

once the remote switch is closed provided the chiller

temperature is above the set point.In addition, this mode of

operation still permits manual control of the dryer via the

Microprocessor Control’s ON & OFF pushbuttons. Note that

the switch must be rated for 120VAC service.

7.6.6.3 MANUAL Mode

After power is supplied to the dryer and once the Crankcase

Heater Delay has timed out, the Microprocessor Control will

display the ASC delay, followed by the “PRESS ON BUTTON”

display on each module. In this mode, the user must depress

the ON button on each Microprocessor Control to operate

each refrigeration system. Note that regardless of the position

of the Dryer Operation Switch, the user may operate each

module individually by depressing the local “ON & OFF”

buttons of each module’s Microprocessor Controller.

Parameter R-404A R-407C

FAN 1 ON 275 psig 235 psig

FAN 1 OFF 195 psig 195 psig

FAN 2 ON 335 psig 265 psig

FAN 2 OFF 235 psig 210 psig

HPCO (Air Cooled) 450 psig 400 psig

HPCO (Water Cooled) 320 psig 320 psig

LPCO 20 psig 20 psig



8.1 LOCATING EQUIPMENT

The dryer should not be located in an area where the ambient

temperature is likely to exceed 113°F (45°C). The dryer should be

located where the ambient temperatures will not be less than 50°F (10°

C) unless equipped with provisions for low ambient operation. If loads

fluctuate significantly, then the dryer should be placed ahead of the

receiver and sufficient storage capacity downstream of the dryer should

then be available to prevent excessive air flow through the dryer.

The dryer must be located in an area that provides sufficient clearance

from walls and other adjoining equipment to allow easy access for

servicing and maintenance requirements. A minimum of three feet is

required to allow free air flow to the condenser inlet. Refer to the multiple

module refrigerated dryer GENERAL ARRANGEMENT drawing for

condenser air flow requirements.

A NOTICE

Failure to comply to the above instructions may result in equipment

malfunction and will void warranty.

8.2 OFFLOADING / LIFTING THE DRYER

(NVC4000 - NVC19200 ONLY)

The headers are constructed with lifting lugs to enable the dryer to be

offloaded and moved. Figure 3 illustrates two methods of using the lifting

lugs for offloading or moving the dryer. For NVC3200 dryers, refer to the

NVC3200 Technical Manual for off-loading instructions.

A WARNING

Prior to attempting to remove the dryer from the delivery vehicle, read

the following section in its entirety. Failure to do so may result in

damage to the dryer or personal injury.

A WARNING

Refer to Engineering Specifications Sheet for estimated weight of dryer

prior to lifting.

To offload the dryer:

• Install lifting chains through the eyes in the lifting lugs on

headers.

• If using two-point lifting, use a spreader bar (not included)

as shown in Figure 3. Be sure that chains / slings do not

bear on sheet metal.

• Adjust chains as required to keep equipment level during

offloading.

• Carefully raise dryer from vehicle and locate according to

criteria described in Section 8.1.

• Securely dryer in place

8.0 INSTALLATION AND INITIAL START-UP

8.3 INSTALLATION OF AIR PIPING

Multiple module dryers are equipped with one blind flange on each of

the Inlet and Outlet Headers. Either side of the header can be used to

connect to the process air piping.

• Connect the inlet and outlet piping to the inlet and outlet headers

• Relocate, if needed, the blind flange on the inlet header to the

remaining flange of the inlet air header.

• Relocate, if needed, the blind flange on the inlet header to the

remaining flange of the outlet air header.

A NOTICE

Insure that adequate piping supports are are in place to prevent

loading on the Inlet and Outlet Headers. Do not allow piping loads to

be exerted on dryer.

A NOTICE

Verify that compressor vibration and vibration from any process air

equipment has been isolated from air system piping. Failure to do so

may damage dryer.

A NOTICE

Verify that air flow pulsations, if present, are eliminated via surge tank,

receiver or pulsation dampener.

8.4 PIPING AND VALVES

Install piping, fittings and accessory items as indicated in Figure 4. For

bypass and isolating purposes, valves (A), (B), and (C) must be installed

(not furnished). In order to test and isolate each drain without

depressurizing the dryer, drain isolation valve (D), has been provided for

your convenience.

FIGURE 3 - LIFTING / OFFLOADING DIAGRAMS




FIGURE 4

TYPICAL PIPING ARRANGEMENT

PRE-FILTER

Drain connections should be piped to an appropriate reservoir or

container. It is recommended that a properly-sized oil / water separator

be installed to comply with EPA regulations for waster water disposal.

When connecting drain valves supplied separately, be sure to use a

single drain for each individual device. It is not recommended that more

than one device be connected to a single valve due to the pressure

differential between the two devices.

8.5 FILTRATION

To protect the air dryer from residual compressor oil and insure

maximum dryer performance, a coalescing pre-filter is recommended.

Filters should be located as close to the dryer as possible and

positioned to allow for ease of access for element replacement. Highly

efficient pre-filters and post-filters sized to your drying application can be

provided by Ingersoll Rand. Contact your local distributor to select the

filter that best suits your filtration requirements. Note that all filters

should be individually supported such that no loads are transmitted to

the dryer inlet and outlet connections.

8.6 ELECTRICAL CONNECTION

Equipment is available in various electrical configurations. All customer

connections can be made at the main electrical box located at the side

of the dryer. All three phase electrical configurations L1, L2 and L3 can

be wired in any configuration and not affect compressor performance.

For all Ingersoll Rand equipment, a suitable fused disconnect switch in

accordance with national and local code requirements is recommended.

See unit specification sheet for voltage requirements and load data.

All Ingersoll Rand Nirvana Cycling Multiple Module dryers are equipped

with module disconnects for safety during maintenance or repair. With

this Multidisconnect feature, each individual module can be isolated

from the power source by using its own dedicated switch.

A WARNING

Crankcase heaters are disconnected through the disconnect switch.

Note that the position of the Dryer On/Off Switch does not affect Crank

Case Heater operation. Refer to wiring diagram supplied with your

dryer.

A NOTICE

Never wire directly or connect any additional wires to the compressor

junction box. This will cause severe system malfunction.

8.7 PRE START-UP AND SYSTEM LEAK CHECK

Once dryer has been installed and prior to initial start-up, all dryer

systems should be checked for proper installation and leaks. Be sure to

check, as a minimum, the following:

• Verify that all air system distribution piping is reasonably leak free.

Note that due to site conditions, it may not be practical to make the

air system completely leak-free.

• Check air connections on dryer to insure there are no leaks present.

• Check drain lines for air or liquid leaks.

• Check all flange connections, if applicable, for gasket compression.

• For units equipped with water-cooled condensers, check that water

supply lines and dryer water connections are leak free. Be sure to

manually open water regulating valves to fill condensers prior to

starting dryer.

• For all compressors, verify that oil is present in sight glass.

After the checks described above have been performed and prior to the

initial starting of the dryer, perform the following:

• Energize Crankcase Heaters

Ensure that dryer is energized for a minimum of (8) hours prior

to startup.



• On the Main Power Enclosure, turn the Compressor Controller

Switch to MANUAL

• On the Main Power Enclosure, turn the Dryer On/Off Switch to

the ON position.

• Supply power to dryer Main Power Enclosure and engage each

individual Module Disconnect Switch for a minimum of (8) hours

prior to dryer startup.

• The Microprocessor Control boards on each Module will indicate

the modules are energized and the crankcase heater delay time

remaining.

A NOTICE

For water cooled models the water valve must be manually opened to

ensure the condenser is full of water prior to start up.

• Verify Proper Refrigerant Pressure

• Check refrigerant pressure readings on the Microprocessor

Control digital display based on the following general guidelines

(refrigeration pressure will vary with ambient temperature):

Ambient Temperature Approximate Refrigerant Pressure(R-404A)

50°F 105 psig

60°F 125 psig

70°F 150 psig

80°F 175 psig

90°F 205 psig

8.8 INITIAL START-UP

The following instructions describe the procedure for INITIAL START-UP

of the dryer. These steps must be followed the first time the dryer is

started after installation or after a prolonged shut down to insure proper

operation of the refrigeration systems For restarting the dryer after short

term shut down, refer to Section 8.9 GENERAL START-UP.

A CAUTION

The multiple module dryer is equipped with a crankcase heater delay.

This delay is controlled by the Microprocessor Controllers to protect

the refrigeration systems. When power is applied to the dryer and the

individual disconnect switches are switched to the “ON” position, the

crankcase heaters are energized and the Microprocessor Controller’s

internal timer begins its eight hour countdown. The refrigeration

compressors are prevented from operating during this period. Note

that the position of the Dryer On/Off Switch does not affect Crank Case

Heater operation.

A CAUTION

The Microprocessor Controllers feature an Anti-Short Cycle (ASC)

Delay. This delay is included to prevent rapid restarting of the

refrigeration compressor. The refrigeration systems will energize only

after the ASC delay count down is completed.

Verify power to the crankcase heaters has been applied for 8 hours

before start up.

Turn the Dryer Operation Switch, located on the Main Power Enclosure,

to the “MANUAL” position and the Dryer On/Off Switch to the “ON”

position.

Power Up of Controls & Operational Check of Each Module

• Depress ON button on the Microprocessor Controller on Module #1.

Provided the glycol temperature is above the Chiller Temperature plus

3°F and after the ASC delay has timed out, the module’s refrigeration

system will energize. Observe operation.


• “The suction pressure display will typically pull down between 50

and 70 psig and the suction temperature reading will vary between

20°F and 40°F. These will vary depending on the glycol

temperature when operating.

• While the glycol temperature is above 50°F, the Microprocessor

Control will indicate a high chiller temperature alarm condition.

• Record operational data on the refrigeration system and check

compressor amp draw.

• Once acceptable operation has been observed, and before the

glycol temperature drops more than 5°F, depress the OFF button on

the Microprocessor Controller. The Microprocessor Controller will

revert to it’s standby state.

Repeat the above “Operational Check of Each Module” for the

remaining modules.

8.9 GENERAL START-UP

Once the dryer operation has been verified using the Initial Start-Up

procedure described in Section 8.9, the dryers may be started either

locally or via a remote connection as described below.

8.9.1 GENERAL START-UP - AUTO MODE (LOCAL OPERATION)

This mode permits automatic operation all modules of the

dryer.

Verify power to the crankcase heaters has been applied

for 8 hours before start up.

Following proper crankcase heater time delay:

• Turn the Dryer Operation Switch, located on the Main Power

Enclosure, to the “AUTO” position. The green “Power On”

light will illuminate on the Main Power Enclosure.

• After the ASC delay has timed out and provided the thermal

mass temperature is greater than the Chiller Temperature

plus 3 °F, each of the refrigeration systems will energize.

The suction pressure reading will typically pull down

between 35 and 60 psig.

• After the alarm delay, provided the Chiller Temperature is

greater than the HIGH TEMPERATURE ALARM set point,

the dryer’s modules will go into HIGH TEMPERATURE

ALARM. The LCD panel will indicate the alarm and the red

“Dryer Fault” light on the Main Power Enclosure will

illuminate. The refrigeration system will continue to operate.

Pressing the SELECT DISPLAY button on each

Microprocessor Control will permit viewing of the available

dryer parameters during this alarm condition. Note that the

alarm condition screen will reappear after approximately 30

seconds until the alarm condition is cleared.

• The CHILLER TEMPERATURE will gradually drop as

indicated on the display. Once the temperature falls below

the HIGH TEMPERATURE ALARM set point, the alarm will

reset and the LCD panel will return to its default display.

Once the HIGH TEMPERATURE ALARM on all modules

has been cleared, the red “Dryer Fault” light located on the

Main Power Enclosure will go out.

• After the refrigeration systems shuts off, air flow may be

introduced to the dryer.

• The refrigeration systems may be shut off by turning the

Compressor Control Switch located on the Main Power

Enclosure to the MANUAL position.




A NOTICE

After installation or a prolonged shutdown, start the dryer with no air

load (no air flow). This enables the dryer to reach its proper operating

temperature in the shortest time possible (typically within 30 minutes).

A NOTICE

Regardless of the position of the Compressor Control Switch on the

Main Control Panel, the refrigeration system of each module may be

turned off by depressing the OFF button located on each module’s

Microprocessor Control. The refrigeration systems also may be turned

on by depressing the ON button located on each module’s

Microprocessor Control.

8.9.2 GENERAL START-UP - REMOTE MODE

This mode of operation permits the dryer to be started and

stopped from a remote location. To operate the dryer in the

REMOTE MODE, the customer must provide a switch as

shown in the Wiring Diagram. This switch must be rated for

120 VAC service.

Following proper crankcase heater time delay:

• Turn the Compressor Control Switch, located on the Main

Power Enclosure, to the “REMOTE” position and the Dryer

On/Off Switch to the “ON” position. The green “Power On”

light will illuminate on the Main Power Enclosure.

• Close the customer-provided remote switch.

• After the ASC delay has timed out and provided the thermal

mass temperature is greater than the Chiller Temperature

plus 3 °F, each of the refrigeration systems will energize.

The suction pressure reading will typically pull down

between 50 and 70 psig.

• After the alarm delay, provided the Chiller Temperature is

greater than the HIGH TEMPERATURE ALARM set point,

the dryer’s modules will go into HIGH TEMPERATURE

ALARM. The LCD panel will indicate the alarm and the red

“Dryer Fault” light on the Main Power Enclosure will

illuminate. The refrigeration system will continue to operate.

Pressing the SELECT DISPLAY button on each

Microprocessor Control will permit viewing of the available

dryer parameters during this alarm condition. Note that the

alarm condition screen will reappear after approximately 30

seconds until the alarm condition is cleared.

• The CHILLER TEMPERATURE will gradually drop as

indicated on the display. Once the temperature falls below

the HIGH TEMPERATURE ALARM set point, the alarm will

reset and the LCD panel will return to its default display.

Once the HIGH TEMPERATURE ALARM on each module

has been cleared, the red “Dryer Fault” light located on the

Main Power Enclosure will go out.

• After the refrigeration systems shuts off, air flow may be

introduced to the dryer.

• The refrigeration systems may be shut off by turning the

Compressor Control Switch located on the Main Power

Enclosure to the MANUAL position.

• Opening the Remote Switch will de-energize the

refrigeration systems.

A NOTICE

Regardless of the position of the Compressor Control Switch on the

Main Control Panel, the refrigeration system of each module may be

turned off by depressing the OFF button located on each module’s

Microprocessor Control. The refrigeration systems also may be turned

on by depressing the ON button located on each module’s

Microprocessor Control.



9.0 SCHEDULED MAINTENANCE

9.1 INTRODUCTION

Ingersoll Rand multiple module refrigerated air dryers require little

maintenance. These dryers utilize hermetically sealed compressors

which do not require any lubrication. Ingersoll Rand recommends

component inspection and service at regular intervals to obtain

maximum performance from your dryer.

9.2 REFRIGERANT CONDENSER

For proper operation, it is essential that the air cooled condenser fins are

free of dirt and dust. Regular cleaning is therefore required.

9.3 CONDENSATE DISCHARGE SYSTEM

On a minimum of a monthly basis, the operation of the automatic drain

should be checked, as well as removed and cleaned to ensure no debris

is trapped inside.

9.4 PRE-FILTERS AND POST-FILTERS

A WARNING

Depressurize the system before disassembling filters. Failure to do so

may result in injury or death.

Filter elements should be changed annually. Change carbon elements

when hydrocarbons are first 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 old

elements can result in reduced air quality.

9.4.1 FLANGED FILTERS:

OPERATION & MAINTENANCE

Filters manufactured to (CEN) EN286.1 are provided with a ½" BSPP

female connection (1) to fit a pressure relief valve (if required).

GP, HE, DP models

The filter elements should be replaced annually.

AC model

Change element(s) after 1000 operating hours or earlier if oil

odour/vapour is detected.

Drains

Manual drain models should be drained periodically. Automatic drain

models should be inspected regularly to ensure correct drain

operation.

REPLACEMENT OF FILTER ELEMENT(S)

1. Isolate air (gas) supply and depressurize filter housing by

opening valve (8) on AC, DP models or valve (9) on GP, HE

models.

2. Remove nuts and bolts (2) from the body flange allowing bowl

(3) to be removed. Larger housings have a hinge (4) allowing

the bowl to swing to one side. It is recommended that the bowl

is supported during this operation.

3. Remove element(s) (5) by unscrewing anticlockwise.

4. Take opportunity to clean inside of housing and inspect for

any signs of corrosion.

5. Check new element(s) (5) are fitted with new O-ring(s) (6).

Hand tighten each element in place before closing the

housing.

6. Replace gasket (7) if damaged.

7. Tighten nuts and bolts (2) evenly.

AUTOMATIC DRAINS

1. Isolate air (gas) supply by closing valve (8).

2. Depressurise drain by opening vent valve 9.

3. Drain can now be removed.

4. Dismantle drain by removing clamp rin (10) - this is achieved

by pressing tab on ring whilst turning.

5. When replacing drain DO NOT pressurize unit unless the

drain bowl is in position and clamp ring (10) is locked in place.



10.0 TECHNICIAN MODE

The Microprocessor Control provides a protected TECHNICIAN MODE

to manipulate several parameters not accessible by the typical operator.

This mode also permits viewing of the factory settings to aid in

troubleshooting of the dryer. Below is a list of parameters that can be

accessed and manipulated by the technician in the TECHNICIAN

MODE:

In TECHNICIAN MODE, the following parameters can be viewed but

not changed:

Parameter Display Set Point

CONFIGURATION (# of

sensors) CONFIG #: 1, 2, 4, 8

OPERATING MODE OP MODE: HS or NC

REFRIGERANT REFRIG: 404 or 407

CONDENSER TYPE COND: AC OR WC

OPERATING

TEMPERATURE

DIFFERENTIAL

T OP DIFF: 3

SHORT CYCLE DELAY SHT CYC DLY: 3

HIGH PRESSURE CUTOUT HPCO: See Table-1

HIGH PRESSURE CUTOUT

DELAYHPCO DLY: 10

LOW PRESSURE CUTOUT LPCO: See Table-1

LOW PRESSURE CUTOUT

DELAYLPCO DLY: 10

HIGH TEMPERATURE

ALARM HITEMP ALRM: 55

LOW TEMPERATURE

ALARM

LOWTEMP

ALRM: 30

LOW TEMPERATURE

ALARM DELAYLOTEMP DLY: 2:00

FAN 1 ON PRESSURE FAN1 ON: See Table-1

FAN 1 OFF PRESSURE FAN1 OFF: See Table-1

FAN 2 ON PRESSURE FAN2 ON: See Table-1

FAN 2 OFF PRESSURE FAN2 OFF: See Table-1

ALARM LISTBEGIN ALARM

LISTN/A

Parameter Display Set Point

DRAIN VALVE ENABLE DRAIN ENABLE OFF (For NO LOSS

DRAIN)

CRANKCASE HEATER

DELAYCCH DLY 8 (or 0,2,4,12 hours)

AUTO RESTART ENABLE AUTO RESTART N (or Y)

10.1 ENTERING TECHNICIAN MODE

A WARNING

TECHNICIAN MODE should only be entered by qualified service

personnel. Altering the set points in TECHNICIAN MODE will have a

significant effect on the operation of the dryer. Incorrect set points may

damage dryer and cause potential serious injury.

To enter the TECHNICIAN MODE, perform the following keystrokes:

Pressing the “2” and “3” buttons simultaneously enters the

TECHNICIAN MODE.

TECH SET MODE

SELECTDISPLAY

Depressing SELECT DISPLAY scrolls through the available

parameters. The first three parameters viewed are adjustable in

TECHNICIAN MODE.

DRAIN ENABLE: OFF

2 3

The DRAIN ENABLE parameter determines whether the

Microprocessor Control shall control an electronic no-loss drain valve. A

value of “ON” will permit the Microprocessor Control to control the drain

valve. A value of “OFF” will disable this feature. Ingersoll Rand dryers

are equipped with a no air loss drain as standard equipment. As such,

DRAIN ENABLE must remain “OFF”:

Depressing the SELECT DISPLAY button advances to the

next adjustable parameter for the Crankcase Heater Delay.

This parameter must not be altered unless instructed by

Ingersoll Rand Service personnel.

CCH DELAY: 4 SELECTDISPLAY

A NOTICE

The Crankcase Heater Delay set point must not be altered unless

directed by Ingersoll Rand Service Personnel. Improperly altering the

set point may result in damage to the dryer. Contact Ingersoll Rand

Compressed Air Solutions before altering the default set point.



10.0 TECHNICIAN MODE

The AUTO RESTART feature permits the dryer to operate once power

is applied to the dryer without requiring operator intervention. This would

be desirable should the user wish to have the dryer restart automatically

after a power outage. Note that the refrigeration system will operate

once the ASC or CCH delay times out. To change the AUTO RESTART

set point from “N” (NO) to “Y” (YES), perform the following. Otherwise,

depress the SELECT DISPLAY button to advance to the next display:

Depressing ENTER saves the selected set point.

AUTO RESTART: Y

SET

Depressing the SET button changes the AUTO RESTART

parameter from “N” to “Y”.

AUTO RESTART: Y

ENTER

Depressing the SELECT DISPLAY button advances to the

next adjustable parameter for the Auto Restart feature.

AUTO RESTART: N SELECTDISPLAY

A WARNING

Changing the AUTO RESTART feature to “Y” will permit the dryer to

operate automatically once power is applied and after a brief delay.

Proper warning signs should be affixed to the dryer to alert users and

service personnel that dryer may start without warning. Failure to do so

may result in serious injury.

Depressing the SELECT DISPLAY button displays the END

TECH SET PTS display.

END TECH SET PTS SELECTDISPLAY

The remaining non-adjustable parameters may be viewed by

depressing the SELECT DISPLAY button as required to arrive at the

desired display.

A NOTICE

To exit the TECHNICIAN MODE at any time, depress the � button toreturn to the CUSTOMER MODE.

10.2 ALARM LIST

At the end of the list of non-adjustable parameters, the Microprocessor

Control displays a list of the most recent 20 alarm conditions. This list

can facilitate troubleshooting the dryer.

At the end of the list of parameters, depressing the SELECT

DISPLAY button displays the beginning of the ALARM LIST.

BEGIN ALARM LIST SELECTDISPLAY

Depressing the SELECT DISPLAY button displays the alarms

that the dryer has experienced, with the most recent alarm

displayed first. The actual display will depend on the most

recent alarm detected by the Microprocessor Control.

HPCO SELECTDISPLAY

The list of alarms can be scrolled by depressing the SELECT

DISPLAY button as needed. At the end of the alarm list, the

END ALARM LIST screen is displayed.

END ALARM LIST SELECTDISPLAY

Depressing the SELECT DISPLAY list displays the ALARM

LIST screen at the top of the ALARM LIST.

BEGIN ALARM LIST SELECTDISPLAY

The Alarm List will repeat as many times as the SELECT DISPLAY

button is depressed. To EXIT the ALARM LIST, perform the following:

Depressing the BLANK button (located above the SET

button) returns the controller to the top of the TECHNICIAN

MODE.

TECH SET MODE

Depressing the BLANK button again returns the controller to

the default display of the CUSTOMER MODE.

CHLLR TEMP: 37



11.0 TROUBLESHOOTING

11.1 INTRODUCTION

Ingersoll Rand multiple module dryers are designed for reliable, trouble-free operation. In the event of any dryer malfunction, the guide below has

been developed to facilitate problem identification and corrective actions.

A WARNING

An air dryer always operates under pressure. Any maintenance

procedure that involves disassembly of pipe fittings, valves or any

other components requires the dryer be isolated from the compressed

air stream and fully depressurized.

A WARNING

Prior to working on the unit, make sure that all circuit breakers or

disconnected switches are tagged “Out of Service.”

A NOTICE

Any in-depth troubleshooting should only be done by qualified service

technicians. Prior to performing any significant corrective action,

consult factory.

11.2 PROBLEM / ACTION GUIDE

PROBLEM

Compressor will not start (no hum)

Compressor will not start hums but trips onoverload protector

Compressor starts and runs, but short cycleson overload protector

Compressor starts and runs, but short cycleson high or low pressure cut out.

Liquid line frosted or sweating

Unit operates long or continuously

Suction line frosted or sweating

Unit noisy

Moisture down stream. Dryer is properlycooling air stream (Check Chllr Temp oncontroller)

POSSIBLE CAUSE

1. Line disconnect switch open2. Fuse removed or blown3. Overload protector tripped

4. Control stuck in open position5. Wiring improper or loose

1. Improperly wired2. Low voltage to unit3. Compressor motor has a winding open or

shorted4. Internal trouble in compressor

1. Excessive discharge pressure 2. Compressor hot - return gas hot3. Compressor has shorted winding

1. High pressure cut-out due to:a. Insufficient air flow across condenser

b. Overchargec. Insufficient water flow across condenser

2. Low pressure cut-out due to:a. Underchargeb. Restriction in or faulty expansion valve

1. Restriction in filter dryer or condenser

1. Shortage of refrigerant2. Control contacts stuck3. System inadequate to handle load.4. Restriction in refrigerant system5. Dirty condenser

1. Expansion valve passing excess refrigerant

2. Overcharge of refrigerant3. Expansion valve stuck open

1. Loose parts or mountings2. Tubing rattle3. Bent fan blade 4. Fan motor bearings worn

Drain failure or adjustment is required

CORRECTIVE ACTION

1. Close start or disconnect2. Inspect and replace fuse3. Allow internal overload to cool and reset.

Check motor windings and starting amps.4. Repair or replace control5. Close start or disconnect

1. Check wiring2. Determine reason and correct3. Replace compressor

4. Replace compressor

1. Check condenser for dirt2. Check refrigerant charge (fix charge)3. Replace compressor

1.High pressure cut-outa. Check condenser for dirt and proper fanoperation.b. Reduce refrigerant chargec. Check complete water circuit makenecessary adjustment

2.Low pressure cut-out a. Fix leak, add refrigerantb. Consult factory prior to replacing valve.

1. Replace part

1. Fix leak then charge2. Clean contacts or replace control3. Review air system parameters.4. Determine location and correct.5. Clean condenser

1. Check super heat and adjust valve ifrequired. Adjustment is rarely required.Consult factory.

2. Correct charge as per manual 3. Clean valve of foreign particles, replace if

necessary.

1. Find parts and tighten2. Reform, to be free of contact3. Replace blade4. Replace motor

Manually activate drain and determinefunctionality. If drain does not dischargeproperly, service drain.



11.0 TROUBLESHOOTING

PROBLEM

Apparent controller display malfunction.Display Blank

Apparent controller display malfunction.Unrealistic temperature displayed

Apparent controller display malfunction. Erraticor inaccurate temperature readings

Apparent controller display malfunction.Unrealistic pressure displayed

Condensate drain does not fire

Condensate drain LED is off

Air bleed from condensate drain outlet port

Condensate drain bowl does not seem to fillwith condensate, drain does not seem to workdue to air locking

POSSIBLE CAUSE

Blown Fuse

Board Failure

Probe loose,off connection or defective probe

Probe not completely in thermal well

Defective probe

Transducer loose, off connection or defectivetransducer

Inlet / outlet pipe internal diameter too smallcausing air-lock or back pressure.

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

Outlet pipe too long / too high causing backpressure.

More than one condensate source connectedproviding alternative path for condensate.

Debris trapped under seal. Damage to seal.

CORRECTIVE ACTION

Check Fuses

Contact your local distributor for furtherassistance.

Inspect probe cable and terminal connectionReplace probe

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

Replace probe

Inspect transducer cable and terminalconnection Replace transducer

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 Service Kit.

If bottom inlet is used, top port must be used asair bleed. Make sure Connect the top inlet to ahigher point in system, which will function as anair bleed for the drain.



12.0 WIRING DIAGRAMS

WIR

ING

DIA

GR

AM

NV

C3250W

WA

TE

RC

OO

LE

D,

460/3

/60

550088-A




WIR

ING

DIA

GR

AM

NV

C3250A

AIR

CO

OLE

D,

460/3

/60

550084-C




WIR

ING

DIA

GR

AM

NV

C4000

AIR

CO

OLE

D,

460/3

/60

550005-E




WIR

ING

DIA

GR

AM

NV

C4000

WA

TE

RC

OO

LE

D,

460/3

/60

550015-E




WIR

ING

DIA

GR

AM

NV

C4800

AIR

CO

OLE

D,

460/3

/60

550161-A




WIR

ING

DIA

GR

AM

NV

C4800

WA

TE

RC

OO

LE

D,

460/3

/60

550162-A




WIR

ING

DIA

GR

AM

NV

C6000W

400

WA

TE

RC

OO

LE

D,

460/3

/60

550022-D




WIR

ING

DIA

GR

AM

NV

C6000W

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WIR

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C8000W

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WIR

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C8000W

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13.0 GENERAL ARRANGEMENT

RIG

HT

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MO

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SID

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8"-1

50#

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T H

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CO

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C43250W

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-1

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7.50

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LA

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C3250A

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550083-C



5500

04

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37Nirvana Cycling Refrigerated Dryer Models 3250-8000ingersollrandproducts.com


5500

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VC

4000

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C6000W

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550021-C




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550025-D




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550025-D


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.

14.0 REPLACEMENT PARTS

DESCRIPTION NVC3250A NVC3250W QTY/MODULE

QTY/UNIT

SPARES1 2 3

BLOCK, CUSTOMER CONNECTION 699350 699350 1CABLE, AIR PRESSURE TRANSDUCER 682946 682946 2CABLE, EXPANSION MODULE 683953 683953 1 1 1 1CABLE, REFRIGERANT TRANSDUCER 682945 682945 2CAPACITOR, CONDENSER FAN MOTOR 683618 - 1COMPRESSOR, REFRIGERATION 682346 682248 1 3 1 1 1CONDENSER, REFRIGERANT 683587 698202 1CONTACTOR, COMPRESSOR 698343 698343 1 1 1 1

CONTACTOR, CONDENSER FAN 699621 - 2 1 1 1

800029 800029 1 1 1 1

DRAIN, CONDENSATE 22699706 22699706 1

DRYER, REFRIGERANT FILTER 600388 600388 1FUSE, CONTROL TRANSFORMER PRIMARY 699793 699793 2 2 2 4FUSE, CONTROL TRANSFORMER SECONDARY 681510 681510 1 2 2 4FUSE, GLYCOL PUMP 684869 684869 1 2 2 4

FUSE, POWER BOX TRANSFORMER PRIMARY 699807 699807 2 2 2 4

FUSE, POWER BOX TRANSFORMER SECONDARY 699391 699391 1 2 2 4HEATER, COMPRESSOR CRANKCASE 682245 682245 1INDICATOR, GLYCOL LOOP FLOW 682368 682368 1LAMPS, POWER BOX 632207 632207 2LENS, POWER BOX GREEN 632208 632208 1LENS, POWER BOX RED 632210 632210 1MODULE, PLC EXPANSION 683955 683955 1 1 1 1MOTOR, CONDENSER FAN 683617 - 2 1 1 1POWER SUPPLY 24V DC 683956 -SP 683956 -SP 1 1 1 1PROBE, EXCHANGER TEMPERATURE 682955L 682955L 1 1 1 1PROBE, TEMPERATURE 6FT LEAD INLET/OUT TEMPERATURE 682955C 682955C 2 2 2 2PUMP, GLYCOL 684825 1 1 1 1RELAY, POWER BOX - - 1RELAY, PUMP 698262 698262 1RESISTOR, CONTROL PANEL DUMMY LOAD 683968 683968 1STRAINER, CONDENSATE DRAIN 683405 683405 1SWITCH, MOTOR DISCONNECT 683619 683619SWITCH, ROTARY DISCONNECT 632358 632358

SWITCH, SELECTOR - POWER ON/POWER BOX 630611 630611 1

SWITCH, SELECTOR 3 POSITION - ON/OFF/REMOTE POWERBOX 633378 633378 1

TRANSDUCER, REFRIGERANT DISCHARGE PRESSURE 682943 682943 1 1 1 1TRANSDUCER, REFRIGERANT SUCTION PRESSURE/AIRPRESSURE 682942 682942 2 1 1 1

TRANSFORMER 600182 600182 1TRANSFORMER, POWER BOX CONTROL 681861 681861 1VALVE, CHECK - GLYCOL LOOP 683983 683983 1VALVE, CONDENSATE BLOCK 680029 680029 1VALVE, EXPANSION 684304 684304 1VALVE, GLYCOL PUMP ISOLATION 2

VALVE, SOLENOID 5/8" REFRIGERANT LIQUID LINE 683338 683338 1

VALVE, WATER CONTROL 1 1/4" - 698204 1VENT, GLYCOL TANK/LINE 683770 683770 1

699350682946683953682945683618684138683587698343

699621

800029

22699706

600388699793

681510684869

699807

699391684595682368632207632208632210683955683617

683956 -SP

682955L682955C

684825-

698262683968683405683619632358

630611

633378

682943

682942

600182

681861683983680029684346684829

683338-

683770

NVC4000A400

DRYER CONTROLLER,TYPE 4 WITH REFRIGERATEDPROGRAM, (Dryer model and serial number must beprovided with order to ensure proper configuration.)

684825

684829684829

MODULE

MODULE CONTROL

45Nirvana Cycling Refrigerated Dryer Models 3250-8000ingersollrandproducts.com

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.


DESCRIPTION NVC4000W400 NVC4800W400 NVC6000W400 NVC8000W400 QTY/MODULE

QTY/UNIT

SPARES1 2 3

BLOCK, CUSTOMER CONNECTION 699350 699350 699350 699350 1CABLE, AIR PRESSURE TRANSDUCER 682946 682946 682946 682946 2CABLE, EXPANSION MODULE 683953 683953 683953 683953 1 1 1 1CABLE, REFRIGERANT TRANSDUCER 682945 682945 682945 682945 2CAPACITOR, CONDENSER FAN MOTOR - - - - 1COMPRESSOR, REFRIGERATION 682346 682346 682346 682346 1 3 1 1 1CONDENSER, REFRIGERANT 683596 683596 683596 683596 1CONTACTOR, COMPRESSOR 698343 698343 698343 698343 1 1 1 1CONTACTOR, CONDENSER FAN - - - - 2 1 1 1

800029 800029 800029 800029 1 1 1 1

DRAIN, CONDENSATE 22699706 22699706 22699706 22699706 1

DRYER, REFRIGERANT FILTER 600388 600388 600388 600388 1FUSE, CONTROL TRANSFORMER PRIMARY 699811 2 2 2 4

FUSE, CONTROL TRANSFORMER SECONDARY 681917 1 2 2 4

FUSE, GLYCOL PUMP 681510 1 2 2 4FUSE, MODULE POWER DISTRIBUTION - - - 632331 632331 3 2 2 4

FUSE, POWER BOX TRANSFORMER PRIMARY 699807 699807 699807 699807 2 2 2 4

FUSE, POWER BOX TRANSFORMER SECONDARY 699391 699391 699391 699391 1 2 2 4

HEATER, COMPRESSOR CRANKCASE 682245 682245 682245 682245 1INDICATOR, GLYCOL LOOP FLOW 682368 682368 682368 682368 1LAMPS, POWER BOX 632207 632207 632207 632207 2LENS, POWER BOX GREEN 632208 632208 632208 632208 1LENS, POWER BOX RED 632210 632210 632210 632210 1MODULE, PLC EXPANSION 683955 683955 683955 683955 1 1 1 1MOTOR, CONDENSER FAN - - - - 2 1 1 1POWER SUPPLY 24V DC 683956 -SP 683956 -SP 683956 -SP 683956 -SP 1 1 1 1PROBE, EXCHANGER TEMPERATURE 682955L 682955L 682955L 682955L 1 1 1 1PROBE, TEMPERATURE 6FT LEAD INLET/OUT TEMPERATURE 682955C 682955 682955 682955C 2 2 2 2

PUMP, GLYCOL 1 1 1 1RELAY, POWER BOX MODULE - - 699866 - 1RELAY, PUMP 698262 698262 698262 698262 1RESISTOR, CONTROL PANEL DUMMY LOAD 683968 683968 683968 683968 1STRAINER, CONDENSATE DRAIN 683405 683405 683405 683405 1SWITCH, MOTOR DISCONNECT 683619 683619 683619 683619SWITCH, ROTARY DISCONNECT 632358 632358 632358 632358

SWITCH, SELECTOR - POWER ON/POWER BOX 630611 630611 630611 630611 1

SWITCH, SELECTOR 3 POSITION - OM/OFF/REMOTEPOWER BOX 633378 633378 633378 633378 1

TRANSDUCER, REFRIGERANT DISCHARGE PRESSURE 682943 682943 682943 682943 1 1 1 1

TRANSDUCER, REFRIGERANT SUCTIONPRESSURE/AIR PRESSURE 682942 682942 682942 682942 2 1 1 1

TRANSFORMER, MODULE CONTROL 600190 1TRANSFORMER, POWER BOX CONTROL 681861 681861 681861 681861 1VALVE, CHECK - GLYCOL LOOP 683983 683983 683983 683983 1VALVE, CONDENSATE BLOCK 680029 680029 680029 680029 1VALVE, EXPANSION 684346 684346 684346 684346 1VALVE, GLYCOL PUMP ISOLATION 2

VALVE, SOLENOID 5/8" REFRIGERANT LIQUID LINE 683338 683338 683338 683338 1

VALVE, WATER CONTROL 1 1/4" 680181 680181 680181 680181 1VENT, GLYCOL TANK/LINE 683770 683770 683770 683770 1

DRYER CONTROLLER,TYPE 4 WITH REFRIGERATEDPROGRAM, (Dryer model and serial number must beprovided with order to ensure proper configuration.)

684825 684825 684825684827

684829 684829 684829 684829

699793 699793 699793

681510 681510 681510

684869 684869 684869

600182 600182 600182




ITE

M

CC

N

DE

SC

RIP

TIO

N

QT

Y.

1

38440889

CO

NT

RO

LH

EA

D A

SS

EM

BLY

1

2

38440897

INLE

TH

EA

D A

SS

EM

BLY

1

3

38440905

FR

PC

YLIN

DE

R

1

4

38440913

RIN

G A

ND

FIL

TE

R K

IT1

5

38440921

TIE

RO

D K

IT1

6

38440939

CO

NT

RO

LA

SS

EM

BLY

1

7

38440947

CO

NT

RO

LT

UB

ING

AS

SE

MB

LY

1

8

38440954

AIR

CY

LIN

DE

R A

SS

EM

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1

9

38440962

BA

LL

VA

LV

E A

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SA

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DR

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VA

LV

E



15.0 ENGINEERING SPECIFICATIONS

Overall dimensions indicated.

Air INLET and OUTLET header centerline remains consistent throughout the model range.

Module number varies depending on model. See last column in chart to indentify modules per model. 3-module model depicted in this illustration.

H

D W

LEFT SIDE FRONT

Overall dimensions indicated.

Air INLET and OUTLET header centerline

remains consistent throughout the model

range.

Module number varies depending on model.

See last column in chart to identify modules

per model. 3-module model depicted in this

illustration.

* Performance data obtained and presented in accordance with CAGI Standard No. ADF 100,

“Refrigerated Compressed Air Dryers – Methods for Testing and Rating.” Pressure dew point at

100 psig, 100°F inlet air, 100°F ambient air.

** Pressure drop +-.5 psi. Pressure drops noted are for the 38°F PDP flows.

*** Average kilowatts per hour of dryer operation at full rated capacity.

460/3/60; 380/3/50; 575/3/60 voltages available.

220 psig maximum working pressure.

Dimensions subject to change without notice.

Shipping weights shown are for air cooled models. Water

cooled model weight is less.

R-404A refrigerant used.

CAPACITY* PRESSURE OVERALL DIMENSIONS SHIP CONNECT DRAIN REFRIG COMP H2O FLOW OPERATING NUMBERSCFM DROP* * W D H WEIGHT SIZE (QTY) SIZE AIR COOL WATER COOL GPM H2O KW* * * OF

MODEL 38°F PDP PSI IN. IN. IN. LBS. IN/OUT FPT (QTY) HP (QTY) HP @85°F CONN AIR COOL WATER COOL MODULES

NVC3250 3,250 3.5 80 99 98 5,000 8” FLG (2) 1/2” (2) 10.5 (2) 9.0 36 1.5 NPT 26.4 17.2 2

NVC4000 4,000 3.5 80 99 98 5,000 8” FLG (2) 1/2” (2) 13.5 (2) 10.5 36 1.5 NPT 30.7 19.7 2

NVC4800 4,800 3.5 80 99 98 5,500 8” FLG (2) 1/2” (2) 13.5 (2) 10.5 43 1.5 NPT 34.5 23.9 2

NVC6000 6,000 3.5 112 100 100 7,500 10” FLG (3) 1/2” (3) 13.5 (3) 10.5 56 2.0 NPT 46.1 29.5 3

NVC7200 7,200 3.5 112 100 100 8,000 10” FLG (3) 1/2” (3) 13.5 (3) 10.5 65 2.0 NPT 51.8 35.8 3

NVC8000 8,000 3.5 148 100 102 9,000 12” FLG (4) 1/2” (4) 13.5 (4) 10.5 78 2.5 NPT 61.5 39.4 4

LEFT SIDE FRONT

ingersollrandproducts.com© 2014 Ingersoll-Rand

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