Ingersoll-Rand 1000 Operator'S Manual Download

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80442791

Revision E

September 2012

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Nirvana Cycling Refrigerated Dryer

Models 1000-1600

Operator’s Manual

Manual Del Operador

Manual do Operador

Manuel De L’opérateur

Operator’s Manual

INTERNAL SALES ORDER# 81730430

DRYER PART NUMBER: NVC1000W400

PROJECT: Niagara Bottling,LLC_Kenosha, WI

Summary of Contents for 1000

Page 1: ...Nirvana Cycling Refrigerated Dryer Models 1000 1600 Operator s Manual Manual Del Operador ES Manual do Operador PT Manuel De L opérateur FR Operator s Manual EN INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 2: ...ONS 10 7 6 6 START MODES 11 7 6 6 1 Manual Mode 11 7 6 6 2 Auto Restart Mode 11 7 6 6 3 Remote Automatic Mode 11 8 0 INSTALLATION AND INITIAL START UP 12 8 1 LOCATION AND MOUNTING 12 8 2 PIPING AND VALVES 12 8 3 FILTRATION 12 8 4 ELECTRICAL CONNECTION 13 8 5 INITIAL START UP 13 8 5 1 START UP SEQUENCE 13 9 0 SCHEDULED MAINTENANCE 14 9 1 INTRODUCTION 14 9 2 REFRIGERANT CONDENSER 14 9 3 CONDENSATE D...

Page 3: ...any 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 suc...

Page 4: ...ctrical disconnect switch and disconnect any separate control lines if used before attempting to work or perform maintenance on the unit Do not attempt to service any part while machine is in an operational mode Do not attempt to remove any parts without first relieving the entire air system of pressure Do not attempt to remove any part of the refrigeration system without removing and containing r...

Page 5: ...CAL MANUAL Removing fuses will not disconnect power from dryer Always disconnect power from ALL sources before performing service READ TECHNICAL MANUAL FAN MAY AUTOMATICALLY START AT ANY TIME This unit is charged with refrigerant under high pressure Air Under Pressure Will Cause Injury Death Or Property Damage Relieve Press Before Servicing Condensate Drain Discharges Under Pressure Drain Requires...

Page 6: ...the compressed air Referring to Figure 1 and following the bold AIR FLOW hot saturated air from the compressor enters the precooler reheater where the air temperature is reduced prior to entering the chiller by the cool air exiting the air moisture separator This precooling allows for the use of a smaller refrigeration system The air then goes into the chiller section where it is further cooled to...

Page 7: ...lso features a test button that permits manual operation of the no loss drain valve Depressing the test button illuminates the LED and energizes the solenoid valve The LED illuminates to indicate POWER ON and goes off when the no loss drain valve is operated by the transducer or manual test button The condensate flows through the feed line into the drain unit and accumulates in the container A cap...

Page 8: ...roprocessor 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 troub...

Page 9: ...ass 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 press...

Page 10: ...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 Alarm Display Alarm Set Point HIGH PRESSURE CUTOUT HI PRESS CO See Table 1 LOW PRESSURE CUTOUT LO PRESS ...

Page 11: ...rigeration system operate Below are brief descriptions of these various start modes 7 6 6 1 Manual Mode Ingersoll Rand dryers are shipped from the factory in the Manual Mode After power is supplied to the dryer the user will be presented with the ASC delay followed by the PRESS ON BUTTON display After the ASC delay has timed out the dryer will only start once the ON button is depressed In this con...

Page 12: ...e 3 indicates a typical piping arrangement for a refrigerated dryer including dryer and filter bypasses This figure can be used as a guide for valve and accessory placement in the system Ingersoll Rand 1000 through 1600 models come factory installed with a drain isolation valve D The isolation valve permits maintenance of the automatic drain without isolating air flow to the dryer To operate dryer...

Page 13: ...te dryer close switch or contact and allow dryer to start after an initial delay The local On OFF pushbuttons may also be used at any time after contact closure a b c 8 5 INITIAL START UP NOTICE For water cooled models the water valve must be manually opened to ensure that the condenser is full of water prior to start up CAUTION Allow 8 hours of warm up time for the crankcase heater prior to start...

Page 14: ...lly closed The drain valve is located near the solenoid valve and requires a quarter turn to isolate the drain from system pressure 9 3 1 1 CLEANING INSTRUCTIONS SOLENOID DRAIN Be sure dryer is depressurized or isolation valve is closed Disconnect drain body from filter stop Loosen connector screw to allow the electrical connector assembly to be removed from the D I N unit solenoid Remove retainer...

Page 15: ...GLAND SOLENOID VALVE SPRING WASHER RETAINER NUT WASHER D I N UNIT SOLENOID PLUNGER TUBE ASSY ORIFICE CUP BEVELLED WASHER STRAINER BODY THREADED FLANGE GASKET PLUNGER W SPRING ASSEMBLY FIGURE 4 SOLENOID DRAIN ASSEMBLY 8 9 9 5 6 7 1 6 2 4 1 3 10 8 9 5 7 1 3 2 4 FIGURE 5 NO AIR LOSS DRAIN INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 16: ...he service unit by downward movement 6 7 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 proper drain operation 2 5 4 3 2 1 6 4 3 1 Assembly Control unit onto service unit Check if service unit 3 matches control unit 1 type designation and colo...

Page 17: ... TECHNICIAN MODE perform the following keystrokes 2 3 TECH SET MODE Pressing the 2 and 3 buttons simultaneously enters the TECHNICIAN MODE SELECT DISPLAY DRAIN ENABLE OFF Depressing SELECT DISPLAY scrolls through the available parameters The first three parameters viewed are adjustable in TECHNICIAN MODE The DRAIN ENABLE parameter determines whether the Microprocessor Control shall control the dra...

Page 18: ... most recent 20 alarm conditions This list can facilitate troubleshooting the dryer SELECT DISPLAY BEGIN ALARM LIST At the end of the list of parameters depressing the SELECT DISPLAY button displays the beginning of the ALARM LIST SELECT DISPLAY HPCO ALARM Depressing the SELECT DISPLAY button displays the alarms that the dryer has experienced with the most recent alarm displayed first The actual d...

Page 19: ...m identification and corrective actions 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 WARNING Prior to working on the unit make sure that all circuit breakers or disconnected switches are tagged Out of Servic...

Page 20: ...TROL fuse Compressor and fan not running Controller indicates compressor is ON Compressor relay may be bad replace relay Check for loose wire connections at contactor or loss of power at control board Defective control board replace as necessary Contact your local distributor for further assistance Compressor and fan are running exchanger temp high pump not running Defective Pump Contact your loca...

Page 21: ... lock or back pressure Replace with larger diam eter piping Excessive use of bends elbows in inlet outlet pipe work causing air lock back pressure Reduce the amount of bends and elbows Outlet pipe too long too high causing back pressure Reconfigure condensate piping More than one condensate source connected providing alternative path for conden sate Reroute condensate to elim inate secondary path ...

Page 22: ...ollrandproducts com 22 12 0 WIRING DIAGRAMS WIRING DIAGRAM NVC1000 1600 AIR AND WATERCOOLED 230 460V 3 60 200 440V 3 50 550028 E OPTIONAL NO AIR LOSS DRAIN ONLY INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 23: ...llrandproducts com 23 12 0 WIRING DIAGRAMS WIRING DIAGRAM WITH SOLENOID DRAIN VALVE NVC1000 1600 A 460V 3 60 440V 3 50 NVC1000 1200 A 230V 3 60 200V 3 50 550184 INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 24: ...lrandproducts com 24 12 0 WIRING DIAGRAMS WIRING DIAGRAM NVC1200 1600A NVC1000W NVC1600W 575 3 60 W TRANSFORMED 460V FANS 550038 C OPTIONAL NO AIR LOSS DRAIN ONLY INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 25: ...ollrandproducts com 25 12 0 WIRING DIAGRAMS WIRING DIAGRAM WITH SOLENOID DRAIN VALVE NVC1200 1600 A NVC1000W NVC 1600W 575 3 60 W TRANSFORMED 460V FANS 550187 A INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 26: ... 1000 1600 ingersollrandproducts com 26 12 0 WIRING DIAGRAMS WIRING DIAGRAM NVC1000A NVC1200W 575 3 60 550039 A OPTIONAL NO AIR LOSS DRAIN ONLY INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 27: ...els 1000 1600 ingersollrandproducts com 27 12 0 WIRING DIAGRAMS WIRING DIAGRAM WITH SOLENOID DRAIN VALVE NVC1000A AND 1200 W 575 3 60 550188 INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

Page 28: ... WATER OUTLET CONNECTION SEE NOTE 1 MPT WATER INLET CONNECTION SEE NOTE 1 1 4 NPT DRAIN CONN STANDARD 3 8 ID NYLON DRAIN TUBE OPTIONAL LCD DISPLAY 1 CHILLER TEMP 2 COMPRESSOR ON OFF 3 DRAIN INTERVAL 4 DRAIN ON 5 PERCENT SAVINGS 6 CUMULATIVE DRYER HOURS 7 CUMULATIVE COMPRESSOR HOURS 8 CUSTOMER SET POINTS PUSHBUTTONS 1 ON 2 OFF 3 RESET 4 TEST 5 SET 6 SELECT DISPLAY 7 ENTER 8 CONDENSER AIR DISCHARGE ...

Page 29: ...3956 POWER SUPPLY 24V DC 1 682955C PROBE EXCHANGER SUCTION TEMPERATURE 2 2 2 2 698262 RELAY PUMP 1 683968 RESISTOR CONTROL PANEL DUMMY LOAD 200 OHM 0 5W 250VAC 1 683739 STRAINER CONDENSATE DRAIN 1 682943 TRANSDUCER REFRIGERANT DISCHARGE PRESSURE 0 500 PSIA EXCEPT NVC1000 1 1 1 1 682942 TRANSDUCER REFRIGERANT SUCTION PRESSURE 0 300 PSIA 1 1 1 1 699640 TRANSFORMER CONTROL 0 25 KVA EXCEPT NVC1000 1 6...

Page 30: ...0 698202 698204 684300 684193 684193 1600 698202 698204 682346 682248 684290 MISCELLANEOUS PARTS FOR NEMA 4 DRYERS PART DESCRIPTION 632207 N4 INDICATOR BULB 632210 N4 INDICATOR RED LENS 632208 N4 INDICATOR GREEN LENS 630611 N4 SWITCH ON OFF 633378 N4 SELECTOR SWITCH GLYCOL PUMPS AUTOTRANSFORMERS SOLENOIDS NVC MODEL GLYCOL PUMP AUTOTRANSFORMER WHOLE UNIT SOLENOID VALVE N1 SOLENOID COIL N4 1000 6837...

Page 31: ...4 0 45 29 5 10 5 19 3 105 0 3 1 2 1 6 4 0 WEIGHT REFRIGERANT R404A MAX FUSE MIN CIRCUIT AMPACITY COMPRESSOR RATINGS MODEL NO VOLTS PH HZ WEIGHT LBS OZ HP RLA LRA NVC1000W 460 3 60 2000 6 8 15 11 3 5 8 6 60 0 NVC1200W 460 3 60 2300 8 0 25 14 4 6 11 1 68 0 NVC1600W 460 3 60 2300 11 0 35 20 2 9 15 7 78 5 MAXIMUM ALLOWABLE WORKING PRESSURE 220 psig NOTICE Specification information above accurate at ti...

Page 32: ...ingersollrandproducts com 2012 Ingersoll Rand plc INTERNAL SALES ORDER 81730430 DRYER PART NUMBER NVC1000W400 PROJECT Niagara Bottling LLC_Kenosha WI ...

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