IR Water-Dryer: Ingersoll-Rand (Shanghai) Co., LTD

Ingersoll Rand Refrigerated Air Dryer Instruction Manual
IR 水冷型干燥机
IR Water-dryer
使用说明书
The INSTRUCTION
英格索兰(上海)有限公司
Ingersoll-Rand (Shanghai) Co., Ltd.
上海市遵义路 100 号虹桥上海城 B 栋 11 楼
No. 100 Zunyi Road, Shanghai Hongqiao Shanghai City, 11th Floor,
Block B
电话：021-22081299
Tel : 021-22081299
传真：021-22081555
FAX：021-22081555
CONTENTS
0
INTRODUCTION-----------------------------------------------------------------------------------1
SAFETY INFORMATION---------------------------------------------------------------------2
1. GENERAL ---------------------------------------------------------------------------------------4
2. TECHNICAL SPECIFICATION------------------------------------------------------5
� AIR COOLED MODELS-------------------------------------------------------5
� WATER COOLED MODELS------------------------------------------------6
3. PART NUMBER--------------------------------------------------------------------------------7
� AIR COOLED MODELS ------------------------------------------------------7
� WATER COOLED MODELS----------------------------------------------14
4. FLOW DIAGRAM---------------------------------------------------------------------------19
5. ELECTRICAL DIAGRAM--------------------------------------------------------------21
6. INSTALLATION------------------------------------------------------------------------------25
7. PERFORMANCE---------------------------------------------------------------------------26
8. MAINTENANCE-----------------------------------------------------------------------------27
9. TROUBLE SHOOTING/SOLUTION--------------------------------------------29
Introduction
The contents of this manual are considered to be proprietary and confidential to Ingersoll
Rand and should not be reproduced without the prior written permission of Ingersoll Rand.
1
Nothing contained in this document is intended to extend any promise, warranty or
representation, expressed or implied, regarding the Ingersoll Rand products described herein.
Any such warranties or other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which are available upon
request.
This manual contains instructions and technical data to cover routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Ingersoll Rand
service department.
All components, accessories, pipes and connectors added to the compressed air system
should be:
• Details of approved equipment are available from Ingersoll–Rand• Outsourcing from name
brand supplier should have fine quality. If possible, the model is approved by Ingersoll Rand.
• Of good quality, procured from a reputable manufacturer and, wherever possible, be of a
type approved by Ingersoll Rand.
• .Clearly rated for a pressure at least is equal to the machine maximum allowable working
pressure.
• Compatible with the compressor lubricant/coolant.
• Accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll–Rand Service departments.
Ingersoll Rand reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such
improvements to products sold previously.
This machine is only operated under following special condition and usage as per design
and supply:
• Drying water vapor in compressed air, the air does not include known or detectable air,
steam, or particles.
If any questions, please contact service center.
Warning
The use of the machine in any of the situation types
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll Rand.
警告
Warning
2
Use of the machine to produce compressed air for:
a) Direct human consumption
b) Indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the GENERAL
INFORMATION SECTION of this manual.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY
EXPLOSIVE ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES
OR VAPOURS MAY BE PRESENT.
Use of the machine fitted with non Ingersoll Rand approved components.
Use of the machine with safety or control components missing or disabled.
Connect to wrong voltage/ or wrong frequency power
Warning
The use of non–genuine spare repair parts other than those included within the Ingersoll
Rand approved parts list may create hazardous conditions over which Ingersoll Rand has
no control. Therefore Ingersoll Rand does not accept any liability for losses caused by
equipment in which non–approved repair parts are installed. Standard warranty conditions
may be affected.
SAFETY
◆General Information
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation. Ensure that the Operation and Maintenance manual is not
removed permanently from the machine. Ensure that maintenance personnel are adequately
trained,
competent and have read the Maintenance Manuals.
DANGER!
Hazard that WILL cause DEATH, SEVERE INJURY or substantial property damage if
ignored. Instructions must be followed precisely to avoid injury or death.
CAUTIONS!
Hazard that CAN cause DEATH, SEVERE INJURY or substantial property damage if
ignored. Instructions which must be followed precisely to avoid injury or death.
CAUTIONS!
Hazard that CAN cause DEATH, SEVERE INJURY or substantial property damage if
ignored. Instructions which must be followed precisely to avoid injury or death.
◆General Information
※Compressed refrigerant and electricity are very dangerous. Before doing maintenance on
3
the unit, ensure that all pressure is released from the system and electricity is cut off,
locked, and tagged.
※All the protective procedure should be done during the operation. Door/cap should be
closed.
※Dryer installation should be complied electric operation specifications, local sanitation and
safety requirements.
◆Compressed air
※Ensure that the machine is operating at the rated pressure and that the rated pressure is
known to all relevant personnel.
※All air pressure equipment installed in or connected to the machine must have safe working
pressure ratings of at least the machine rated pressure.
※If more than one compressor is connected to one common downstream plant, effective
isolation valves must be fitted and controlled by work procedures, so that one machine
cannot accidently be pressurized / over pressurized by another.
※If safety valve is installed between isolating valve and dryer, then it must have capable
ability to release the air from air compressor.
※If the discharged air is to be ultimately released into a confined space, adequate ventilation
must be provided.
※When using compressed air always use appropriate personal protective equipment.
※All pressure containing parts, especially flexible hoses and their couplings, must be
regularly inspected, be free from defects and be replaced according to the Manual
instructions.
※Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit,
ensure that all pressure is vented from the system and that the machine cannot be started
accidentally.
※ Avoid bodily contact with compressed air.
◆Refrigerant
※Refrigerant pipe could be either very hot or very cold, it is depending on the operation
pressure and media condition, please avoid bodily contact with the components.
※Any refrigerant system maintenance should only be made by a suitably qualified technician.
Carry, recycle, and prepare refrigerant should have the local or world refrigerant
certificate.
DANGER!
Breathing refrigerant can cause death by suffocation. DO NOT breathe refrigerant gas.
◆Transportation
※When loading or transporting machines ensure that the specified lifting and tie down points
are used.
4
※Forklift slot on the bottom is suggested for using to move the machine.
※Dryer is high precision equipment. All precision components, pipeline, and control system
electrical parts cannot be bearing big impact and shaking. When driving on high way, the
speed cannot be too fast, and when driving on poor quality roads, should drive slowly to
prevent unnecessary loss caused.
※When handling, moving and installing machine, forklift should be used to lift from the
bottom of machine no matter before of after packing. Never lift the machine on the air
inlet/outlet pipes.
◆Electrical
※Dryer motor starter and control cabinet have dangerous high voltage. All the installation
has to comply with electrical operating specifications. Before operating the electrical
system, ensure using manual circuit breaker to cut off electric voltage in the system. Power
line connecting dryer must have the circuit breaker or fuse safety switch.
※Any electrical connections or adjustments should only be made by a suitably qualified
electrician.
※Keep all parts of the body and any hand–held tools or other conductive objects, away from
exposed live parts of the dryer electrical system. Maintain dry footing, stand on insulating
surfaces and do not contact any other portion of the dryer when making adjustments or
repairs to exposed live parts of the dryer electrical system.
※Close and lock all access doors when the dryer is left unattended.
※Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only
extinguishers suitable for class BC or class ABC fires.
※Attempt repairs only in clean, dry, well lighted and ventilated areas.
※Connect the compressor only to electrical systems that are compatible with its electrical
characteristics and that are within it’s rated capacity.
◆Condensate
Condensate disposal
※Condensed water can not be discharged into the water / surface water system.
※As waste water regulations vary by country and region it is the responsibility of the user to
establish the limitations and regulations in their particular area.
◆Refrigerant oil
※Steps to take when refrigerant oil flows over: Use absorbing material to absorb oil, and put
it into plastic bag.
※To burn away the oil in incinerator, or disposal it as per regulations in the particular area.
Warning
5
Every dryer has high temp (high pressure) shutdown function. Please see the maintenance
part for the repair.
Hazard that WILL cause DEATH, SEVERE INJURY or substantial property damage if
ignored. Instructions must be followed precisely to avoid injury or death.
• All the air/water inlet, air/water outlet, and the pipes which connects the outlets should be
thought of vibration, pulse, temperature, and application maximum pressure, corrosion
and chemical resistance factors. • Based on above factors, air pipes should avoid the
following material: plastic, soldering copper fittings, and rubber tube. Besides, only based
on the specification of flexible connector/ and bend meets the system operating
parameters, those parts could be used.
• Installer or owner should be providing the maintenance pipes which connecting to the
machine.
Warning
The specification of this machine is such that the machine is not suitable for use in
flammable gas risk areas.
Warning
Release the pressure in the compressed air system before starting the dryer.
◆ Symbols
Please read and understand the safety and information symbols, make sure you operate the
machine as per the symbols, if you have trouble understanding, please contact your facility.
Read Manual
Lifting up
1. Introduction
� Principle
Refrigerated air dryer cooled down the compressed air to condense moisture to the
liquid drop, and separaed liquid, oil, dust from the compressed air through the gas/water
separator, then disposed through auto drain. It decreases the oil, dust, and moisture content
in the compressed air to get the dry and clean outlet air.
6
� Work flow
COMPRESSED AIR CIRCUIT:
The refrigerated air dryer cools the incoming compressed air first in an air-to-air heat
exchanger where the outgoing cool dry air pre-cools the hot incoming air and condenses
some moisture out. Then the incoming air enters an air-to-refrigerant heat exchanger where
the air is cooled to 38º F by the liquid refrigerant. This process causes the moisture to
condense into liquid water and it is drained away. The out going air then enters the air-to-air
heat exchanger and is warmed up to keep the outside of pipes from sweating. 。
REFRIGERATION CIRCUIT:
The refrigeration compressor pumps hot hi-pressure gas refrigerant (Freon) into the
condenser which transfers the heat from the refrigerant gas to the ambient air as the gas
condenses into a liquid. The liquid refrigerant (Freon) is then metered to a cold low pressure
where it enters the air-to-refrigerant heat exchanger and the heat from the hot compressed air
is adsorbed into the cold refrigerant (Freon). The refrigeration compressor then sucks low
pressure hot gas refrigerant (Freon) into the refrigeration compressor and the cycle starts
over again.
2. Technical Specification
◆ Air cooled dryer dimensions and connection pipes table
Inlet pressure:0.7-1.0MPa, inlet temp<45℃，ambient temp<40℃, pressure dew point 10℃
Dimension
Capacity Connection W（k
kg
Model Power L W H
m3/min size ）
（mm
mm）（mm
mm mm
mm）（mm
mm
mm）
D42INR-A 0.7 0.75” thread 430 325 540 45
D72INR-A 1.2 0.75”thread 530 325 540 52
D108INR-A 1.8 1”thread 560 400 640 64
D216INR-A 3.6 1.5”thread 680 430 745 82
220V/1/5
D294INR-A 4.9 1.5”thread 680 500 810 104
0Hz
D342INR-A 5.7 1.5”thread 680 500 810 120
D390INR-A 6.5 1.5”thread 725 500 810 138
D444INR-A 7.4 1.5”thread 775 500 810 155
D540INR-A 9 1.5”thread 850 610 925 175
D690INR-A 11.5 1.5”thread 950 750 1320 203
D810INR-A 13.5 2”thread 380V/3/5 1050 750 1320 245
D990INR-A 16.5 2”thread 0Hz 1175 800 1350 272
D1050INR-A 17.5 2”thread 1175 800 1350 295
7
D1170INR-A 19.5 2.5”thread 1420 900 1530 360
D1380INR-A 23 2.5”thread 1520 900 1520 422
D1590INR-A 26.5 2.5”thread 1670 900 1520 486
D1740INR-A 29 2.5” thread 1670 900 1520 498
D2100INR-A 35 3”Flange 1800 980 1600 535
D2340INR-A 39 3”Flange 1850 980 1600 610
D2700INR-A 45 3”Flange 1850 1000 1610 655
D3090INR-A 51.5 3”Flange 1850 1000 1610 720
D3480INR-A 58 4”Flange 2000 1080 1810 825
D4080INR-A 68 4”Flange 2200 1080 1810 910
D4200INR-A 70 4”Flange 2200 1080 1810 930
D4560INR-A 76 4”Flange 2400 1200 1650 1080
D4800INR-A 80 4”Flange 2400 1200 1650 1210
D5520INR-A 92 4”Flange 2400 1200 1650 1375
D5940INR-A 99 4”Flange 2400 1200 1650 1420
D7680INR-A 128 4”Flange 2400 1550 1650 1750
D8700INR-A 145 6”Flange 2700 1750 1650 2000
◆ IR water cooled dryer dimensions and connection pipes table

Inlet pressure:0.7-1.0MPa, inlet temp<45℃, cooling water temp <32℃, pressure dew point 10℃
Dimension
Capacity Connection W（k
kg
Model Power L W H
m3/min size ）
（mm
mm）（mm
mm mm
mm）（mm
mm
mm）
D690INR-W 11.5 1.5”thread 1020 720 1020 203
D810INR-W 13.5 2”thread 1080 720 1020 250
D990INR-W 16.5 2”thread 1180 750 1020 280
D1050INR-W 17.5 2”thread 1180 750 1020 295
D1170INR-W 19.5 2.5”thread 1420 800 1200 375
D1380INR-W 23 2.5”thread 1520 800 1200 435
380V/3/50
D1590INR-W 26.5 2.5”thread 1610 800 1200 495
Hz
D1740INR-W 29 2.5” thread 1610 800 1200 505
D2100INR-W 35 3”Flange 1730 860 1300 565
D2340INR-W 39 3”Flange 1630 1000 1400 640
D2700INR-W 45 3”Flange 1680 1000 1520 685
D3090INR-W 51.5 3”Flange 1730 1000 1520 755
D3480INR-W 58 4”Flange 1880 1200 1620 860
8
D4080INR-W 68 4”Flange 1880 1200 1620 960
D4200INR-W 70 4”Flange 1880 1200 1620 980
D4560INR-W 76 4”Flange 2200 1200 1720 1160
D4800INR-W 80 4”Flange 2200 1200 1720 1260
D5520INR-W 92 4”Flange 2400 1300 1720 1410
D5940INR-W 99 4”Flange 2400 1300 1720 1450
D7680INR-W 128 4”Flange 2400 1600 1720 1820
D8700INR-W 145 6”Flange 2400 1750 1800 2100
3. Part number
◆ Air cooled part number
no.:: D42INR-A
Model no. no..：D72INR-A
Model no D72INR-A
IR No Title IR No Title
15460843 Compressor 15460843 Compressor
15486632 Air condenser 15486632 Air condenser
15486756 Fan motor 15486756 Fan motor
15480403 Dry filter 15480403 Dry filter
99282535 Expansion valve 99282535 Expansion valve
15486228 Electric drain 15486228 Electric drain
15457963 Refrigerant low pressure gauge 15457963 Refrigerant low pressure gauge
15485949 Condensed
gaugause apurifier
gau 15485956 Condensed
gaugause apurifier
gau
15489545 Fan motor pressure switch 15489545 Fan motor pressure switch
15483837 Temp protection switch 15483837 Temp protection switch
15483811 Start switch 15483811 Start switch
99282857 Needle valve 99282857 Needle valve
no.:: D108INR-A
Model no. Model no. D216INR-A
no.：D216INR-A
15485964 Condensed
gaugause apurifier
gaugause apurifier
gau
Model no. D294INR-A
no.：D294INR-A Model no. D342INR-A
no.：D342INR-A
9
15485980 Condensed
gaugause apurifier
gaugause apurifier
gau
Model no. D390INR-A

no.：D390INR-A Model no. D444INR-A
no.：D444INR-A
15486004 Condensed purifier 15486012 Condensed purifier
Model no. D540INR-A

no.：D540INR-A
IRNo Title IRNo Title
15486681 Compressor 15486020 Condensed purifier
15486244 Air condenser 15465149 Electric magnet contactor
15486806 Fan motor 99282733 Auto air switch
15453400 Dry filter 15489545 Fan motor pressure switch
99282386 Expansion valve 15483837 Temp protection switch
15486228 Electric drain 15483811 Start switch
15457963 Refrigerant low pressure gauge 99282857 Needle valve
Model no. D690INR-A

no.：D690INR-A
15486699 Compressor 15465156 Electric magnet contactor
15483993 Air condenser 99282733 Auto air switch
15486376 Fan motor 15489545 Fan motor pressure switch
15453400 Dry filter 15489529 High pressure protective switch
10
99282386 Expansion valve 15489537 Low pressure protective switch
15486038 Condensed purifier 99282857 Needle valve
15457963 Refrigerant low pressure gauge 15465610 Bypass valve
Model no. D810INR-A

no.：D810INR-A
15486699 Compressor 15457963 Refrigerant low pressure gauge
15486376 Fan motor 15441967 Phase protector
99282386 Expansion valve 15488529 High pressure protective switch
15453400 Dry filter 15489537 Low pressure protective switch
15465610 Bypass valve 15489545 Fan motor pressure switch
Model no. D990INR-A
no.：D990INR-A
15442783 Compressor 15457963 Refrigerant low pressure gauge
15486384 Fan motor 15441967 Phase protector
99282394 Expansion valve 15489529 High pressure protective switch
15465610 Bypass valve 15489545 Fan motor pressure switch
Model no. D1050INR-A
no.：D1050INR-A
15486251 Air condenser 15489529 High pressure protective switch
15486384 Fan motor 15489537 Low pressure protective switch
99282394 Expansion valve 15489545 Fan motor pressure switch
15440522 Dry filter 15442999 Start switch
15486228 Electric drain 15441967 Phase protector
15465610 Bypass valve 99282733 Auto air switch
15457963 Refrigerant low pressure gauge
no.：D1170INR-A
15484009 Air condenser 15441967 Phase protector
15486392 Fan motor 15489529 High pressure protective switch
11
15465610 Bypass valve 99282733 Auto air switch

no.：D1380INR-A
15440860 Compressor 99282741 Auto air switch
99282394 Expansion valve 15442999 Start switch
15457963 Refrigerant low pressure 99282857 Needle valve
auge
15486079 Condensed purifier 15465610 Bypass valve
15465156 Electric magnet contactor
no.：D1590INR-A
no.：D1740INR-A
15465610 Bypass valve 15441967 Phase protector
15486228 Electric drain 99282741 Auto air switch
15486095 Condensed
gaugepurifier
no.：D2100INR-A
12
15486103 Condensed
gaugepurifier 15440613 Bypass valve
no.：D2340INR-A
15486111 Condensed
contactor
no.：D2700INR-A
no.：D3090INR-A
15440894 Compressor 15489529 High pressure protective switch
15484017 Air condenser 15489537 Low pressure protective switch
15486384 Fan motor 15489545 Fan motor pressure switch
15467566 Dry filter 15442999 Start switch
15486467 Expansion valve 15441967 Phase protector
15486137 Condensedgaugepurifier 15440613 Bypass valve
15465164 Electric magnet contactor 15465339 Sight glass
contactor Model no. D3480INR-A
no.：D3480INR-A
13
no.：D4080INR-A
no.：D4200INR-A
no.：D4560INR-A
no.：D4800INR-A
14
no.：D5520INR-A
no.：D5940INR-A
15486194 Condensed
no.：D7680INR-A
15

no.：D8700INR-A
� Water cooled parts no.
Model no. D690INR-W

no.：D690INR-W Model no. D810INR-W
no.：D810INR-W
15483928 Water condenser 15483928 Water condenser
15486038 Condensed purifier 15486046 Condensed purifier
15465149 Electric magnet contactor 15465149 Electric magnet contactor
15489529 High pressure protective switch 15489529 High pressure protective switch
15489537 Low pressure protective switch 15489537 Low pressure protective switch
15441967 Phase protector 15441967 Phase protector
15465610 Bypass valve 15465610 Bypass valve
15486582 Water regulating valve 15486582 Water regulating valve
Model no. D990INR-W

no.：D990INR-W
15442783 Compressor 15486053 Condensed purifier
15483928 Water condenser 15465149 Electric magnet contactor
15467483 Water/gas separator 15486582 Water regulating valve
16
Model no. D1050INR-W

no.：D1050INR-W
15483928 Water condenser 15486582 Water regulating valve
15457963 Refrigerant low pressure gauge 99282733 Auto air switch

no.：D1170INR-W
15483936 Water condenser 15489529 High pressure protective switch
15465149 Electric magnet contactor 15486582 Water regulating valve

no.：D1380INR-W

no.：D1590INR-W
17

no.：D1740INR-W

no.：D2100INR-W

no.：D2340INR-W

no.：D2700INR-W
18
15440894 Compressor 15489511 High pressure protective switch
15483951 Water condenser 15489537 Low pressure protective switch
15467566 Dry filter 15441967 Phase protector
15486228 Electric drain 99282857 Needle valve
15457963 Refrigerant low pressure gauge 15465339 Sight glass
15486129 Condensed
99282758 Auto air switch
no.：D3090INR-W
15440894 Compressor 15489511 High pressure protective
15483951 Water condenser 15489537 Low pressure
switchprotective
15467566 Dry filter 15441967 Phase protector
switch
15486228 Electric drain 99282857 Needle valve
15457963 Refrigerant low pressure gauge 15465339 Sight glass
15486137 Condensed
99282758 Auto air switch

no.：D3480INR-W
15486145 Condensed
gaugepurifier 99282857 Needle valve
15465339 Sight glass
no.：D4080INR-W
15486145 Condensed
no.：D4200INR-W
19
15486145 Condensed

no.：D4560INR-W
15486145 Condensed
no.：D4800INR-W
15486145 Condensed
no.：D5520INR-W
15486145 Condensed
no.：D5940INR-W
20
15486145 Condensed
no.：D7680INR-W

no.：D8700INR-W
21
4. Flow diagram
D42INR-A D540INR-A
D42INR-A～D540INR-A Flow diagram
22
Note: Air cooled - Water/gas separator, Water cooled - Water/gas separator.
D690INR-A D690INR-A
D690INR-A～D690INR-A W）～Ｄ4560INR-A(W)
D690INR-A（W 4560INR-A(W) Flow diagram
23
D4800INR-A W）and
D4800INR-A（W and above Flow diagram
5. Electric diagram
D42INR-A 540INR-A
D42INR-A～Ｄ540INR-A Electric diagram
24
D690INR-A D4560INR-A
D690INR-A～D4560INR-A Electric diagram
25
D48
D48000INR-A and above Electric diagram
D690INR-W D4560INR-W
D690INR-W～D4560INR-W Electric diagram
26
D4800INR-W and above Electric diagram
6. Installation
� Position
27
1. Refrigerated air dryer should be installed in a indoor place which is under the ambient
temp of 2 ～ 40℃, well-ventilated with cleaning air. If air in the place is not good,
ventilation equipment should be installed.
2. There should be certain distance between refrigerated air dryer and air compressor to
prevent from the vibration of air compressor affecting refrigerated air dryer’s performance.
Air cooled model distance should be at least 3 meters, and water cooled is 2 meters.
3. Refrigerated air dryer should be horizontally installed on the flat cement road.
4. Drain outlet pipe should be directly connected to the gutterway to prevent the on site
pollution, gutterway height should be lower than auto drain outlet.
5. The setting of refrigerant air dryer in the compressed air system is as below:
温度：<45°C
油份:5ppm w/w
固体尘:<3μ
油水分离
空压机后冷器过滤器
贮气罐（3μ ）
压力露点：3-10° C
油份:1ppm w/w
固体尘:<1μ
过滤器
（1μ）
压力露点：3-10° C
油份:0.01ppm w/w
冷冻式干燥机固体尘:<0.01μ
过滤器过滤器
（1μ）（0.01 ）
μ
� Piping
Refrigerant air dryer locked into each other in the air system, for maintenance we suggest
to parallel connect a pipe from air inlet to outlet, and add a cut-off valve at the middle.
Note: Sweeping the air piping system before starting the machine to prevent dusts
entering air dryer and air filter to affect the performance.
� Power supply and wiring
1. Set up power supply as per the standard voltage, phase, and capacity on the nameplate.
2. Voltage fluctuation range should not be over rated voltage 10%.
3. Refrigerated air dryer should be safely connect to the ground by grounding bolt which is at
28
the bottom of power entrance, ground wire is YELLOW GREEN wire.
Caution
Any electrical connections or adjustments should only be made by a suitably qualified
electrician or Ingersoll Rand air center.
7. Running
� Preparation before starting the machine
1. Preparation before starting the machine
a. Check power supply voltage is consistent with the nameplate.
b. Work condition requirement: work pressure（MPa）:0.7-1.0
Air cooled model ambient temp: 2-40˚C; Water cooled model cooling water temp: 2-32˚C
c. Check machine external canopy and installation condition, whether canopy is safely
connected with ground.
d. Check readings of the Refrigerant low pressure gauge, readings should be above
0.5MPa. If it is lower than 0.5MPa, please check if refrigerant is leaking.
e. If readings of the refrigerant low pressure gauge is 0, it means refrigerant is leaking,
starting machine under this condition is prohibited, otherwise, refrigerant compressor
would be caused damages, please report to service dept.
f. After confirmed gauge pressure, check power wiring and voltage, 3 phase 4 wires, esp.
check if it has null line and ground wire.
Warning
※Machine
Machine connecting power, shutdown indication light is on, means machine
electricity is set up and phase is correct;
※Press
Press start button, when shutdown indication light and start indication light
both are on （ D690INR and above models ） , means time relay is working,
machine enters the delay starting mode. When start indication is on, shutdown
indication light is off, means time relay is completed work, machine starting
successfully.
※This
This function is called delay protective function
function,, it is normal setting. Default
ime is 10 mins, it can be adjustable.
2. Empty load debug

a. Close hot gas bypass valve, make refrigerant stop through expansion valve.（This
This step
step
is for D690INR and above models
models）
b. Start refrigerant air dryer, observe the refrigerant low pressure change（readings should
be obviously decreasing ）; observe refrigerant low pressure should maintain at 0.18-
0.3MPa（depend on the opening of the expansion valve）, make compressor freeze, and
29
running about 10 and more mins.
c. Slowly adjusting hot gas bypass valve, make refrigerant low pressure increase to
0.4MPa, Compressor freezing starts to melt at this time. Compressor temperature is
around 10˚C, outlet temperature is around 50-80˚C.
3. Load debug
a. Air dryer operates normal for 10 mins, then slowly open the gas valve to supply
compressed air though air dryer. Observe the operation time for fan motor, and compare
with the empty mode.
b. Refrigerant low pressure should be within 0.4-0.55MPa when it is normally operating.
When refrigerant low pressure is lower than 0.4MPa or higher than 0.55MPa, adjust hot
gas bypass valve, if there is no bypass valve installed, adjust expansion valve;
c. Train operation staff for normal starting machine and the maintenance, especially how
to adjust hot gas bypass valve as per seasons change.
valve,, only when hot gas bypass valve
Note: In general, do not adjust expansion valve
cannot be adjusted, close all the hot gas bpass valve first, adjust expansion valve
0.3MPa,, then adjust hot gas bypass
to stabilize the refrigerant low pressure at 0.3MPa
valve..
valve
� Debugging after starting the machine （ Steps for the new machine or repaired
machine
machine）
Observe if gauge reading is within the normal range; Refrigerant low pressure gauge reading
should be 0.4～0.55MPa. If the reading is lower than this range, torque hot gas bypass valve
anticlockwise, if the reading is higher than this range, torque bypass valve clockwise（See
graph below）.
Hot gas bypass valve adjust method

During the installation and debugging of refrigerated air dryer, the flow of hot gas
expansion valve already adjusted to the evaporated temp range as per suction degree of
superheat. During the normal operation, it will adjust its flow capacity as per heat load. If the
work condition has been changed due to some factors in the system, such as decreasing of
compressor capapcity, condenser temp high, and refrigerant filling difference（Refills during
30
maintenance）, above factors will all cause expansion valve capacity exceeding the range.
When adjusts Expansion valve, torque valve 1/4 ～1/2 cycle, turn clockwise to increase
the degree of superheat, anticlockwise to decrease it, increase/decrease 0.28℃ every circle.
After running for 20 mins, observe suction pressure change, if suction pressure has no big
change, keep adjusting the valve.
Note: Hot gas bypass valve and expansion valve adjustment is related, adjust the
valve and observe the gauge together till it is within normal range.
� Normal operation and the notice:

Listen to the compressor operation sound, when it is normal operation, inlet/outlet valve
have the clear steady sound. Cylinder, piston, connecting rod and bearing should not have
knocking noise, otherwise, shutdown and check the machine.
Note: Do not open and shutdown refrigerated air dryer frequently. After machine
shutdown, restart after 5～10
10 mins to prevent the compressor damages.
� Shutdown: Close air inlet valve, then press STOP button and cut off power.
8. Maintenance
Caution!
Before doing the maintenance, please read the safety in this manual. Cut off power, lock
the main electric components, and mark them, at the same time isolate the compressed
air system. Do not start the machine without above procedures.
Caution!
Please ensure to have protection for every electric component before clean with any forms
of liquid.
◆ Air condenser
The surrounding of air condenser should have enough space for ventialition, it cannot
be work under direct sunlight and the dusts on the air condenser should be blowed off by
compressed air regularly (internal to external).
31
Compressed air
◆ Water condenser
Cooling water should be clean. So user should clean water inlet filter （Y filter）and shell
tube type water condenser as per cooling water condition. If cooling water quality is bad,
clean every season; if cooling water quality is good, clean annually.
Clean water inlet filter（Y filter）, remove the hex cap, pull the internal filter mesh and
clean it with clean water. When clean shell tube type water condenser, first remove non
inlet/outlet water cap. Then clean it with long brush, chemical cleaning is the best for the
cycle cleaning.
� Electronic auto drain

Observe electronic auto drain and if there is clogging, clean the internal dusts to smooth
the draining. Steps of cleaning as below:
a. Close the ball valve before the drain, loosen the screw nut on the drain.
b. Take out the timer coil and remove the spool.
c. Wash auto drain base and spool by clean water
d. Install back after cleaning.
Note: The importance of draining system: when dryer removes the condensed
water but cannot drain immediately, condensed water would be taken by air flow to
the outlet air. So user should manually press ESC button to drain, observe the time
cycle of the electric drai
drainn to set up time cycle.
� Electric
Check if parts and wire connection are loose, fixed if it is loose.
9. Troubleshooting
Warning
Only properly trained and competent persons should undertake any maintanence tasks with
the machine. Big maintenance and repair are recommended to be carried out only by an
Ingersoll–Rand authorized service technician. Ingersoll Rand is not responsible for any
damages caused by non Ingersoll Rand personnel.
32
Trouble Shooting
Problem Cause Remedy
Incoming terminal has no Check incoming terminal
voltage or low voltage power switch and fuse.
High pressure protective switch Reconnected
disconnected
Dryer fails
Loose wiring Check wiring and fasten.
to run
Compressor motor burned Check and replace
AC contactor defective Check and replace
Refrigerant leakage Check, fill refrigerant
Auto air switch not opened Open Auto air switch
Check if low pressure switch
Low pressure switch not
control pipe clogging, check
normal running
Compressor the position of the switch.
running Lack of refrigerant Fill refrigerant
stops Suction valve closed or Open
partially closed.
Hot gas bypass valve clogged Repair
High ambient temperature Increase amient ventilation
Overload Check compressed air if
Condenser exceeding.
temp （ high Air condenser cooling effet not Clean air condenser
pressure good
Excessive refrigerant Discharge refrigerant
Air in the refrigerant system Discharge air in the system
Fan motor nonstop running Check fan motor pressure
Condenser
under low temp condition switch
temp （ low
Hot Bypass valve open too big Clockwise adjust Bypass
pressure
valve
Expansion valve open too big Adjusting Expansion valve
Refrigerant Expansion valve thermo-bulb
low not cling to outlet pipe of the Reinstalled.
pressure too evaporator
high Expansion valve defective Replacing Expansion valve
Low
refrigerant Lack of refrigerant Fill refrigerant
low presure
Compressor distance of piston Replacing components
Noise
and valve platenot enough
33
Fill refrigerant and replace
Expansion valve noise
Dry filter
Hot gas Bypass valve noise This is normal.
Capacity is over rated value Pick up the correct capacity
Pipe size too small/ pipe too
Reset pipe system
Big long/ too many bendings
pressure Inlet/outlet of valve not open Open inlet/oulet of valve
drop at Leakage in pipes Sealed after check leakage
outlet air Filter clogging Wash or replace filter
Heat exchanger pipe freeze to Adjust bypass valve
clog air pipes
Ambient temp too high/ Select a machine which fits
capacity too big/ inlet temp too for the work condition.
high
Air bypass valve not closed. Close Bypass valve tight.
Bad
Cut off valve not open Open cut-off valve
Dehumidific
Drain clogging and damaged Wash and replace drain
ation
Air pressure lower than the Air pressure should not be
rated. lower than the rated.
Drain pipes higher than the Reinstall drain pipes.
outlet
Check power voltage and
Fuse burned control wiring, fix it and
replace fuse
Check voltage and current if
Heat relay disconnected compressor is not functioned ,
fix it and reinstall heat relay.
Auto air switch disconnected Fix it and reinstall
Condensed pressure too high Adjust refrigerant to normal
Shutdown to cause high pressure switch range.
during protection
operation Ambient temp too hig/ inlet Adjust work condition or
temp too high/ capacity too big replace with a new dryer
Clean the dust on the

Condenser bad cooling
surface of air condenser
Refrigerant low pressure too Anticlockwise to adjust
low to cause cut-off of the bypass valve
switch
Expansion valve clogging Adjust or replace expansion
valve
34
Dry filter clogging Replace dry filter
Refrigerant leakage Check and mend a leak, then
refill refrigerant.
Electric components damaged Replace the electric
components
Compressor damaged Replace Compressor
警告
35

IR Water-Dryer: Ingersoll-Rand (Shanghai) Co., LTD

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What are the main components of an air dryer and their functions?

What are the main components of an air dryer and their functions?

What are some common problems that may occur in an air dryer and how to troubleshoot them?

What are some common problems that may occur in an air dryer and how to troubleshoot them?

Ingersoll Rand Refrigerated Air Dryer Instruction Manual

� AIR COOLED MODELS-------------------------------------------------------5

� WATER COOLED MODELS------------------------------------------------6

� AIR COOLED MODELS ------------------------------------------------------7

� WATER COOLED MODELS----------------------------------------------14

Use of the machine with safety or control components missing or disabled.

Connect to wrong voltage/ or wrong frequency power

◆ IR water cooled dryer dimensions and connection pipes table

Model no. D390INR-A

Model no. D540INR-A

Model no. D690INR-A

Model no. D810INR-A

Model no. D1380INR-A

Model no. D8700INR-A

� Water cooled parts no.

Model no. D690INR-W

Model no. D990INR-W

Model no. D1050INR-W

Model no. D1170INR-W

Model no. D1380INR-W

Model no. D1590INR-W

Model no. D1740INR-W

Model no. D2100INR-W

Model no. D2340INR-W

Model no. D2700INR-W

Model no. D3480INR-W

Model no. D4560INR-W

Model no. D8700INR-W

Note: Air cooled - Water/gas separator, Water cooled - Water/gas separator.

D4800INR-W and above Electric diagram

2. Empty load debug

Hot gas bypass valve adjust method

� Normal operation and the notice:

� Electronic auto drain

Clean the dust on the

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