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DIRECT EXPANSION COMPRESSED AIR DRYERS

- EN - Operators Manual
Valid for 60 Hz dryers G version

D12IN-A
D25IN-A
D42IN-A
D54IN-A
D72IN-A
D108IN-A
230/1/60
D144IN-A
D180IN-A
D240IN-A
D300IN-A
D360IN-A
D480IN-A
D600IN-A 230/1/60 460/3/60
D780IN-A
380/3/60 460/3/60
D950IN-A

Cod. 710.0138.45.00 Rev04 – 02.2019


1 - 33
- EN -
INTRODUCTION
This manual is an integral part of the dryer you bought, and must remain with the machine even if this will be resold.
- EN - It is highly recommended that the qualified*personnel for installation maintenance and/or control will fully comply with the contents of
this manual and the prevention and safety rules in force in the country where the system will be used. In this way, not only the usage of
CONTENTS the machine will be rational, but also the service will result cost effective.
In case your dryer will present any kind of problem, please contact your local authorized Ingersoll Rand distributor.
Please note that, when necessary, the use of original spare parts will ensure efficiency and long duration to your dryer.
1. GENERAL INFORMATION Due to the continuous technological evolution, Ingersoll Rand reserves the right to modify the specifications contained in this
manual without giving previous notice.
1.1 Functional description 3

1.2 Safe use of the dryer 3


SYMBOLS AND LABELS USED IN THE MANUAL AND ON THE DRYER

Air Air
2. INSTALLATION or or or or inlet. or or or or outlet.
2.1 Acceptance and transportation 4
Read the Operators manual before attempt to
Pay particular attention to components or systems
2.2 Installation site 4 start up the machine and to perform any service
under pressure.
operation on the dryer.
2.3 Installation 4
Pay particular attention to the indications
Pay particular attention to hot surfaces.
preceded by these symbols.
3. START UP

3.1 Control panel 5 Installation, maintenance, and/or control


Pay particular attention to the risk of electric
operations preceded by these symbols must be
3.1.1 Keys function 6 shock.
performed exclusively by qualified personnel*.

3.1.2 Condensate discharge Condensate drain point. Rotation direction of the fan.
or
parameters programming 6

3.1.3 Anomaly warning 7 Pay particular attention to the risk of moving


parts
3.1.4 Remote signalling alarm 7

Attention: Before performing any


3.2 Before start up 8 maintenance operation on this
3.3 Start up 8
machine, do not forget to disconnect
the electric supply, to completely
discharge air pressure, and to refer to
4. MAINTENANCE, TROUBLESHOOTING
the Operators manual

AND DISMANTLING

4.1 Maintenance 8

4.2 Troubleshooting 8

4.3 Dismantling 12
- Turn main power switch on position 1.
- Wait for 8 hours before starting the dryer.
ATTACHMENTS TO THIS MANUAL

A) Refrigerant circuit 14 * Qualified personnel must be trained and certified in accordance with local laws and regulations.

B) Electric circuit diagram 16 WARRANTY


C) Technical data sheet 26 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
D) Correction factors 28 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
E) Dryer dimensions 29
repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed,
F) Basic spare parts 32 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.

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2. INSTALLATION
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.
2.1 ACCEPTANCE, UNPACKING AND HANDLING
The Purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing Upon receiving your Ingersoll Rand air dryer, please inspect the unit closely. If rough handling is detected, please note it
of its intention to do so. Any such use of Equipment will be at Purchaser's sole risk and liability. on your delivery receipt, especially if the dryer will not be uncrated immediately. Obtaining the delivery person's signed
Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the equipment or agreement to any noted damages will facilitate any insurance claims by the customer.
negotiated as part of the purchase order may take precedence over this warranty. It is mandatory to keep the dryer always in vertical position, as indicated by the symbols present on the packaging. For
handling, use devices having sufficient capacity for the weight of the machine.
Remove the packaging after having positioned the dryer in the installation site. Dispose the various packaging materials in
1. GENERAL INFORMATION compliance with the relevant rules locally in force.
1.1 FUNCTIONAL DESCRIPTION If not in use, the dryer can be stored in its packaging in a dust free and protected site between 32°F (0°C) and 120 °F (50
°C), and a specific humidity not exceeding 90 %. Should the stocking time exceed 12 months, please contact your local
Ingersoll Rand refrigerated air dryers remove moisture from compressed air. Moisture is detrimental to pneumatically
Ingersoll Rand authorized distributor.
operated appliances, controls, instruments, machinery and tools.
Compressed air enters the patented aluminum heat exchanger where it is cooled down to the dew point temperature in two Under no circumstances should any person attempt to lift heavy objects without proper lifting equipment (i.e., crane, hoist,
different stages: In the first air/air sector compressed inlet air is cooled thanks to the colder compressed air coming out slings or fork truck). Lifting any unit without proper lifting equipment, may cause serious injury. Use fork lift channels
counterflow from the condensate separator. In the second refrigerant / air sector, compressed air temperature is further lowered where provided.
to the dew point temperature. During this two stages almost all the oil and water vapours contained in compressed air are
condensed to liquid and successively be separated from the compressed air in the condensate separator and drained out by the 2.2 INSTALLATION SITE
automatic drain. At this point the obtained cold air re-enters counterflow the initial air / air exchanger and it is reheated by the
inlet hot air with the consequence of energy recovering and also reduction of the relative humidity contained in the outflowing air.
While preparing a proper site for the installation of the dryer, please take into account the following
This dryer can be easily installed into various pneumatic systems in which dry air is required or desired. Please refer to
requirements
Principles of Operation for complete operating details.
The machine must be protected from atmospheric agents and not directly exposed to sun light.
The dryer comes provided with all the control, safety and adjustment devices, therefore no auxiliary devices are A seating base flat and capable to hold the weight of the machine.
needed.
Ambient temperature complying with the nominal data of the dryer.
A system overload not exceeding the maximum operative limits can worsen the operational performance of the dryer
(high dew point), but it will not affect its safety.
The dryer should be located in a clean area, without forced air draft that can affect the fan control
system.
The electric diagram (attachment B) shows the minimum protection degree IP 42.
Make sure to leave sufficient clearance (20 inches, 500 mm) around the dryer in order to allow an
Improper grounding can result in electrical shock and can cause severe injury or death. adequate cooling of the machine and for maintenance and/or control operations.
This product must be connected to a grounded, metallic, permanent wiring system or an equipment-grounding
terminal or lead on the product. The incoming air must be free from smoke or flammable vapours which could lead to explosion or fire risks.
All grounding must be performed by a qualified electrician and comply with national and local electrical codes.
In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for
the electric current.
2.3 INSTALLATION
Ground must be established with a bare grounding wire sized according to the voltage and minimum branch circuit
requirements. Before attempting any installation operation, make sure that
Ensure good bare metal contact at all grounding connection points, and ensure all connections are clean and tight.
Check grounding connections after initial installation and periodically thereafter to ensure good contact and No parts of the air system are under pressure.
continuity has been maintained. No parts of the system are electrically powered.
Check with a qualified electrician or service technician if the grounding instructions are not completely understood, or Tubing to be connected to the dryer are free of impurities.
if in doubt as to whether the product is properly grounded.
All interconnecting piping has been tightened.
1.2 USE OF THE MACHINE IN SAFE CONDITIONS After having verified the points listed above, you can proceed to the installation of the machine.
This system has been designed and manufactured in compliance with the European safety directive in force and 1. Connect the dryer to the compressed air lines. If not already existing, we suggest to install a by-pass
UL/ULC, therefore any installation, use and maintenance operations must be performed respecting the instructions allowing to isolate the machine from the plant, thus to facilitate eventual maintenance operations.
contained in this manual.
2. Perform the electrical connection in accordance with any local laws and regulations after reviewing
Because an air dryer is pressurized and contains rotating parts, the same precautions should be observed as with any the dryer electrical specifications and wiring diagram.
piece of machinery of this type where carelessness in operation or maintenance could be hazardous to personnel. In
3. Check the condensate drainage assembly, and connect the drain flexible hose to the draining line,
addition to obvious safety rules that should be followed with this type of machinery, safety precautions as listed below
keeping in mind that the condensate separated by the dryer may contain oil, therefore, in order
must be observed.
to dispose of it in compliance with the local rules in force, we suggest installing a water-oil
separator having adequate capacity.
1. Only qualified personnel shall be permitted to adjust, perform maintenance or repair this air dryer.
4. Power the dryer after having checked that the nominal voltage and line frequency are constant and
2. Read all instructions completely before operating unit.
matching the nominal values of the machine. The user must provide the installation with an
3. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before adequate line protection and a ground terminal complying with the electrical rules locally in
attempting to work or perform maintenance on the unit. force.
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. In order to optimise the use of the dryer, we suggest to place it in such a way that all the control instruments
of the machine will result easily visible.
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. A suitably sized prefilter must be installed before the dryer. Failure to install and maintain a proper
prefilter will void the dryer warranty. The rating for this filter must be at least 10 micron.
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.

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DISPLAY VISUALIZATION AND SIGNALLING LEDS (Mod. D600IN-A ÷ D950IN-A)
3. START UP
Ensure that the dryer is by−passed, or there is no load on the cooler.
Switch on the main electrical isolation switch (if present). The control panel will show the message OFF, indicating that the line and DISPLAY DESCRIPTION LED STATUS DESCRIPTION
control voltages are available.
Start sequence the unit is ON with low load ON Compressor energized
The dryer will initially start by pressing and holding the local ON/OFF button. The start sequence will progress only if there are no active
alarms. The compressor motor will start AFTER 120 SECONDS. The fan motor will start simultaneously with the compressor for D240- Blinking Programming mode activated
480IN-A models, after 30 seconds for smaller models. the unit is ON with normal load
Condensate drain energized
Mod.D600-950IN-A: the fan motor is controlled only by the fan pressure switch. ON (Not used with "No loss
Stop sequence the unit is ON with normal-high load condensate drain")
The dryer can be stopped locally from the control panel. After having pressed the ON/OFF switch for 1 second, the compressor and the
fan motor (only the compressor on D600-950IN-A) keep on running for further 10 seconds in order to re-balance the internal pressures.
The dryer can be also stopped due to an alarm or energy saving condition (ESA or ES2). Any alarm will de−energize the compressor, the unit is ON with high load Not used Not used
fan motor can still running (only on D12-480IN-A), it depends on the type of alarm (see Display indications chapter). If the shutdown is due
to an alarm, a message will blink on display indicating the reason for the shutdown. Energy saving condition (ESA or ES2) occurs when
the dew point stands below the set value for a long time in order to save energy and avoid heat exchanger freezing. This situation can
happen when ambient temperature is low and there is no compressed air load. 3.1.1 KEYS FUNCTION
Mod.D600-950IN-A: the fan motor is controlled only by the fan pressure switch.
TEST: When pushed for 3 sec. during normal operation, it activates the condensate drain.
Variable speed fan control (Mod. D12–480IN-A) (Not used on No loss condensate drain)
A patented microprocessor allows to adjust dryer’s cooling capacity by changing the fan motor speed. If the dew point is greater than
the set value, the fan speed is increased, if the dew point is smaller than the set value, the fan velocity is decreased. The range can be SET: When pushed and released during normal operation, it displays the dew point set value (decimal).
from 0 to 100% and the higher is the fan speed, the faster the fan LED blinks, you can read the exact value by pressing the UP button. When pushed for 10 seconds, it allows to enter the C8 and C9 condensate drain parameters programming menu (see
If the velocity is 100% you will read FL (Full Load). Under load standard condition the fan speed is usually at 100%, if there is no load relevant table).
the fan velocity can oscillate between 0 and 20%. When pushed after having set new configuration values, it stores the applied modifications.
In models D240-480IN-A, in order to adjust the greater dryer’s cooling capacity, a hot gas by-pass valve cooperates with the variable DOWN: When pushed while setting the drain set point, it decreases the displayed value of one unit per second, during the
speed system. first 10 seconds, than of one unit every 0,1 sec.
3.1 CONTROL PANEL When pushed for 10 seconds during normal operation, it starts an automatic test cycle of the controller.
The dryers are provided with an electronic control system. All adjustments and resets can be performed by means of the digital UP: When pushed while setting the drain set point, it increases the displayed value of one unit per second, during the first
panel located on the front of the dryer. 10 seconds, than of one unit every 0,1 sec.
The control panel is composed of 5 keys (ON/OFF, TEST, SET, DOWN and UP) and a 3 digit display, with three signalling LEDs ON / OFF: Pressed, it activates or deactivates the dryer. When the dryer is deactivated, the display shows OFF.
indicated by icons (PIC 1)
PIC. 1 (D12IN-A ÷ D480IN-A) NOTE: when the controller is in the OFF position, some parts of the dryer may still be energized. Therefore, for
safety purposes, disconnect the electrical power before performing any operation on the machine.

3.1.2 CONDENSATE DISCHARGE PARAMETERS PROGRAMMING


Push the SET key for 10 seconds to enter the parameters configuration menu: the display will show in
sequence the set point value, the code of the first modifiable parameter (C8) and its value).
Only if strictly necessary, use the UP and/or DOWN keys to change the displayed parameter value.
Press the SET key to store the previously changed parameter value or to browse the parameters without
changing them.
15 seconds after the last performed operation, the controller will return automatically to the normal
operation mode.

PARAMETER DESCRIPTION RANGE DEFAULT SET VALUE

Delay between condensate


C8 1 ÷ 999 (min) 1
discharges

Time required for condensate D12-144IN-A D180IN-A D240-950IN-A


C9 1 ÷ 999 (sec)
discharge 1 2 3

NOTE: Changes entered for timing values will be effective only after exiting the programming, while changes to other
DISPLAY VISUALIZATION AND SIGNALLING LEDS (D12IN-A ÷ D480IN-A) variables will be immediately effective.
Please remember that eventual changes to the configuration parameters of the machine could negatively affect its efficiency.
Thus, changes have to be performed by a person familiar with the operation of the dryer.
DISPLAY DESCRIPTION LED STATUS DESCRIPTION
WARNING FOR USER:
the unit is ON with low load ON Compressor energized IT’S FORBIDDEN TO ATTEMPT TO MODIFY THE OTHER CONFIGURATION PARAMETERS OF THE ELECTRONIC
CONTROLLER WITHOUT AUTHORIZATION AND COLLABORATION OF INGERSOLL RAND’S AUTHORIZED DISTRIBUTOR.
Blinking Programming mode activated
the unit is ON with normal load
ON Condensate drain energized
the unit is ON with normal-high load ON Speed of the fan = 100%
Blinking Speed of the fan < 100%
the unit is ON with high load
OFF Fan not running

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3.1.3 DISPLAY INDICATIONS 3.2 BEFORE START UP
The controller is capable of recognizing certain types of anomalies in the drying circuit. In such cases, a message will blink on the
display, alternated to the current dew point value. Before starting the machine, make sure that all operating parameters correspond to the nominal data.
MESSAGE The dryer is supplied already tested and preset for normal operation, and it doesn’t require any calibration.
CAUSE OUTPUTS ACTIONS Nevertheless, it’s necessary to check the operating performances during the first working hours.
(BLINKING)

High dew point value Alarm output ON Resettable by switching off the
HtA
(delayed alarm) Refrig. Compressor output OFF dryer. 3.3 START UP
Very high dew point value Fan output ON If problem persists call your local
Ht2 Drain cycle standard Ingersoll Rand distributor. The operations specified below must be performed after the first start up and at each start up after a
(immediate alarm)
prolonged inactive period of time due to maintenance operations, or any other reason.
Resettable by switching off the
Alarm output ON 1. Make sure that all instructions contained in chapters INSTALLATION SITE and INSTALLATION
dryer. May require replacing the
Interruption or short circuit on the Refrig. Compressor output OFF have been observed.
PF1 faulty probe.
PTC probe input line Fan output OFF
If problem persists call your local 2. Ensure dryer by-pass is open and air inlet/outlet valves closed. (if existing).
Drain cycle standard
Ingersoll Rand distributor.
3. Activate power supply and press the ON/OFF switch on the control panel for at least 1 second.
ESA Alarm output OFF
The automatic Energy saving Refrig. Compressor output OFF No action necessary.
(note there is a 2 minute delay before the dryer will start after the dryer is turned on).
mode activated due to low load Fan output OFF Automatic Reset Only on D780-950IN-A
ES2 Drain cycle standard - Turn main power switch on position 1.
Alarm output ON - Wait for 8 hours before starting the dryer
Refrig. Compressor output OFF Call your local Ingersoll Rand
ASt Activated after repeated alarms (the warranty is not valid if this procedure is not respected).
Fan output ON distributor.
Drain cycle standard 4. Wait 5 to 10 minutes until machine has achieved its standard operating parameters.
Note: PF1 has priority on all other messages. 5. Slowly open the air outlet valve and successively open the air inlet valve.
6. If existent, close the air by-pass valve.
3.1.4 REMOTE SIGNALING ALARM 7. Check if the condensate drain is working properly.
8. Check if all connecting pipes are properly tightened and fixed.
The dryer control board is equipped with a dry contact for a remote alarm signal. This is normally open
contact: when an alarm is detected, this contact is closed.
Proceed as follows to activate a remote alarm output: Before disconnecting the dryer from electrical power supply, use ON/OFF switch to stop the
1. The User must review the diagram below. dryer. Otherwise wait 10 minutes before switching the dryer on again, in order to allow freon
2. Disconnect the dryer from electrical power supply, remove cover and left side panel. pressure to rebalance.
3. Connect the alarm circuit to the terminal blocks (See PIC.2).
4. Replace cover, left side panel and reconnect power.
4. MAINTENANCE, TROUBLESHOOTING AND DECOMMISSIONING
4.1 MAINTENANCE
Before attempting any maintenance operation, make sure that:
1. No parts of the system are under pressure.
Alarm Output relays electric features: 2. No parts of the system are electrically powered.
Max. 250VAC / 3A – AC 15 (Amp. Inductive) WEEKLY OR EVERY 40 HOURS OF OPERATION
Verify the temperature on the control panel display is acceptable.
Visually check if the condensate is drained regularly.
MONTHLY OR EVERY 200 HOURS OF OPERATION
PIC.2 Clean the condenser with compressed air, taking care not to damage the condenser fins..
At the end of the above mentioned operations, check if the dryer is working properly.
The activation of the above function is at the User’s discretion. The User will purchase all necessary Check the condition of any filters installed with the dryer. Replace elements as needed.
installation material. Any operation which needs access to the dryer must be carried out by qualified
personnel. YEARLY OR EVERY 2000 HOURS OF OPERATION
Check if the flexible tube used for condensate drainage is damaged and replace it if necessary.
Check if all connecting pipes are properly tightened and fixed.
At the end of the above mentioned operations, check if the dryer is working properly.
EVERY 24 MONTHS OR EVERY 4000 HOURS OF OPERATION (Mod. D600IN-A ÷ D950IN-A)
Replace the fan pressure switch.
4.2 TROUBLESHOOTING
NOTE: FOLLOWING BEHAVIORS ARE NORMAL CHARACTERISTIC OF OPERATION AND NOT TROUBLES
• Variable speed of the fan. (Mod D12IN-A ÷ D480IN-A)
• Display of message ESA and ES2 in case of operation without load or low load.
• A 2 minute delay for dryer to start after pressing the on/off switch.
Troubleshooting and eventual control and/or maintenance operations must be performed by
qualified personnel.
For maintaining the refrigerating circuit of the machine, contact a refrigeration engineer.
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TROUBLE DISPLAY POSSIBLE CAUSE REMEDY TROUBLE DISPLAY POSSIBLE CAUSE REMEDY

No power in the line. Restore the power in the line. Check the probe; if the trouble persists, replace it.
Control panel
display is Problems with cabling. Check cabling; if the trouble persists, replace it. Check the electronic control board; if the trouble persists,
Ice formation in the evaporator. replace it.
blank Check the electronic control board; if the trouble persists,

LOW PRESSURE IN THE LINE


Problems with the electronic control board.
replace it. Contact our Service Centre to check the gas charge.
The dryer is off. Turn it on by pressing the ON/OFF switch for 1 second.
Check if the compressed air inlet/outlet is connected properly.
Dryer in stand-by. Wait 2 minutes after the dryer is switched on. Check if the connecting tubing is clogged; in case proceed
Clog. accordingly.
Check if the compressed air inlet/outlet is connected
Compressed air inlet/outlet inverted. Check if any valves are closed.
properly.
The flow rate and/or temperature of the air Check the condition of any filter.
entering the dryer are higher than the Restore the nominal conditions. D12-480IN-A
nominal values. Drainage solenoid valve jammed, clean or replace it.
The ambient temperature is higher than the D12-480IN-A. Verify the condensate drainage times set on the
Restore the nominal conditions. Air flows continuously through the electronic control board (C8 and C9).
nominal values.
condensate drainage. D12-480IN-A. Check the signal from the control board: if it is
The condenser is dirty. Clean the condenser. continuous, replace the control board.
Clean the condensate drainage system pre-filter. (Pic.3) D600-950IN-A. Check the no loss condensate drain; if the
trouble persists, replace it.
D12-480IN-A Replace the coil of the drainage solenoid valve if burned.
Condensate drain is not functioning. IMPORTANT:
Clean or replace the drainage solenoid valve if
Pic.3 clogged/jammed. The temperature control probe is extremely delicate. Do not remove the probe from its position. In case
Check the C8 and C9 parameters of the electronic control of any kind of problem, please contact your local Ingersoll Rand distributor
board; if the trouble persists, replace it.
D600-950IN-A
Check the no loss condensate drain; if the trouble persists,
Condensate drain is not functioning.
replace it.
D12-480IN-A Pic.3
Pic.4
WATER IN THE SYSTEM

The temperature control probe is positioned


Check the probe; if the trouble persists, replace it.
improperly or faulty.
Problems with cabling or with the electronic Check the cabling and the electronic control board, if the
control board. trouble persists, replace them.
Activation of compressor’s internal thermal Wait one hour and check again. If the fault persists: stop
protection. dryer and call your local Ingersoll Rand distributor.
Problems with the electrical components of
Check the electrical components of the compressor.
the compressor.
Defective compressor. Replace the compressor.
The flow rate and/or temperature of the air
entering the dryer are higher than the Restore the nominal conditions.
nominal values.
The ambient temperature is higher than the
Restore the nominal conditions.
nominal values.
The condenser is dirty. Clean the condenser.
The temperature control probe is positioned
Check the probe; if the trouble persists, replace it.
improperly or faulty.
Fan pressure switch defective or burned out Turn off the dryer and call your local Ingersoll Rand
(if present). distributor.
High pressure switch defective or burned out Turn off the dryer and call your local Ingersoll Rand
D600-950IN-A Pic.4
(if present). distributor. No loss condensate drain (Beko)
Turn off the dryer and call your local Ingersoll Rand
Gas leakage in the refrigerating circuit.
distributor.
Defective fan. Replace the fan.
Electronic drain discharge is the new discharger applicable to any
Protection fuse burned out (if present). Replace the fuse. compressed air systems. It eliminates the condensate without wasting
The temperature control probe is positioned compressed air.
Check the probe; if the trouble persists, replace it. Electronic drain discharge starts automatically, without the need of any
improperly or faulty.
Gas leakage in the refrigerating circuit Turn off the dryer and call your local Ingersoll Rand adjustment. The condensate discharge occurs to the use of an
without load. distributor. electronic sensor, which detects the amount of condensate in the
integrated water collecting tank. The level sensor drives start and
The temperature control probe is positioned
Check the probe; if the trouble persists, replace it. duration of the drainage, so preventing any wasting of compressed air.
improperly or faulty.
At the end of installation, put the system under pressure and push the
Series of alarms very close to each other. Call your local Ingersoll Rand distributor. TEST key repeatedly to eliminate the air bubbles contained in the
discharger inlet fittings.
To this discharger will be applied the Beko warranty conditions.

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Pic.5 4.3 DECOMMISSIONING
Option: No loss condensate drain (Zero Drain) In case of necessity, decommission the machine and the relevant packaging in compliance
with the rules locally in force.
Zero Drain is the new electronic drain discharger applicable to any Pay particular attention to the refrigerant, as it contains part of the refrigerating compressor
compressed air systems. It eliminates the condensate without wasting lubricating oil. Always contact a waste disposal and recycling facility.
compressed air.
Electronic drain discharge starts automatically, without the need of any
adjustment. The condensate discharge occurs to the use of an
electronic sensor, which detects the amount of condensate in the
integrated water collecting tank. The level sensor drives start and
duration of the drainage, so preventing any wasting of compressed air.
At the end of installation, put the system under pressure and push the
TEST key repeatedly to eliminate the air bubbles contained in the
discharger inlet fittings.

The Zero Drain unit is equipped with a remote alarm connection (dry
contact, trigged when the drain is in alarm for more than 30 seconds):
see terminal block diagrams (attachment B) for futher details.
Maintenance
Zero Drain is equipped with Service Unit, which is recommended to be changed every year to ensure proper working conditions.

1. Disconnect Dryer from


electrical supply and
depressurize to 0 bar.

2. Unscrew and remove the


electrical connector from the
service unit.

3. Unscrew 4 screws that holds


the unit.

4. Remove the Service Unit from


the drain.

1 2 5. Clean the filter mesh.

6. Replace the Service Unit.

7. Screw four screws into


housing.

8. Connect the electrical


connector.

9. Connect the dryer to power


supply.

10. Pressurize dryer back to


Filter mesh working pressure.

11. Press TEST button.


3 4

Should the discharger not operate correctly, try to act on the TEST key to clean the mesh
filter.
Never remove the discharger body. Should the malfunctioning persist, contact our Customer
Service.

Before carrying out any work on the electrical parts, make sure that the main switch
interrupts the electricity supply to the dryer and then affix appropriate warning signs
to avoid the machine being reconnected to the electricity mains!

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ATTACHMENTS TO THIS MANUAL
Legend

1P1 High pressure Switch


1M2 Fan Motor
1M1 Refrigerant compressor
1B1 Drain solenoid valve coil
1A1 Electronic Controller
FQ Air filter 5 micron
FP Air filter 1 micron
FH Air filter 0.01 micron
FF Filter dryer
FD Air filter 10 micron
F1-F2 Fuses
EVA Evaporator
K2 Fan contactor switch
K1 Contactor switch
IM Moisture indicator
G Grid
FV Fan motor fuse
FR Drain screen
RBF Tap with strainer
PSC Air-air heat exchanger (D__IT)
PR Air-air heat exchanger
PCP Thermal protection
SSC Condensate drain
SLI Liquid separator
SCO Condensate separator
SC Heat exchanger base
RT1 Temperature probes
RR Rotalock tap
VE Expansion valve
VB By-pass hot gas valve
TLT Remote cont. Thermostat
TH Thermostat
TEMP Time setter
X1-X2-X3-X4 Terminal blocks
VT Fan blade
VNR One way valves with strainer

Cod. 710.0138.45.00 Rev04 – 02.2019 13 - 35


(A) REFRIGERANT CIRCUIT

Cod. 713.0048.03.00 – Rev. 00


Models D12IN-A to D180IN-A

Cod. 713.0057.01.00 – Rev. 00


Models D240IN-A to D600IN-A

Cod. 710.0138.45.00 Rev04 – 02.2019 14 - 35


Cod. 713.0034.03.00 – Rev. 00
Models D780IN-A to D950IN-A

/ / /
Condensate drain Air inlet Air outlet

Refrigerant line Compressed air line Condensate drain line Equalization line

Cod. 710.0138.45.00 Rev04 – 02.2019 15 - 35


(B) WIRING DIAGRAM

Cod. 714.0166.01.00 – Rev. 01


Models D12IN-A to D72IN-A (230V/1Ph/60Hz)

Cod. 714.0166.03.00 – Rev. 01


Models D108IN-A to D180IN-A (230V/1Ph/60Hz)

Cod. 710.0138.45.00 Rev04 – 02.2019 16 - 35


Cod. 714.0170.09.00 – Rev. 00
Models D240IN-A to D360IN-A (230V/1Ph/60Hz)

30µ

Cod. 710.0138.45.00 Rev04 – 02.2019 17 - 35


Cod. 714.0171.02.00 – Rev. 01
Models D480IN-A (230V/1Ph/60Hz)

µ
µ

Cod. 710.0138.45.00 Rev04 – 02.2019 18 - 35


Cod. 714.0188.05.00 – Rev. 00
Model D600IN-A (230V/1Ph/60Hz – 220V/1Ph/60Hz)

µ
µ
µ

Terminal blocks

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Components layout

µ
µ

Cod. 710.0138.45.00 Rev04 – 02.2019 20 - 35


Cod. 714.0219.01.00 – Rev. 01
Models D600IN-A – D780IN-A – D950IN-A (460V/3Ph/60Hz)

Power Circuit

Control Circuit diagram

Cod. 710.0138.45.00 Rev04 – 02.2019 21 - 35


Terminal blocks

Cod. 710.0138.45.00 Rev04 – 02.2019 22 - 35


Components layout

Cod. 714.0176.01.00 – Rev. 00


Models D780IN-A – D950IN-A (380V/3Ph/60Hz)

Power Circuit

Cod. 710.0138.45.00 Rev04 – 02.2019 23 - 35


Control Circuit diagram

Terminal blocks

Cod. 710.0138.45.00 Rev04 – 02.2019 24 - 35


Components layout

Cod. 710.0138.45.00 Rev04 – 02.2019 25 - 35


(C) DATA SHEET

MODEL D12IN-A D25IN-A D42IN-A D54IN-A D72IN-A D108IN-A D144IN-A D180IN-A D240IN-A D300IN-A D360IN-A D480IN-A

mᶟ/h 12 25 42 54 72 108 144 180 240 300 360 480


AIR FLOW RATE*
CFM 7 15 25 32 42 64 85 106 140 176 212 280
VOLT/
POW SUPPLY 230/1/60
PH/HZ
HP 1/10 1/10 1/6 1/6 1/6 1/2 1/2 1/2 1 1 1 1.1/2
kW 0,13 0,13 0,24 0,24 0,24 0,49 0,49 0,66 1,00 1,00 1,00 1,73
1M1 Max kW 0,19 0,19 0,37 0,37 0,37 0,76 0,76 0,88 1,55 1,55 1,55 2,79
COMPRESSOR RLA 0,83 0,83 1,46 1,46 1,46 3,2 3,2 4,21 4,73 4,73 4,73 8,70
FLA 1,07 1,07 1,89 1,89 1,89 4,16 4,16 5,13 7,36 7,36 7,36 13,50
LRA 8 8 16,5 16,5 16,5 26,5 26,5 23 35 35 35 50
QTY 1 1 1 1 1 1 1 1 1 1 1 1
1M2 HP 1/120 1/120 1/120 1/120 1/120 1/60 1/40 1/40 1/4 1/4 1/4 1/4
FAN MOTOR RLA 0,24 0,24 0,24 0,24 0,24 0,28 0,54 0,54 0,83 0,83 0,83 0,83
LRA 0,32 0,32 0,32 0,32 0,32 0,72 0,72 0,72 0,94 0,94 0,94 0,94
TOTAL A A 1,4 1,4 2,2 2,2 2,2 4,8 4,8 5,9 8,7 8,1 8,1 14,4
CONNECTION BSP 3/8" 3/8" ½" ½" ½" ¾" ¾" ¾" 1½" 1½" 1½" 1½"
°C 35
AIR T
°F 95
°C 60
AIR T MAX
°F 140
°C 25
AMB T
°F 77
°C 50
AMB T MIN-MAX
°F 122
bar 7
PRESS W
psi 100
bar 14
AIR PRESS MAX
psi 203
°C 7 (CLASS 5)
DEW POINT*
°F 45 (CLASS 5)
TYPE R134a R407C R134a
KG 0,17 0,17 0,23 0,30 0,30 0,35 0,35 0,47 0,90 0,90 0,90 1,40
REFRIGERANT
LB 0,37 0,37 0,51 0,66 0,66 0,77 0,77 1,04 1,98 1,98 1,98 3,09
OZ 6,00 6,00 8,11 10,58 10,58 12,35 12,35 16,58 31,75 31,75 31,75 49,38
W KG 17 18 26 26 26 33 38 43 87 87 87 110
WEIGHT LB 37,48 39,68 55,11 57,32 57,32 72,75 83,77 94,80 191,79 191,79 191,79 242,50
°C 3–5 3–5 3–5
EVAP, TEMP,*
°F 37 – 41 37 – 41 37 – 41
°C 4–6 4 – 10 4–6
SUCTION TEMP,*
°F 39 – 43 39 – 50 39 – 43
barg 12 – 16 13 – 17 12 – 16
DISCH, PRESS,*
psig 170 – 230 188 – 246 170 – 230

DB(A) dB(A) < 70

Cod. 710.0138.45.00 Rev04 – 02.2019 26 - 35


MODEL D600IN-A D780IN-A D950IN-A

m3/h 600 780 950


AIR FLOW RATE*
cfm 353 459 559
VOLT/
POW SUPPLY PH/HZ
230/1/60 220/1/60 380/3/60 460/3/60 380/3/60 460/3/60
kW 1,73 1,73 2,3 2,64 2,3 2,64
Max kW 2,79 2,79 3,53 4,11 3,53 4,11
1M1
RLA 8,7 8,7 4,33 3,8 4,33 3,8
COMPRESSOR
FLA 13,50 13,50 6,11 5,8 6,11 5,8
LRA 50 50 32 45 32 45
QTY 1 1 1 1 1 1
1M2
RLA 1,1 1,1 0,58 0,97 0,58 0,97
FAN MOTOR
LRA 1,92 1,92 1,00 1,38 1,00 1,38
TOTAL A A 15,4 15,4 7,1 7,2 7,1 7,2
CONNECTION BSP 2"
°C 35
AIR T
°F 95
°C 60
AIR T MAX
°F 140
°C 25
AMB T
°F 77
°C 50
AMB T MIN-MAX
°F 122
bar 7
PRESS W
psi 100
bar 14 13
AIR PRESS MAX
psi 203 188
°C 3 (CLASS 4)
DEW POINT*
°F 37 (CLASS 4)
TYPE R134a R407C
KG 1,8 1,8 2 2,15 2,1 2,25
REFRIGERANT
LB 3,97 3,97 5,51 4,74 4,63 4,96
OZ 63,49 63,49 70,55 75,84 74,07 79,37
W KG 120 130 150
WEIGHT LB 264,6 286,6 330,7
°C 3–5 1–2
EVAP, TEMP,*
°F 37 – 41 34 – 35,5
°C 4–6 4 – 10
SUCTION TEMP,*
°F 39 – 43 39 – 50
barg 12 – 16 13 – 18
DISCH, PRESS,*
psig 170 – 230 188 – 261
FAN PRESSURE barg 3–5 15 – 19
SWITCH SETTING psig 37 – 41 218 – 276
barg 4–6 28
HP SWITCH SETTING
psig 39 – 43 406
DB(A) dB(A) < 70 76 < 70 76 < 70

*Rating conditions of: 35°C (95°F) and 100 psig air Inlet, 25°C (77°F) ambient temperature
Performance and specifications + / - 5%

Cod. 710.0138.45.00 Rev04 – 02.2019 27 - 35


AIR FLOW RATE Air flow rate
POW SUPPLY Power supply
HP Nominal power
kW Nominal consumption
Max kW Full load consumption
RLA Nominal Current
FLA Full load current
LRA Locked rotor current
CONN Air connections
AIR T Air inlet temperature
AIR T MAX Max, air inlet temperature
AMB T Ambient temperature
AMB T MAX Max, ambient temperature
PRESS W Working pressure
PRESS MAX Max, pressure
DEWP Pressure dew point
REF Refrigerant
W Weight
TOTAL A Total current
EVAP,TEMP Evaporation temperature
SUCTION TEMP Suction temperature
FAN PRESSURE SWITCH SETTING Fan pressure Switch setting
DISCH,PRESS, Discharge pressure
HP SWITCH SETTING High pressare switch setting
MIN CIRCUIT AMPACITY Minimum circuit ampacity

(D) CORRECTION FACTORS

Correction factor for working pressure


bar 5 6 7 8 9 10 11 12 13 14
psi 73 87 102 116 131 145 160 174 188,5 203
FC1 0,85 0,93 1 1,06 1,11 1,15 1,18 1,20 1,22 1,24

Correction factor for ambient temperature


°C 25 30 35 40 42 45 50
°F 77 86 95 104 107,6 113 122
FC2 1,00 0,96 0,92 0,88 0,85 0,76 0,52

Correction factor for inlet air temperature


°C 30 35 40 45 50 55 60
°F 86 95 104 113 122 131 140
FC3 1,20 1,00 0,85 0,71 0,56 0,42 0,27

Calculation of the dryer REAL FLOW RATE = nominal dryer flow rate x FC1 x FC2 x FC3
Calculation of the GIVEN FLOW RATE to select a suitable dryer = given flow rate ÷ FC1 ÷ FC2 ÷ FC3

Cod. 710.0138.45.00 Rev04 – 02.2019 28 - 35


(E) DRYER DIMENSIONS

Model D12IN-A to D25IN-A

A B C D E F G H

3/8" 3/8" Ø 230/1/60


mm 305 360 408 51 40 50 332 24
BSP BSP 6mm V/ph/Hz

Models D42IN-A to D180IN-A

A B C D E F G H L

D42IN-A
1/2" 1/2" 230/1/60
to mm 390 432 441 100 85 65 45 65 12 Ø 6mm
BSP BSP V/ph/Hz
D72IN-A

D108IN-A
3/4" 3/4" 230/1/60
to mm 420 516 551 100 85 80 44 63 12 Ø 6mm
BSP BSP V/ph/Hz
D180IN-A

Cod. 710.0138.45.00 Rev04 – 02.2019 29 - 35


Models D240IN-A to D480IN-A

A B C D E F G H

1" 1/2 1" 1/2 230/1/60


mm 500 679 980 157 254 99,5 114 40 Ø 6mm
BSP BSP V/ph/Hz

Model D600IN-A

IN

OUT

A B C D E F G H I L

2" 2" V/ph/Hz


mm 720 750 1340 109 346,5 180 60 148,5 105,5 29 Ø 6mm
BSP BSP 230/1/60 460/3/60

Cod. 710.0138.45.00 Rev04 – 02.2019 30 - 35


Models D780IN-A to D950IN-A

IN

OUT

A B C D E F G H

2" 2" V/ph/Hz


mm 720 750 1425 109 346,5 180 60 105,5 Ø 6mm
BSP BSP 380/3/60 460/3/60

Power supply Air flow

Cod. 710.0138.45.00 Rev04 – 02.2019 31 - 35


(F) BASIC SPARE PARTS

Model
D12IN-A D25IN-A D42IN-A D54IN-A D72IN-A D108IN-A D144IN-A D180IN-A
Pos Element
1A1 Electronic Controller 38459608 38459608 38459608 38459608 38459608 38459608 38459608 38459608
RT1 Temperature probe 38457412 38457412 38457412 38457412 38457412 38457412 38457412 38457412
1M1 Refrigerant compressor 38458931 38458931 23530041 23530041 23530041 24066839 24066839 24066854
1M2 Fan Motor 24641383 24641383 24641383 24641383 24641383 38458972 38458972 38458972
VT Fan blade 38457784 38457784 38457784 38457784 38457784 38457792 38457792 38457792
G Grid 38457800 38457800 38457800 38457800 38457800 38457818 38457818 38457818
1S1 Main power switch - - - - - 38457826 38457826 38457826
1V1 Complete solenoid drain valve 38459665 38459665 38459665 38459665 38459665 38459665 38459665 38459665
1B1 Drain solenoid valve coil 38459673 38459673 38459673 38459673 38459673 38459673 38459673 38459673
CND Condenser 38459087 38459087 38459046 38459053 38459053 38459079 38459079 38459186
FF Filter dryer 38457594 38457594 38457594 38457594 38457594 38457602 38457602 38457602
FR Drain screen 38457891 38457891 38457891 38457891 38457891 38457636 38457636 38457636
SC Heat exchanger base 38457909 38457909 38459012 38459012 38459012 38459020 38459194 38459194
STC Control panel cover 38457883 38457883 38457917 38457917 38457917 38457917 38457917 38457917

1M2

SC

G STC

VT

RT1

1M1
1S1
FR
1A1
1B1
1V1

FF

CND

DETAIL A
Cod. 710.0138.45.00 Rev04 – 02.2019 32 - 35
Model
D240IN-A D300IN-A D360IN-A D480IN-A
POS Element
1A1 Electronic Controller 38459608 38459608 38459608 38459608

RT1 Temperature probe 38459616 38459616 38459616 38459616

1M1 Refrigerant compressor 24044976 24044976 24044976 23530090

1M2 Fan Motor


38460168 38460168 38460168 38460168
VT Fan blade

G Grid 38458980 38458980 38458980 38458980

1S1 Main power switch 38459657 38459657 38459657 38459657

1V1 Complete solenoid drain valve 38459665 38459665 38459665 38459665

1B1 Drain solenoid valve coil 38459673 38459673 38459673 38459673

CND Refrigerant condenser 38460218 38460218 38460218 38460226

K1 Contactor switch 38459723 38459723 38459723 38459723

RBF Drain screen 38457636 38457636 38457636 38457636

SC Heat exchanger base 23516370 23516370 23516370 23516388

VB By-pass hot gas valve 23716095 23716095 23716095 38461356

FF Dehydrator filter 38459707 38459707 38459707 38459707

STC Control panel cover 38457917 38457917 38457917 38457917

VT

FF

SC

K1

VB

Cod. 710.0138.45.00 Rev04 – 02.2019 33 - 35


Model D600IN-A D780IN-A D950IN-A
POS Element 230/1/60 220/1/60 380/3/60 460/3/60 380/3/60 460/3/60
1A1 Electronic board 38459608 38459608 18301721 18301721 18301721 18301721
RT1 Probe 18301689 18301689 18301689 18301689 18301689 18301689
1M1 Frigorific compressor 23530090 23530090 23530116 23711949 23530116 23711949
1M2 Fan Motor
38460168 38460168 49093933 49213267 49093933 49213267
VT Fan blade
G Grid 18301523 18301523 18301531 49230139 18301531 49230139
1P1 High pressure Switch - - 38461406 38461406 38461406 38461406
1P2 Fan pressure Switch - - 18301622 18301622 18301622 18301622
CND Freon condenser 18301960 18301960 18301978 18301978 18301978 18301978
FF Filter dryer 38459707 38459707 18301879 18301879 18301879 18301879
SC Heat exchanger base 23716251 23716251 23716251 23716251 23716251 26718851
STC Control panel cover 38457917 38457917 38457917 38457917 38457917 38457917
VB By-pass hot gas valve 38461356 38461356 23718851 23718851 23718851 23718851
SLI Liquid separator - - 18301929 18301929 18301929 18301929
F1 Primary Fuse - - 18301762 18301762 18301762 18301762
F2 24V Secondary Fuse - - 18301770 18301770 18301770 18301770
K1 Contactor switch 18301754 18301754 23545312 23545312 23545312 23545304
K2 Fan contactor switch - - 23545338 23545338 23545338 23545338
1T1 Transformer - - 23530165 23530157 23530165 23530157
No loss condensate
49087497 49087497 49087521 18302448 18302448 18302448
SSC drain
Service kit 23851496 23851496 23851496 23851496 23851496 23851496

Cod. 710.0138.45.00 Rev04 – 02.2019 34 - 35

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