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Ingersoll-Rand DXR Series User Manual

Ingersoll-Rand DXR Series
48 pages
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Bulletin 553 Revision M (2/00)
Copyright ©2000 Ingersoll-Rand Company
Printed in USA
DXR SERIES
REFRIGERATED AIR DRYERS
OPERATOR'S
INSTRUCTION MANUAL
DXR425
DXR600
DXR800
DXR1000
English: 1-1
Español: 2-1
Before installation or starting the dryer for the
first time, study this manual carefully to obtain
a clear knowledge of the dryer and of the
duties to be performed while operating and
maintaining the dryer.
RETAIN THIS MANUAL WITH DRYER.
This technical manual contains IMPORTANT
SAFETY DATA and should be kept with the
dryer at all times.

Table of Contents

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Ingersoll-Rand DXR Series Specifications

General IconGeneral
BrandIngersoll-Rand
ModelDXR Series
CategoryDehumidifier
LanguageEnglish

Summary

Introduction

Safety

Safety Instructions

Explains signal words (DANGER, WARNING, CAUTION) for hazard levels.

Safety Labels

Information about safety labels on the dryer and how to obtain replacements.

Data Plate and Labels

Importance of dryer data plates and labels for safety and identification.

Receiving and Inspection

Installation

Ambient Air Temperature

Specifies ideal indoor ambient air temperature range (40°F-100°F) for dryer operation.

Location and Clearance

Guidance on mounting the dryer on a level base and ensuring adequate clearance for airflow and service.

System Arrangement

Advice on dryer placement relative to other system components like separators and receiver tanks.

Piping and Connections

Requirements for user-supplied piping, pressure ratings, and support.

Drains

Instructions for connecting and routing condensate drain lines to a disposal system.

Electrical Connections

Compliance with NEMA standards, local codes, and ensuring correct line voltage.

Cooling Water

Information for water-cooled models, including water supply requirements and regulating valve.

How It Works

Air Flow

Explains how air passes through the heat exchanger and dryer to remove moisture.

Refrigeration System

Describes the refrigeration system components and their function in cooling the air.

Air-Cooled Models Cooling Requirements

Specifies requirements for cooling air intake for air-cooled dryer models.

Instrumentation

Power Signal

Details the ON-OFF switch and the indicator light for power status.

System Operation Monitor

Overview of the monitor, its display, indicators, and controls for dryer status.

Indicating Lights

Explains the meaning of the four indicator lights: Normal Operation, Check Operating Conditions, Service Due, System Alarm.

Temperature SCAN/SEEK Push Button

How to use the SCAN/SEEK button to view different system temperatures.

System Operation Monitor Indicating Lights Details

Critical Air and Refrigerant Temperatures

Normal and Warning Temperature Ranges

Explains normal ranges and warning/alarm set points for various system temperatures.

Temperature Monitoring and Analysis

Inlet Air Temperature Monitoring

Discusses the impact of inlet air temperature on dew point and potential dryer performance issues.

Refrigerant Suction Temperature Analysis

Guides on troubleshooting based on refrigerant suction temperature readings and potential malfunctions.

Refrigerant Discharge Temperature

Notes its use by service personnel for analyzing refrigeration system performance.

Ambient Air Temperature Impact

Explains how ambient air temperature affects dew point and potential dryer shutdown.

Inlet Condensing Water Temperature

Details how water temperature impacts dryer performance and potential issues.

Intermediate Air Temperature Interpretation

Explains how to display and interpret intermediate air temperature for performance analysis.

Communication and Control Features

RS-232 Serial Port Communication

Details the serial port for monitoring temperature and error flags, including message format.

Remote Alarm Contacts

Describes optional contacts for remote signaling of operating conditions or alarms.

Automatic Drain Valves

ADV Adjustment Procedure

Instructions on setting the drain valve open and closed times for efficient condensate discharge.

Start-Up and Shutdown Procedures

Dryer Start-Up Instructions

Step-by-step instructions for safely starting the dryer, including pre-start checks and warm-up.

Dryer Shutdown Instructions

Procedures for shutting down the dryer, especially for electrical repairs.

Maintenance Schedule and Procedures

General Maintenance Guidelines

Guidance on refrigeration system maintenance by qualified personnel and warranty considerations.

Daily Maintenance Checks

Daily checks for automatic drain valve operation and system monitor readouts.

Weekly Maintenance Tasks

Checking the prefilter differential pressure gauge and replacing the element.

Monthly Maintenance Tasks

Inspecting condenser coils and replacing the ambient air filter.

Service Due Indicator Reset

Explains the SERVICE DUE indicator and the procedure for resetting it after maintenance.

Returns to Manufacturer Process

Process for returning dryers or components to the manufacturer for service.

Specific Component Maintenance

Ambient Air Filter Replacement

Instructions for inspecting and replacing the ambient air filter element for optional units.

Automatic Drain Valve Servicing

Step-by-step guide for disassembling, cleaning, and servicing the automatic drain valve.

Prefilter Element Replacement

Instructions for replacing the prefilter element, especially for cold coalescing options.

Field Service Guide

Troubleshooting Common Dryer Problems

Provides guidance for common problems like water downstream or excessive pressure drop.

Troubleshooting Water Downstream Issues

No Automatic Drain Valve Discharge

Troubleshooting steps for non-functioning automatic drain valves.

Inlet Air Temperature Issues

Addresses issues related to inlet air temperature affecting dew point.

Liquid Water Entry into Dryer

Explains causes of liquid water entering the dryer system.

Excessive Airflow Problems

Discusses problems caused by excessive airflow, including pressure drop.

Compressor Protection and Performance Issues

Compressor Shutdowns

Troubleshooting compressor shutdowns due to high discharge pressure, internal overload, or winding faults.

Indicator Lights and Temperature Anomalies

Addresses issues indicated by HIGH EVAP light, red dew point indicator, high suction, or low discharge temperatures.

Advanced Troubleshooting Guide

Water Downstream, High Discharge Temp, and Pressure Drop

Continues troubleshooting for water downstream, high discharge temp, and excessive pressure drop.

Icing, Intermediate Temp, and Cooling Issues

Diagnosing and resolving system icing, low/high intermediate temperatures, and compressor cooling problems.

Automatic Drain Valve Malfunctions

Steps to take when the automatic drain valve is not discharging condensate or is venting continuously.

Display and Timer Issues

Steps to resolve issues where the digital display is blank or unresponsive, or timer malfunctions.

Appendix A: Parts and Schematics

Replacement Parts List

Lists available replacement parts for the dryer.

System Schematics

Provides diagrams and schematics for the dryer systems.

Replacement Parts Details

Filter-Dryer and Expansion Valve Parts

Details for the filter-dryer and expansion valve replacement parts.

Automatic Drain Valve Components

Replacement parts and kits for the automatic drain valve (ADV).

Compressor and Transformer Parts

Replacement parts for compressors and transformers used in the dryer.

Condenser and Fan Components

Replacement parts for condensers (air and water-cooled) and fan assemblies.

Pressure Switches and Ambient Filter Parts

Replacement parts for pressure switches and ambient air filters.

System Monitor and Indicator Light Parts

Replacement parts for the System Operation Monitor and indicator lights.

Additional Replacement Parts

Dryer Components and Specific Parts

Lists replacement parts for various dryer components for different models.

Refrigeration Flow Schematics

DXR425-DXR600 Refrigeration Flow Schematic

Diagram illustrating the refrigerant flow for DXR425 and DXR600 models.

Water-Cooled Refrigeration Flow Schematics

DXR425W-DXR600W Refrigeration Flow Schematic

Diagram showing refrigerant flow for water-cooled DXR425W and DXR600W models.

Refrigeration Flow Schematics for Larger Models

DXR800-DXR1000 Refrigeration Flow Schematic

Diagram illustrating the refrigerant flow for DXR800 and DXR1000 models.

Water-Cooled Refrigeration Flow Schematics for Larger Models

DXR800W-DXR1000W Refrigeration Flow Schematic

Diagram showing refrigerant flow for water-cooled DXR800W and DXR1000W models.

Electrical Schematics

DXR425-DXR1000-A Electrical Schematic

Electrical schematic for DXR425-A through DXR1000-A models.

Electrical Schematics for Water-Cooled Models

DXR425W-DXR1000W Electrical Schematic

Electrical schematic for DXR425W through DXR1000W models.

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