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D600IN-A TO D5400IN-A 1 of 9
4-Nov-08

QUOTATION: DRYERS D600IN-A TO D5400IN-A

Refrigerated Air Dryers

D600IN-A to D5400IN-A

1.

GENERAL DESCRIPTION.............................................................................................. 2 1.1. Introduction ............................................................................................................... 2

1.2. Operating principle.................................................................................................... 2 1.2.1. Compressed air circuit....................................................................................... 2 1.2.2. Refrigeration circuit............................................................................................ 2 2. COMPONENTS AND CONSTRUCTION ........................................................................ 4 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. Refrigerant Compressor ........................................................................................... 4 R507 Refrigerant ...................................................................................................... 5 Heat Exchanger ........................................................................................................ 5 Liquid Separator ....................................................................................................... 5 Condenser ................................................................................................................ 5 Cooling Fan............................................................................................................... 5 Fan pressure switch.................................................................................................. 6 Hot Gas By-pass Valve............................................................................................. 6 No Loss Condensate Drain....................................................................................... 6

2.10. Control Panel ............................................................................................................ 6 3. 4. 2.11. Enclosure .................................................................................................................. 6 TESTING.......................................................................................................................... 7 COMMERCIAL OFFER ................................................................................................... 7 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 5. 6. Delivery Terms.......................................................................................................... 8 Payment Terms......................................................................................................... 8 Warranty ................................................................................................................... 8 Start up ..................................................................................................................... 8 Standard packaging.................................................................................................. 8 Validity of the offer .................................................................................................... 8

4.7. Other conditions........................................................................................................ 8 EXCLUSIONS FROM THE SUPPLY .............................................................................. 8 TERMS & CONDITIONS OF SALE................................................................................. 9

Ingersoll Rand Company Confidential

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D600IN-A to D5400IN-A 2 of 9 4-Nov-08

QUOTATION: DRYERS D600IN-A to D5400IN-A

1. General Description
1.1. Introduction

The D series refrigerated dryer models D600IN-A to D5400IN-A are non-cycling compressed air dryer designed for superior and reliable performance in a compressed air solution. The purpose of this document is to describe the operating principle and the principal components of refrigerated dryers. This range of dryers has three frames. The smaller frame is designed for models D600IN-A to D950IN-A. The second frame is build for models D1300IN-A to D2520IN-A. The larger frame is for models D3000IN-A to D5400INA. 1.2. Operating principle
D600IN-A to D950IN-A D1300IN-A to D2520IN-A

D3000IN-A to D5400IN-A

Dryers are split into a compressed air circuit and a refrigeration circuit. 1.2.1. Compressed air circuit Saturated compressed air enters the dryers heat exchanger, where it is pre-cooled by the cold compressed air exiting the dryer. Then it passes to the evaporator, where it is further cooled by the cold evaporating refrigerant. Ingersoll Rand uses environmentally friendly refrigerant R507. The cold air and condensed liquids flow to the de-mister separator, where the liquids are separated out of the air-stream by the de-misters mesh filter. The liquids are then drained away by a no-loss condensate drain. The now dry but still cold compressed air exits the dryer via the air-to-air heatexchanger. As it cools the incoming air, it is itself warmed up, thereby eliminating condensation accumulation on the outside of the air piping and decreasing the relative humidity. 1.2.2. Refrigeration circuit The refrigeration circuit begins at the discharge of the refrigerant compressor; the hot high pressure gas flows through towards the air-cooled condenser. Here the refrigerant is cooled by ambient air flowing across the condenser coil, causing the gas to condense into a liquid state. On exiting the condenser the liquid refrigerant passes through the filter/dryer, where any moisture and impurities within the refrigerant are

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QUOTATION: DRYERS D600IN-A to D5400IN-A

removed. Next the refrigerant passes through the capillary. The capillary expands the high pressure refrigerant before entering the evaporator. The cold liquid refrigerant then enters the evaporator, where it exchanges heat with hot compressed air. It adsorbs heat from the compressed air and cools the compressed air to the required dew point. As the refrigerant flows through the evaporator it transforms from a cold liquid to a warm (and superheated) gas. The warm refrigerant gas then exits the evaporator and returns back to the refrigerant compressor, where it repeats the whole above cycle again. The dew point performance is accurately controlled by a hot gas bypass valve which is combined to a fan system. In the following table you can find the flow associated with each dryer model at a C Pressure Dew Point: (ISO 8573-1: 2001) 3

Model D600IN-A D780IN-A D950IN-A D1300IN-A D1410IN-A D1890IN-A D2520IN-A D3000IN-A D4200IN-A D4800IN-A D5400IN-A

ISO 8573-1: 2001 Class 4 < 3 C Pressure Dew Point m3/min m3/hr 10,0 600,0 13,0 780,0 15,8 950,0 21,7 1300,0 23,5 1410,0 31,5 1890,0 42,0 2520,0 50,0 3000,0 70,0 4200,0 80,0 4800,0 90,0 5400,0

Data refers to the following conditions: Ambient temperature = 25 C Air inlet temperature = 35 C Pressure = 7 bar g Operating Capabilities Maximum operating pressure D600IN-A Maximum operating pressure D780IN-A to D5400IN-A Maximum air inlet temperature Ambient temperature D600IN-A to D950IN-A Min/Max Ambient temperature D1300IN-A to D5400IN-A Min/Max Electrical protection = 14 bar (g) = 12 bar (g) = +60 C = +2 /+50 C = +2 /+45 C = IP42

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QUOTATION: DRYERS D600IN-A to D5400IN-A

2. Components and construction
Each dryer are designed with the following components: 1. Refrigerant compressor 2. Heat exchanger 3. Liquid separator 4. Condenser 5. Hot gas by-pass valve 6. No loss condensate drain 7. Control Panel 8. Motor Fan 9. Fan pressure switch 10. Enclosure

2.1.

Refrigerant Compressor

A hermetically sealed reciprocating compressor is utilized throughout the design. All compressors have an oil sump heater with primary external motor temperature protection and internal, secondary motor temperature protection. A primary, external sensor with secondary, internal protection protects compressor discharge temperature. Installing the compressor on isolation mounts to the baseplate reduces noise and vibration.

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QUOTATION: DRYERS D600IN-A to D5400IN-A

2.2.

R507 Refrigerant

Environmentally friendly R507, a non-ozone depleting refrigerant, is used. 2.3. Heat Exchanger

Each dryer uses aluminum cross flow heat exchanger, with a high surface area which is used to cool the air to the desired dew point. The ultra compact aluminum version includes an air-to-air heat exchanger, evaporator and service-free demister separator, all in one. Larger models feature up to 6 exchanger modules. Removal of the condensed moisture is accomplished through the high efficiency, demister type moisture separator, fitted with a condensate no-loss drain. The dry, cold air passes through the air air reheater, where the air is warmed, Thereby eliminating condensation accumulation on the outside of the air piping and decreasing the relative humidity. The Ingersoll Rand aluminum heat exchanger offers compactness, robustness and energy efficiency which reduce the operating costs of dryers.

2.4.

Liquid Separator

The liquid separator has the task of ensuring that no liquid refrigerant enters the compressor. It improves the stability of the dew point and it reduces the energy consumption of the unit. 2.5. Condenser

Parallel flow aluminum condensers and axial fans provide cooling to the refrigerant. The condensers are made of aluminum. Industrial Grade Axial fans provide cooling airflow across the condenser. 2.6. Cooling Fan

Dryers are cooled by an axial fan(s) installed in the top of each unit. Depending on the unit size, number of fan may vary. The fan dissipates heat of the dryer and is controlled by the fan pressure switch. Fans are located on the top of the units to improve air flow and ease of maintenance.

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QUOTATION: DRYERS D600IN-A to D5400IN-A

2.7. Fan pressure switch

The fan pressure switch allows the cooling fan(s) to adjust the dryer's cooling capacity at different working conditions. Condensation pressure is controlled by the control panels activation and deactivation of the fans. The fan pressure switch deactivates the fan when the pressure is lower than 16 bar g and reactivates it when the pressure is higher than 20 bar g. 2.8. Hot Gas By-pass Valve

To ensure that there is no risk of freezing within the dryer a hot gas by-pass valve acts as the controller for the whole refrigeration circuit. The hot gas by-pass operates according to the refrigerant pressure within the evaporator. It reacts by taking a percentage of the refrigerant exiting the refrigerant compressor, and re-injecting it into the compressor inlet. In this way the hot gas by-pass can ensure that the pressure of the refrigerant entering the evaporator is always constant. This ensures a stable refrigeration circuit regardless of changes in operating conditions. 2.9. No Loss Condensate Drain

Dryers come equipped with a no-loss drain as a standard feature. This no loss drain eliminates the need for pre-setting the unit. The system uses state-of-the-art software combined with a special transducer interface to measure the presence of condensate. The condensate is released only when needed. There is no loss of compressed air. Continuous monitoring ensures fast, effective discharge of the condensate ate reliably without wasting any power. 2.10. Control Panel A full feature electronic control panel system ensures proper dryer operation. Individual alarms are provided for high and low dew point and probe failure. The control board is equipped with a dry contact for common alarm. Alarm history is available for review. For model D600IN-A to D950IN-A, a history of 10 alarms is available. For models D1300IN-A to D5400IN-A, and history of 50 alarms is available. The control panel comes with a terminal for remote alarm signal and for models D1300IN-A to D5400INA the control panel comes with an additional terminal for remote alarm for the no-loss drain. For models D600IN-A to D950IN-A, a visual display is used to indicate dryer conditions. Three LEDs are provided to indicate compressor, drain and condenser fan status. For models D1300IN-A to D5400IN-A the control panel come with 11 icons to indicate different status and modes of the dryers. An energy saving/anti-freezing mode will shut the dryer off during periods of low demand

2.11. Enclosure The cabinet is designed to safely contain components yet offer an aesthetically pleasing appearance and ergonomically planned maintenance access. The sheet metal enclosure is steel and is painted with electro-statically applied powder coat paint.

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QUOTATION: DRYERS D600IN-A to D5400IN-A

3. Testing
Final package and functional testing is performed on all dryers: Electrical functionality test Helium leak test to the refrigeration side Refrigeration leak test at designed system pressure

4. Commercial Offer
Qty Description Dryer model XXX supplied as per description of the technical proposal Ultracare Part Kit zzz Filter model YYY supplied as per description of the technical proposal Unit Price [] Total Price []

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D600IN-A to D5400IN-A 8 of 9 4-Nov-08

QUOTATION: DRYERS D600IN-A to D5400IN-A

4.1.

Delivery Terms

Ex-works Ingersoll Rand facility (Unicov, Czech Republic). Lead time: {complete as appropriate} Lead time begins after official order acceptance by Ingersoll Rand or, if requested, from the date of the letter of credit. In case the Buyer has to delay the shipment or does not provide clearance to ship the material after the readiness for shipment of the material, a storage fee will be applied. 4.2. Payment Terms

20% at order 80% at shipment 4.3. Warranty

Ingersoll Rand warrants that the equipment will be free of defects in material and workmanship for a period of twelve months from the date of placing the equipment in operation or eighteen months from the date of shipment, whichever occurs first. Extended warranties (beyond above period) are available with Ingersoll Rands UltraCare programs. Please contact Ingersoll Rand Services Dept. for further details. 4.4. Start up

Excluded. If requested, Ingersoll Rands supervision at start up will be invoiced according the local rates in force at the time of the intervention. 4.5. Standard packaging

The dryer will ship in a plastic wrap with a cardboard box mounted on a wooden skid. 4.6. Validity of the offer

30 days 4.7. Other conditions

For what not specifically mentioned the attached Ingersoll Rand Terms & Conditions of Sale apply.

5. Exclusions from the Supply

Everything not explicitly listed in this offer is intended as excluded from Ingersoll Rand scope of supply.

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QUOTATION: DRYERS D600IN-A to D5400IN-A

In particular, unless otherwise specified in this proposal, Customer liabilities are: Foundation working Piping and installation outside of package for air, cooling water and condensate Piping and connections between the package and loose items Interconnecting piping and cabling to Customer network Handling/lifting devices for customer installation Compliance with standards or specifications not clearly mentioned in this offer or attached to the quotation request

6. Terms & Conditions of Sale

{Attach as appropriate}