Comfort Systems USA (Arkansas), Inc. P.O. Box 16620 Little Rock, AR 72231 Phone 501-834-3320 Fax 501-834-5416 4806 Rixey Road No. Little Rock, AR 72117 Date: 10/28/2019 Return Request: 11/4/2019 Project: Lockheed Martin ATACMS PrSM Building Supplier: Arkansas Industrial Machinery, Inc. Manufacturer: Various Submittal: Compressed Air Equipment Submittal Number: 23 00 00-03 Spec Section: N/A Drawing # and Installation: Plumbing Drawings (Found on Plan Page P-105) ARCHITECT ENGINEER Cromwell Architects Engineers Cromwell Architects Engineers 1300 E. 6 th Street 1300 E. 6 th Street Little Rock, AR 72202 Little Rock, AR 72202 501-372-2900 501-372-2900 GENERAL CONTRACTOR MECHANICAL SUBCONTRACTOR Baldwin & Shell Construction Comfort Systems USA (Arkansas), Inc. 1000 W. Capitol Ave. 4806 Rixey Road Little Rock, AR 72201 North Little Rock, AR 72117 501-374-8677 501-834-3320 CSUSA PROJECT NO. 19-212 [email protected]*Lead times for this item will be 8-10 weeks; +/- weeks due to the Holidays, factories shut down process from the end of November through the beginning of the new year.
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Various Compressed Air Equipment 23 N/Acsdocs.comfortar.com/Matt/19-212 Lockheed Martin... · Atlas Copco’s GA Variable Speed Drive + (VSD ) technology closely matches the air demand
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Comfort Systems USA (Arkansas), Inc. P.O. Box 16620
Little Rock, AR 72231 Phone 501-834-3320
Fax 501-834-5416
4806 Rixey Road No. Little Rock, AR 72117
Date: 10/28/2019 Return Request: 11/4/2019Project: Lockheed Martin ATACMS PrSM Building Supplier: Arkansas Industrial Machinery, Inc. Manufacturer: VariousSubmittal: Compressed Air Equipment Submittal Number: 23 00 00-03 Spec Section: N/A Drawing # and Installation: Plumbing Drawings (Found on Plan Page P-105)
ARCHITECT ENGINEER Cromwell Architects Engineers Cromwell Architects Engineers 1300 E. 6th Street 1300 E. 6th Street Little Rock, AR 72202 Little Rock, AR 72202 501-372-2900 501-372-2900
GENERAL CONTRACTOR MECHANICAL SUBCONTRACTOR Baldwin & Shell Construction Comfort Systems USA (Arkansas), Inc. 1000 W. Capitol Ave. 4806 Rixey Road Little Rock, AR 72201 North Little Rock, AR 72117 501-374-8677 501-834-3320
*Lead times for this item will be 8-10 weeks; +/- weeks due to the Holidays, factories shut down processfrom the end of November through the beginning of the new year.
OIL-INJECTED ROTARY SCREW COMPRESSORS GA 15-26 / GA 11+-26+ / GA VSD+ 15-37 (11-37 kW/20-50 hp)
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for CA-1, CA-2 & CA-3 we are offering 30 hp Atlas Copco GA22+-100-Air-Cooled- 460-Volt air compressor with: Constant speed, oil-injected rotary screw compressors. Each compressor includes electronic load/ no load controller, motor starter, after-cooler with auto drain and trap. See page 19 for highlighted flow and pressure. In-bound freight is included, plus start-up service by factory trained service technician including extended warranty activation and customer training for operation and maintenance.
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Comfort Systems, USA Lockheed Martin- ATACMS AC-1, AC-2 & AC-3 Atlas Copco Air Compressors
MEETING YOUR EVERY NEED FOR COMPRESSED AIRAtlas Copco's GA oil-injected screw compressors
provide you with industry-leading performance
and reliability and allow you to benefit from a low
cost of ownership. Atlas Copco offers a trinity
line-up of compressors that matches your precise
requirements. The GA 15-26 stands for a high
quality, reliable air compressor with the lowest initial
investment. The GA 11+-30 delivers top performance
in the fixed speed compressor market. Our premium
product, the GA 15-37 VSD+, is a unique state-of-the-
art air compressor with unparalleled performance
and energy savings.
GA 15-26 COMPACT ECONOMICAL COMPRESSORS• Premium GA quality and optimal serviceability
at the lowest initial investment.
• Good-quality, dry air thanks to the integrated dryer.
• Total control and assured efficiency with the
Elektronikon® controller.
GA 11+-30 STATE-OF-THE-ART PERFORMERS• Exceptional Free Air Delivery.
• Best-in-class power consumption and noise emission.
• Thanks to the integrated dryer, high quality dry air
is guaranteed.
• Easy monitoring and maintenance thanks to the Elektronikon®
graphic controller with high-definition color display.
GA 15-37 VSD+ ULTIMATE ENERGY SAVERS• On average 50% energy savings compared to traditional
fixed speed compressors via advanced Variable Speed
Drive+ technology.
• Flexible pressure selection: 4-13 bar.
• Excellent-quality, dry air at the lowest energy cost thanks to
the new, integrated dryer range.
• Easy monitoring and maintenance thanks to the Elektronikon®
graphic controller with high-definition color display.
• Innovative vertical design minimizes the required floor space
while improving serviceability.
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GA 15-26: COMPACT ECONOMICAL COMPRESSORS Set to tackle your daily challenges, Atlas Copco’s high-performance tank-mounted GA compressors beat
any workshop solution. Ready to supply high-quality air, they keep your air network clean and your
production up and running.
Robust element & motor• The GA 15-26’s compression element, the most used
in its size, is combined with an IE3/NEMA Class 1
efficiency motor.
• A 2-3% higher efficiency with the gear-driven
drive train compared to belt-driven systems.
• Gear-driven drive train for best-in-class
reliability and limited maintenance.
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Advanced monitoring• State-of-the-art monitoring using a simple Ethernet connection,
thanks to the Elektronikon® with a built-in server.
• Service and warning indications, error detection and
compressor shut-down.
• Optional Elektronikon® graphic controller for further enhanced
remote monitoring features and service time indications.
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Easy installation• A true plug-and-play solution, ideal machine for installation
companies and OEMs.
• Optional integrated dryer, air filters and factory-mounted
500L receiver.
• Easy transportation by forklift.
• Remarkably compact footprint.
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High tech oil vessel • Protection from oil contamination: extremely low oil carry-
over thanks to the vertical design of the oil vessel.
• Extremely low losses of compressed air during load/unload
cycle thanks to minimized oil vessel size.
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Integrated quality air solutions • The integrated dryer avoids condensation and corrosion
in the network. Optional filters for air quality up to
ISO Class 1 level (<0.01 ppm).
• Standard included water-separator.
• Additional energy savings with the dryer’s no-loss
electronic drain.
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GA 11+-30: INDUSTRY-LEADING PERFORMERS Re-engineered to break records, the industrial GA 11+-30 compressors have the best air delivery capacity in
the industry. These all-in-one solutions provide high-quality air at the lowest possible operating costs and offer
extended monitoring possibilities.
Reliable motor & drive train• The gearbox’s maintenance-free transmission
maximizes durability.
• The motor and drive train are greased for life
to avoid improper re-lubrication.
• Free Air Delivery is increased by 6-17% and power
consumption is reduced by 3-12% thanks to
packaging and new compressor element.
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Electrical cubicle• Reduced cubicle temperature doubles the lifetime of the electrical components.
• Avoid damage with the electrical cubicle’s standard phase sequence relay.
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Quality air solutions• Integrated dryer range with counterflow heat exchanger,
integrated water separator and optional Dryer Saver Cycle.
• The integrated dryer can be outfitted with optional UD+ filter,
resulting in oil carry-over as low as 0.01 ppm.
• Water separation of nearly 100% in all conditions with the
standard electronic no-loss drain and integrated water
separator in the aftercooler.
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Advanced control• High-tech Elektronikon® graphic controller with
warning indications, compressor shut-down and
maintenance scheduling.
• Optional centralized control over up to 6 compressors
via Elektronikon®.
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Energy-saving features• Optional energy recovery system.
• Optional fan Saver Cycle, reducing energy consumption.
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GA 15-37 VSD+: ULTIMATE ENERGY SAVERS With its innovative vertical design, Atlas Copco's GA 15-37 VSD+ brings a game-changing revolution in
the compressor industry. It offers Variable Speed Drive as standard, a compact motor and small footprint
thanks to its in-house design and iPM (permanent magnet) technology. The GA VSD+ reduces energy
consumption by on average 50%, with uptimes assured even in the harshest conditions.
Interior Permanent Magnet (IPM) motor• Very high efficiency: exceeds IE3.
• Compact, customized design for optimal cooling by oil.
• Designed in-house in Belgium.
• IP66 vs. IP55.
• No cooling air flow required.
• Oil-lubricated motor bearing: no (re)grease(ing), increased uptime.
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Element• Made by Atlas Copco.
• Robust and silent.
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Direct drive • Vertical design, fewer parts.
• Oil-cooled, pressure-tight.
• No gears or belts, no shaft seal.
• Compact: footprint down 60%.
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Innovative fan • Based on the newest technologies.
• In compliance with ERP2015 efficiency.
• Low noise levels.
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Robust oil filter/separator• Integrated bypass valve with the oil filter.
• Easy maintenance.
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Electronic no-loss water drain• Included as standard.
• Efficient removal of condensate without loss of compressed air.
• Manual integrated bypass for effective condensate removal in
case of power failure.
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Elektronikon® controller• Integrated smart algorithms reduce system pressure
and energy consumption.
• Warning indications, maintenance scheduling and online
status visualization.
• Graphic display of key parameters (day, week, month) and
32 language settings.
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Sentinel inlet valve• No inlet arrestor.
• No blow off losses.
• Maintenance free.
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VSD+ cubicle• VSD+ superior to idling machines.
• Electrical components remain cool, enhancing lifetime of components.
• Dedicated drive for iPM technology motors.
• 5% DC choke as standard.
• Heat dissipation of inverter in separate compartment.
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VSD+ FOR 50% AVERAGE ENERGY SAVINGS* Atlas Copco’s GA Variable Speed Drive+ (VSD+) technology closely matches the air demand by automatically
adjusting the motor speed. Combined with the innovative design of the iPM (Permanent Magnet) motor,
this results in average energy savings of 50% and an average cut of 37% in the lifecycle cost of a compressor.
VSD+ works with permanent, in-house designed permanent magnet motors.
Why Atlas Copco Variable Speed Drive+ technology?• On average 50% energy savings with an extensive flow range (20-100%).
• Integrated Elektronikon® Graphic controller controls the motor speed and high efficiency frequency inverter.
• No wasted idling times or blow-off losses during operation.
• Compressor can start/stop under full system pressure without the need to unload with special VSD+ motor.
• Eliminates peak current penalty during start-up.
• Minimizes system leakage due to a lower system pressure.
• EMC Compliance to directives (2004/108/EG).
Energy Investment Maintenance
GA Fixed Speed GA VSD+
In almost every production environment, air demand fluctuates depending on different factors such
as the time of the day, week or even month. Extensive measurements and studies of compressed air
demand profiles show that many compressors have substantial variations in air demand.
* Compared to fixed speed compressors, based on measurement performed by an independent energy audit agency.
SAVINGS50%
Energy consumptionFixed speed load/unload
Air demand
Air demand
Time
Energy consumption
GA VSD+ energy consumption
Air demand
Time
Energy consumption
Air demand
A STEP AHEAD IN MONITORING AND CONTROLSThe next-generation Elektronikon® operating system offers a great variety of control and monitoring features
that allow you to increase your compressor’s efficiency and reliability. To maximize energy efficiency,
the Elektronikon® controls the main drive motor and regulates system pressure within a predefined and
narrow pressure band.
• Improved ease of use: intuitive navigation system with clear
pictograms and extra 4th LED indicator for service.
• Visualization through web browser using a simple
Ethernet connection.
• Easy to upgrade.
• Increased reliability: more durable keyboard.
Key features:• Automatic restart after voltage failure.
• Delayed Second Stop function.
• Option to upgrade to the advanced Elektronikon®
graphic controller.
• Improved user-friendliness: 3.5-inch high-definition color
display with clear pictograms and extra 4th LED indicator
for service.
• Internet-based compressor visualization using a simple
Ethernet connection.
• Increased reliability: new, user-friendly, multilingual user
interface and durable keyboard.
Key features:• Automatic restart after voltage failure.
• Dual pressure set point.
• More flexibility: four different week-schedules that can be
programmed for a period of 10 consecutive weeks.
• On-screen Delayed Second Stop function and
VSD savings indication.
• Graphical indication Serviceplan.
• Remote control and connectivity functions.
• Software upgrade available to control up to 6 compressors
by installing the optional integrated compressor controller.
GA 15-26: Elektronikon® controller GA 11+-30 & GA 15-37 VSD+: Advanced Elektronikon® graphic controller
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Optional integrated compressor controllerInstall, with a simple license, the optional integrated compressor controller and get
simple, central control to reduce system pressure and energy consumption in
installations of up to 4 (ES4i) or 6 (ES6i) VSD compressors.
Dual pressure set point & delayed second stopMost production processes create fluctuating levels of demand which,
in turn, can create energy waste in low use periods. Using either the
standard or graphic Elektronikon® controller, you can manually or
automatically create two different system pressure bands to optimize energy use
and reduce costs at low use times. In addition, the sophisticated Delayed Second Stop
(DSS) runs the drive motor only when needed. As the desired system pressure is maintained
while the drive motor’s run time is minimized, energy consumption is kept at a minimum.
Recover and save energyAs much as 90% of the electrical energy used by a compressed air solution is converted into heat. Using Atlas Copco’s integrated
energy recovery systems, it is feasible to recover up to ≈ 75% of that power input as hot air or hot water without any adverse influence
on the compressor’s performance. Through efficient usage of the recovered energy, you bring about important energy cost savings and
obtain a high return on investment.
Time Time
Power Power
Applications• Auxiliary or main heating of warehouses,
workshops…
• Industrial process heating
• Water heating for laundries, industrial
cleaning and sanitary facilities
• Canteens and large kitchens
• Food industry
• Chemical and pharmaceutical industries
• Drying processes
Without DSS With DSS
Saved energy
LoadedLoaded
Unloaded
Unloaded Stopped
EXCELLENCE IN QUALITY AIRUntreated compressed air contains moisture, aerosols and dirt particles that can damage your air system
and contaminate your end product. The resulting maintenance costs can far exceed air treatment costs.
GA compressors provide the clean, dry air that improves your system’s reliability, avoiding costly downtime
and production delays, and safeguarding the quality of your products.
Main benefits of the new, integrated dryer solutions• Thanks to the Saver Cycle, based on an extra ambient
sensor, the dryer will shut down when a normal dew point
is reached, meaning that 2/3 of the dryer’s power can be
recuperated (standard on GA VSD+, optional for GA+).
• Available in several variants, allowing you to gain
high-quality air in all ambient conditions.
• The heat exchanger with integrated water separator
minimizes the energy required to reach a certain air quality.
• Pressure dew point at 3°C on GA+ and GA VSD+ (100%
relative humidity at 20°C, 5°C on GA).
• The dryer’s global warming potential has been reduced by
44%. This not only results from the refrigerant type R134a’s
environmentally-friendly characteristics, but also from the
smaller volume that is needed (valid for both GA+
and GA VSD+).
• Can be outfitted with optional UD+ filter,
allowing you to obtain the exact air quality you need for
your specific application (DD and PD for GA 15-26; UD+ for
GA 11+-30 and GA 15-37 VSD+).
ISO QUALITY CLASS* DIRT PARTICLE SIZEWATER PRESSURE DEW POINT GA **
WATER PRESSURE DEW POINT GA+ **
OIL CONCENTRATION
Pack unit 3.-.4 3 microns - - 3 ppm
Full Feature unit 3.4.4 3 microns +5°C, 41°F +3ºC, 37°F 3 ppm
Full Feature unit with Class 2 integrated filter 2.4.2 1 micron +5°C, 41°F +3ºC, 37°F 0.1 ppm
Full Feature unit with Class 1 integrated filter 1.4.1 0.01 microns +3°C, 37°F +3ºC, 37°F 0.01 ppm
* The table values are maximum limits according to the respective ISO quality class.** Water pressure dew point based on 100% RH at 20°C/68°F.
Integrated purityMany Atlas Copco compressors (Full Feature option) come with an integrated dryer that efficiently removes moisture, aerosols and
dirt particles to protect your investment. This quality air expands the life of equipment, increasing efficiency and ensuring quality
in your final product.
GA 15-26 GA 11+-30 GA 15-37 VSD+
Integrated filter Class 1 • • •Integrated filter Class 2 • • •Dryer bypass • • •Integrated oil/water separator OSD - • •Electronic Water Drains (EWD) on coolers •Air receiver drain EWD • - -Oil retaining frame - • •Motor space heater • - -Motor space heater + thermistors - • •Phase sequence relay •Tropical thermostat • • -Freeze protection • • •Heavy duty air inlet filter - • •Fan Saver Cycle - •Compressor inlet pre-filter - • •Rain protection - • •Main power isolater switch • • •Lifting device - • •Nema 4 & Nema 4X cubicle (under release) - • •Relays for ES100 sequence selector - • -Central control license 4 (ES4i) or 6 (ES6i) machines (on graphic) • • •Elektronikon® graphic controller* •Food-grade oil • • •Roto-Xtend duty oil • • •Energy recovery - • •Modulating control - • -High ambient temperature versions (55°C for pack, 50°C for FF) - • -Compressor duct power fan (under release) - - -Dryer Save Cycle - • •
TAILORED TO YOUR NEEDSSome applications may need or may benefit from additional options and more
refined control and air treatment systems. To meet these needs, Atlas Copco has
developed options and easily integrated compatible equipment providing the
lowest cost compressed air.
* Optional for GA 30. - : Not available : Standard • : Optional
TECHNICAL SPECIFICATIONS GA 15-26
GA 15-26 (FULL FEATURE)
GA 15-26 (STANDARD)
H1: 1832 mm, 72”H2 : 1220 mm, 48”L1: 1280 mm, 50”L2: 1904 mm, 75”W: 833 mm, 33”
H1: 1827 mm, 72"H2: 1220 mm, 48”L1: 1775 mm, 70”L2: 1904 mm 75"W: 833 mm, 33”
COMPRESSOR TYPE
Max. working pressureCapacity FAD* Installed motor power
Noise level**
Weight (kg)
WorkPlace WorkPlace Full FeatureWorkPlace
WorkPlace Full Featurebar(e) psig bar(e) psig l/s m³/h cfm kW hp dB(A)
* Unit performance measured according ISO 1217 ed. 4 2009, annex E, latest edition. ** Mean noise level measured at a distance of 1 m according to ISO 2151: 2004 using ISO 9614/2 (sound intensity method); tolerance 3 dB(A).
Reference conditions: - Absolute inlet pressure 1 bar (14.5 psi). - Intake air temperature 20°C, 68°F.
FAD is measured at the following effective working pressures: - 5.5 bar(e)- 7 bar(e)- 9.5 bar(e)- 12.5 bar(e)Maximum working pressure: - 13 bar(e) (188 psig)
COMPRESSOR TYPE
Maximum working pressureCapacity FAD* min-max Installed motor power Noise level**
Weight (kg)
WorkPlaceWorkPlace
WorkPlace Full Featurebar(e) psig l/s m³/h cfm kW hp dB(A)
* Unit performance measured according to ISO 1217, Annex C, latest edition.** Mean noise level measured according to ISO 2151/Pneuro/Cagi PN8NTC2 test code; tolerance 2 dB(A).
Reference conditions: • Absolute inlet pressure 1 bar (14.5 psi)• Intake air temperature 20°C, 68°F
FAD is measured at the following working pressures:• 7.5 bar versions at 7 bar • 8 bar versions at 8 bar• 10 bar versions at 9.5 bar • 13 bar versions at 12.5 bar
Pressure dew point of integrated refrigerant dryer of GA 11+ - GA 15+ - GA 18+ - GA 22+ - GA 26+ - GA 30 at reference conditions 2°C to 3°C, 36°F to 37°F.
GA 26+ - GA 30
GA 11+ - GA 22+H: 1475 mm, 58”L: 1255 mm, 49”W: 692 mm, 27”
H: 1475 mm, 58”L: 1255 mm, 49”W: 865 mm, 34”
LW
H
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COMMITTED TO SUSTAINABLE PRODUCTIVITYWe stand by our responsibilities towards our customers, towards the environment and the
people around us. We make performance stand the test of time. This is what we call –
DD-1 Desiccant Air Dryer Zeks Eclipse 400ZBA Blower Purge air Dryer with pre-pipied inlet coalescing filter & particulate after filter and by-passes.
A MODEL FOR EVERY NEED
ZEKS Eclipse desiccant dryers have been engineered fromthe ground up to include the most desirable operating andservice benefits. Each component has been selected to provide long-term durability as well as energy efficiency. Inaddition, Eclipse’s low profile design permits easy viewingof critical dryer indicators while allowing for easy access to all serviceable parts.
Three models are available to enable air treatment selectionto suit the requirements of each installation:
Your authorized ZEKS Distributor will help you select thebest dryer model to meet the application requirements andprovide the most favorable energy use profile.
• Heated & Heatless Regeneration Models–Designs for all drying requirements
• Options for Energy Savings-Minimize operating cost
• Low Profile Design-Reduces shipping costs and simplifies installation
• High Performance Valves-Reliable operation plus reduced maintenance
• Convenient Service Access-Minimizes maintenance time requirement
• Remote Communication Ready-Multiple communication options
• Comprehensive Warranty Coverage-Standard dryer warranty PLUS five years on flow valves and heater
RELIABLE PERFORMANCEINNOVATIVE DESIGNBefore compressed air is used in production, finishing orsensitive research or manufacturing processes, it must betreated to remove moisture and contaminants. Withoutproper treatment, air can damage tools and equipment,reduce productivity and adversely affect the quality of finishing processes and precision operations.
While the use of oil free compressors can reduce theamount of contaminants in a compressed air system, thecompression process itself causes concentrations of waterand airborne particulate to increase to harmful levels.ZEKS EclipseTM desiccant dryers effectively dry compressedair to extremely low moisture levels for use where the presence of even minimal amounts of moisture can not betolerated. In addition, with ZEKS Eclipse desiccant dryers,installations where compressed air piping is exposed toextremely low ambient temperatures won’t encounter thedetrimental effects of moisture that freezes inside compressed air lines.
www.zeks.com
DESICCANT AIR DRYERS
WARRANTY COVERAGE
1Moist compressed airenters dryer
4ZEKS particulate afterfilter protects
pneumatic tools and equipment
7Purge air flows counter-
current to regenerate thedesiccant media in the
offline (regenerating) tower, assisted by the
heat-of-adsorption
6A portion of dry purge air is directed to
the offline tower for
regeneration
8Moisture is exhausted to
atmosphere through muffler 2ZEKS coalescing prefilter
protects dryer
3Inlet flow valves automaticallydirect moist compressed air throughonline (drying) tower. As air passes overthe desiccant, the moisture is adsorbedby the desiccant. Heat is generated bythis removal of the moisture from the air(Heat-of-Adsorption)
5Dry air exits dryer for use
1Moist compressed air enters dryer
4ZEKS particulate afterfilter protects
pneumatic tools and equipment
7Purge air flows counter-current to regenerate the desiccant media in the offline (regenerating) tower
8Moisture is exhausted to atmosphere through muffler
2ZEKS coalescing prefilter
protects dryer
3Inlet flow valves automatically
direct moist compressed air throughonline (drying) tower. As air passes over thedesiccant, moisture is adsorbed by the media
5Dry air exits dryer for use
ECLIPSE TM DRYER OPERATION
ZPAmodels use a portion of dry,unheated compressed air to regeneratethe offline tower.
ZHAmodels use a smallamount of dry, heated compressedair to regenerate the offline tower.
ZBAmodels use air from a dedicatedblower that passes through a heater toregenerate the offline tower.
6A portion of dry purge air is directedthrough heater then into the offlinetower for regenerationH
EAT
ER
1Moist compressed air enters dryer
4ZEKS particulate afterfilter protects
pneumatic tools and equipment
7Purge air flows counter-current to regenerate the desiccant media in the offline (regenerating) tower
8Moisture is exhausted to atmosphere through muffler
2ZEKS coalescing prefilter
protects dryer
3Inlet flow valves automatically
direct moist compressed airthrough online (drying) tower.
As air passes over the desiccant, moisture is
adsorbed by the media5Dry air exits dryer for use
6Purge air is generated by blower anddirected through heater then into theoffline tower for regenerationH
EAT
ER
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ZPAHeatless RegenerationZEKS’ ZPA desiccant dryers are available in flow rangesfrom 90 SCFM to 5000 SCFM. ZPA dryers require the use of no more than 15% of the compressed air volume forregeneration of the desiccant beds. Standard ZPA dryersdeliver -40°F pressure dew point air. For critical applications,ZPA dryers can be equipped to deliver -80°F and -100°Fpressure dew point air. With the optional DPC™ Controller,dew points ranging from -40°F to +38°F may be selectedusing the SelectDry™ feature for increased energy savings.In addition, the DPC Controller’s PurgeMizer™ feature permitsthe user to reduce the amount of purge air for applicationswhere the dryer is operated below full flow conditions. All ZPA dryers are supplied as 115V-1Ph-60Hz.
STANDARD FEATURES:
Dependable Diaphragm Switching and Purge Valves:Non-lubricated valves engineered fortrouble-free operation. Design allowsfor higher flows with lower associatedpressure drop than alternate valves.Internal valve components are easilyaccessed for routine maintenance without disconnecting valves frompipework. ZEKS dryers are designedso that the switching valves fail “open”and the purge valves fail “closed”,insuring continuous air delivery even in the event of power loss.
Reliable Solid State Timer: Used onZEKS heatless dryers for over tenyears, this design and technologydelivers precise control over all switchingand purge valve functions.
Dryer Status Indication Lights:Standard NEMA 1 dryers feature lights to indicate Left and Right Tower operation and Power On.
Purge Pressure Gauge: Visual indication of purge reactivation flow rate.
High Strength Desiccant: Minimizes dusting, increasesafterfilter element life and is unaffected by liquid waterexposure.
Blue Moisture Indicator: Continuously monitors outletairstream for excessive moisture. Indicator turns from blueto gray in the presence of an elevated air moisture content.
Control Air Filtration: ZEKS ZTF™ particulate filter protectsdryer operating controls.
ASME Coded Pressure Vessels: Carbon steel towers constructed for 150 psig MAWP operation meet ASMESection VIII, Div. 1 requirements. Towers are sized to provide low air flow velocity and high contact time.
Tower Pressure Gauges: Indicate pressure within eachtower.
Pressure Relief Valves: Standard fire-rated relief valves per API RP-520. Optional flow-rated valves available.
Sound Attenuating Purge Mufflers: Large mufflers minimize noise and include built-in relief valves to enhance safety.
Accessible Fill and Drain Ports: Port locations on eachvessel enable easy service access for scheduled change of desiccant media.
Removable Stainless Steel Diffuser Screens: Evenly distribute air through desiccant beds.
1200ZPA in NEMA 4 configuration with Purge SaverTM, Failure-to-Shift Alarm and
High Humidity Alarm options
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www.zeks.com
WARRANTY COVERAGEON FLOW VALVES
Contact your ZEKS distributor for details
OPTIONAL FEATURES:
NEMA 4/DPC™ Package: This premium electrical packageprovides increased protection of electrical components aswell as enhanced digital dryer controls and displays andincludes the following features:
– NEMA 4 Electrical Enclosure: Type 4 enclosure protects against splashing, falling, and hose-directed water as well as severe external condensation.
– UL/ULC Panel: Electrical panel constructed in accordance with UL/ULC 508A.
– DPC Controller: PLC Controller with integrated keypad interface provides instant access to dryer performance controls. The DPC controller is specifically program-med to execute all valve switching functions as well as monitor dryer operation. This fully-featured controller includes the following:
• Backlit LCD Display: Permits viewing of critical dryer parameters in all lighting conditions.
• Human-Machine Interface (HMI): Integrated keypad provides user with access to all internal functions and selectable displays.
• MODBUS Compatible: A port permits connection of the controller to MODBUS-capable networks.
• Remote Alarm Contact
• Failure Code Storage
– DynOptic™Panel: Schematic depiction of dryer provides visual indication of current operating status including:
– Enhanced Dryer Operation Functions: ZPA dryers with the NEMA 4/DPC Package provide the following operating functions:
• SelectDry™– Permits user to select between -40°F, -4°F or +38°F pressure dew point air. Selecting a higher dew point means lower energy costs for applications that do not require consistent -40°F pressure dew point air.
• PurgeMizer™- PurgeMizer allows the user to reduce the amount of purge air used for regeneration. Settings ranging from 30% to 100% of purge flow in 10% increments may be selected. Ideally suited to low flow applications.
• PurgeSync™- PurgeSync permits operation of the ZPA dryer to “mirror” that of the main air compressor. When the air compressor either unloads or is turned off, PurgeSync automatically completes the current drying cycle and closes the purge valves until the compressor indicates the need for more air. For applications with downstream (dry) storage, ZEKS recommends the Downstream Purge Option, sold separately, to maximize PurgeSync effectiveness.
EclipseTM dryers have been engineeredto provide a high ratio of premium desiccant per SCFM of compressed air for high operating efficiency.
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Dew Point Display: Highly accurate monitoring of dryerdew point performance with an Aluminum Oxide-type moisture sensor. Pressure dew point reading is displayedon DPC controller screen. Should a high dew point condi-tion occur, a visual alarm will be activated. Requires DPCController.
Failure-to-Shift Alarm: Automatically monitors tower pressure for proper sequencing and operation of valves.Should a valve be out of position, a visual alarm will beactivated.
High Humidity Alarm: Accurately monitors humidity levelsof the compressed air. Should a malfunction occur and ahigh humidity condition exist, a visual alarm will be activated.
Moisture Load Control: Reduces purge air consumption bymonitoring moisture loading in both towers. During low airdemand periods or low water loading (i.e. dry ambient con-ditions) the purge valves remain closed while flow controlvalves cycle as normal. By keeping purge valves closed, asignificant reduction in purge air consumption can occur,with subsequent savings in operating costs. When the moisture loading increases, the purge valves will open and begin reactivation of both towers sequentially.
Downstream Purge: Enables dryer to use dry purge airfrom downstream storage, as well as from the drying tower.Use of downstream purge in conjunction with properly sizedstorage can reduce compressor starts when air demand is low.
-80°F and -100°F Dew Points: Specially designed dryersprovide extremely low dew point air for critical applications.
250 psig and 300 psig MAWP: High pressure dryer designfor applications above 150 psig.
Filter Packages: High quality, factory installed coalescing prefilter and particulate afterfilter packages are available in a wide variety of configurations. Filter packages, featuring ZEKS ZTF filters, are available with filter and dryer bypasses for ease of service.
ZHAHeated RegenerationZBAHeated Blower RegenerationZHA heated desiccant dryers include an external heater toheat dry purge air for regeneration. This allows the dryersto use 7% purge air – significantly less than is required forheatless pressure swing type dryers. Available in sizesranging from 150 – 8000 SCFM, ZHA dryers deliver -40°Fpressure dew point air for critical drying applications. ZHA dryers are designed for a Maximum Allowable Working Pressure (MAWP) of 150 psig and are provided in 460V-3Ph-60Hz electrical configuration.
ZBA heated blower desiccant dryers are provided with adedicated blower to provide purge air for regeneration.With this design, the dryer does not rely on the dry com-pressed air for regeneration. Instead, the blower directsambient air through an external heater, thereby regeneratingthe offline tower. Using no compressed air for purge meansmore air available for critical compressed air applications.150 – 8000 SCFM models are available with each delivering -40°F pressure dew point air. A MAWP of 150 psig and460V-3Ph-60Hz electrics are standard.
STANDARD FEATURES:
High Performance Switching & Purge Valves:Dryers are equipped with reliable Jamesburyhigh performance ball and butterfly valves.These non-lubricated valves are designedspecifically for high temperature applicationsand feature stainless steel internals and filledPTFE seats. Valves include double-actingpneumatic actuators.
NEMA 4 Electrical Enclosure: Provides protection of electrical components against falling or hose-directed water and severe external condensation. Enclosure is suitable for indoor and outdoor use.
DPC™ Controller and DynOptic™ Panel:PLC Controller with integrated keypadinterface along with a schematic repre-sentation of the dryer provide instantaccess to dryer performance controlsand visual depiction of current operatingstatus. The controller is specifically programmed to execute all valve switching functions as well as monitor dryer operation. This fully-featured panel includes the following:
– Backlit LCD Display: Permits viewing of critical dryer parameters in all lighting conditions.
– Human-Machine Interface (HMI): Integrated keypad provides user with access to all internal functions and selectable displays.
– DynOpticTM Panel: Schematic depiction of dryer provides visual indication of current operating status.
• Dryer On/Off Control• Dryer Alarm Annunciation/Cancellation• Heater Operation & Temperature Control• High Heater Temperature Alarm Indication• Heater Failure Alarm Indication• Blower Operation Control (ZBA Only)• Left/Right Tower Drying Indication• Left/Right Tower Regeneration Indication• Failure-to-Shift Alarm Indication• Regeneration Sequence Status
Failure-to-Shift Alarm: Automatically monitors tower pressure for proper sequencing and operation of valves and provides visual indication of alarm condition.
Bi-Mode Operation: ZEKS’ Bi-Mode provides systemredundancy should a heater (ZHA & ZBA) or blower (ZBAonly)- related failure occur, keeping potential downtime to a minimum. Should the heater and/or blower become inoperative, the Bi-Mode feature allows the dryer to beswitched to a heatless pressure swing operating mode.
150ZBA in standard configurationand 500ZHA with factory
installed filters
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OPTIONAL FEATURES:
High Humidity Alarm: Accurately monitors humidity levelsof the compressed air. Should a malfunction occur and ahigh humidity condition exist, a visual alarm is activated.
Moisture Load Control with Dew Point Display: Providesfully automated dryer operation based on continuous moni-toring of outlet air moisture content. Timing of the dryerregeneration sequence is adjusted to match the moistureloading on the dryer. Includes dew point display, highlyaccurate Aluminum Oxide dew point sensor and high dewpoint alarm.
Compressed Air Cooldown (ZBA Only): For blower purgedryer applications requiring tighter dew point control andlower air temperature at switchover. Control and pipingconfiguration uses unheated, dry compressed air for thefinal stage of regeneration, thereby cooling bed prior totower switchover.
Power Saver: Reduces energy consumption by matchingthe regeneration heating cycle to the actual moisture loadingof the regenerating bed. A sensor monitors the temperatureof the outlet purge air stream and stops the heater when full regeneration of the offline tower is detected. Especiallyeffective during times of low moisture loading.
Filter Packages: High quality, factory installed ZTF™coalescing prefilter and particulate afterfilter packages areavailable in a wide variety of configurations. Available withfilter and dryer bypasses for ease of service.
-100°F Dew Point (ZHA Only): Specially designed dryers provide extremely low dew point air for critical applications.
300 psig MAWP: High pressure dryer design for applicationsabove 150 psig.
AccuTemp™ Heater Control: Innovative Solid State Relayheater control. Unlike heater contactors that permit wideswings of heater temperature, ZEKS’ AccuTemp™ controllerprecisely monitors and controls heater temperature.
The result is longer valve life and extended heater life.
Incoloy Sheath External Heater: Heaters include Incoloysheath for increased element life. External mounting outsideof desiccant bed eliminates potential for desiccant scorchingwhile low watt density design provides long, reliable service life.
Heater High Temperature with Interlock Alarm: Providescontinuous monitoring of heater sheath temperature. If thesensor indicates a high temperature condition, the heater isde-energized and an alarm routine is initiated.
High Efficiency Blower (ZBA Only): Blowerprovides quiet, reliable operation. Intakefilter is positioned for convenient accessto facilitate filter element changeout.
Pressure & Temperature Gauges:Stainless steel temperature and pressuregauges, located on each tower, providevisual indication of pressure and temperature during the drying and regeneration processes.
High Strength Desiccant: Minimizes dusting, increasesafterfilter element life and is unaffected by liquid waterexposure.
Control Air Filtration: ZEKS ZTFTM particulate filter protectsdryer operating controls.
ASME Coded Pressure Vessels: Carbon steel towers constructed for 150 psig MAWP operation meet ASMESection VIII, Div. 1 requirements. Towers are sized to provide low air flow velocity and high contact time.
Pressure Relief Valves: Standard fire-rated relief valves per API RP-520. Optional flow-rated valves available.
Sound Attenuating Purge Mufflers: Large mufflers minimize noise and include built-in relief valves to enhance safety.
Accessible Fill and Drain Ports: Port locations on eachvessel enable easy service access for scheduled change of desiccant media.
Removable Stainless Steel Diffuser Screens: Evenly distribute air through desiccant beds.
RELIABILITY&
INNOVATION
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DESICCANT AIR DRYERS
395oF
390oF
385oF
380oF
375oF
370oF
365oF
360oF
355oFAccuTempTM Control Thermostat and Contactor
WARRANTY COVERAGEON FLOW VALVES
AND HEATERContact your ZEKS distributor for details
Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication wasapproved for printing. The company reserves the right to change specifications, discontinue models, equipment or design withoutnotice and without incurring obligation. The information set out in this brochure is for preliminary information only and is not intendedto constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.
ZPA/ZHA/ZBA-1207-DBO
Performance data obtained and presented in accordance with CAGI Standard 200. Pressure dew point (PDP) at 100 psig, 100oF inlet air, 100oF ambient air.Pressure vessels are designed and constructed in accordance with ASME and CRN requirements.Maximum working pressure is 150 psig.Minimum working pressure is 75 psig.Desiccant is factory-installed on models 90-2700 ZPA and 150-2100 ZHA/ZBA.Desiccant ships loose on all other models.
* ** Dimensions shown are for base models only. Optional equipment mayalter dryer dimensions. Dimensions and weights are approximate. All ZPA dryers are supplied as 115V-1Ph-60Hz.All ZHA and ZBA dryers are supplied as 460V-3Ph-60Hz.CF = Consult Factory
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TM ZBA 150-8000 V0615
TECHNICAL MANUAL
COMPRESSED AIR SOLUTIONS
ZBA HEATED BLOWER PURGE150-8,000 SCFM
ZEKS Compressed Air Solutions
1302 Goshen ParkwayWest Chester, PA 19380
Phone: 610-692-9100800-888-2323
Fax: 610-692-9192
Web: www.zeks.com
NOTICE
Those operating the machine or performing maintenanceshould read and understand the decals positioned on themachine and the contents of this Technical Manual.Ensure that this Technical Manual is not removed permanently from the machine.
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DD-1 Desiccant Air Dryer Zeks Eclipse 400ZBA Blower Purge air Dryer with pre-pipied inlet coalescing filter & particulate after filter and by-passes.
TABLE OF CONTENTSPAGE
1. INTRODUCTION 2
2. ABBREVIATED WARRANTY 2
3. HEATED BLOWER DRYER NOMENCLATURE 3
4. RECEIVING AND INSPECTION 4
5. SAFETY AND OPERATION PRECAUTIONS 5
6. PRINCIPLES OF OPERATION 8
7. ALARMS AND INDICATORS 17
8. TECHNICIAN MODE 21
9. INSTALLATION/INITIAL START-UP 30
10. MAINTENANCE AND SYSTEM CHECK 35
11. TROUBLESHOOTING 39
ATTACHMENTS
A. GENERAL ARRANGEMENT DRAWING
B. WIRING DIAGRAM
C. P & ID DIAGRAM
D. ENGINEERING SPECIFICATIONS
E. PARTS LIST
ZBA HEATED BLOWER PURGE150-8,000 SCFM
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1. INTRODUCTION
ZEKS Eclipse™ Blower Purge Desiccant Dryers are designed to adsorb moisture from
compressed air. The dryers are constructed with two towers, each containing desiccant
beads, that alternate between on-line (drying) and offline (regenerating) modes, yielding
a continuous stream of dry air at the dryer’s outlet.
During normal operation, wet air passes through the on-line tower and water vapor from the
air is adsorbed (collected) on the desiccant beads. While air is being adsorbed in the on-line
tower, the moisture on the desiccant in the offline tower is removed by a process called
desorption (regeneration). In standard blower purge operation, after an initial rapid depres-
surization, air from a blower on the dryer skid passes through a heater and over the desiccant
bed and carries the moisture off the bed and out the dryer’s exhaust. With the dryer’s Bi-Mode
feature, the dryers may also be operated in a Heatless mode, which uses dry compressed
air as the purge air source but does not require use of the heater or blower.
The continuous, alternating process of adsorption and desorption is controlled using a
Programmable Logic Controller that switches the towers in a specific timed sequence. Very
dry compressed air dew points are achieved through the continuous switching and operation
of this dryer.
2. ABBREVIATED WARRANTY
ZEKS Eclipse™ blower purge desiccant dryer products are warranted to be free from
defects in material and workmanship for a period of 12 months from the original date of
shipment from the factory. To allow the warranty to be in effect for 12 months from the date
of equipment start-up, the Warranty Registration Card must be completed and returned to
ZEKS. Alternately, the Warranty Registration Card may be completed on-line at www.zeks.com.
The total warranty period cannot exceed 18 months from the original date of shipment from
the factory.
Equipment must be installed and operated in accordance with ZEKS’ recommendations.
ZEKS liability is limited to repair of, refund of purchase price paid for, or replacement in kind
at ZEKS’ sole option, during the warranty time period stated above. IN NO EVENT SHALL
ZEKS BE LIABLE OR RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,
even if the possibility of such incidental or consequential damages has been made known to
ZEKS Compressed Air Solutions. In addition, the usual maintenance and replacement type
products are not covered by this warranty.
The warranties expressed above are in lieu of and exclusive of all other warranties. There
are no other warranties, expressed or implied, except as stated herein. There are no implied
warranties of merchantability or fitness for a particular purpose, which are specifically
disclaimed.
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3. HEAT REACTIVATED DRYER NOMENCLATURE
NOMINAL
FLOW
SCFM* TYPE / DESIGN SERIES ELECTRICAL POWER OPTIONS
150 ZBA = Blower Purge 4 = 460-3-60 ( -40°F pdp)
200 D = 460-3-60 (-100°F pdp)
250 5 = 230-3-60 ( -40°F pdp)
300 E = 230-3-60 (-100°F pdp)
400 6 = 575-3-60 ( -40°F pdp)
500 F = 575-3-60 (-100°F pdp)
600
800
1000
1200
1500
1800
2100
3000
4000
5000
6000
8000
H = NEMA 4, 150 psig
E = NEMA 4, 300 psig
F = NEMA 4XF, 150 psig
J = NEMA 4XF, 300 psig
S = NEMA 4XS, 150 psig
U = NEMA 4XS, 300 psig
0 = Standard
P = Non Standard PLC
R = Remote START/STOP
E = Non-Fused Disconnect
F = Fused Disconnect
0 = Standard
B = High Humidity
M = Moisture Load Control
P = Power Saver
T = High Outlet Temp.
0 = Standard
3 = Tower Insulation
9 = SS Control Air Lines
G = INLET/OUTLET Temp.
and Press. Gauges
S = Steam Heat Reactivation
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4
4. RECEIVING AND INSPECTION
4.1 INSPECTION
Upon receiving your ZEKS air dryer, please inspect the unit closely. Visually check the
dryer to make certain that all air lines and electrical connections are securely fastened and
were not damaged in transit. If rough handling is detected, note it on your delivery receipt,
especially if the dryer will not be immediately uncrated. Obtaining the delivery person’s
signed agreement to any noted damage will facilitate filing of an insurance claim.
4.2 UNPACKING AND HANDLING
Refer to the General Arrangement drawing for the appropriate means for lifting or moving
the dryer. For those dryers that indicate lifting via the structural skid, forks should extend
all the way through the skid to reduce unnecessary forces to the dryer during moving.
When lifting the dryer, ensure that no stress is applied to the piping or valving. Refer to
SECTION 7.2 for locating and mounting of dryer.
Under no circumstances should any person attempt to lift heavy objects without proper
lifting equipment (ie.: crane, hoist, slings or fork truck). Lifting any unit without proper
lifting equipment can cause serious injury.
NOTICE
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The user of any air dryer manufactured by ZEKS Compressed Air Solutions is
hereby warned that failure to follow the above Safety and Operation Precautions
can result in personal injuries or equipment damage. However, ZEKS Compressed
Air Solutions does not state as fact, nor does it mean to imply, that the preceding
list of Safety and Operating Precautions is all inclusive, and further, that the obser-
vance of this list will prevent all personal injuries or equipment damage.
1. Only qualified personnel shall be permitted to
adjust, perform maintenance or repair this dryer.
2. Read all instructions completely before operating
unit.
3. Pull main electrical disconnect switch and discon-
nect any separate control lines, if used, before
attempting to work or perform maintenance on the
unit.
4. Do not attempt to remove any part while dryer is in
an operational mode.
5. Do not attempt to remove any parts without first
relieving the entire air system of pressure.
6. Do not operate the dryer at pressures in excess of
its rating.
7. Inspect unit daily to observe and correct any unsafe
operating conditions.
“Notice” is used to indicate a
statement of company policy as
the message relates directly or
indirectly to the safety of person-
nel or protection of property.
Notice should not be associated
directly with a hazard or haz-
ardous situation and must not be
used in place of “Danger,”
“Warning,” or “Caution.”
“Caution” is used to indicate a
hazardous situation which may
result in minor or moderate injury.
“Warning” is used to indicate a
hazardous situation which has
some probability of death or
severe injury. Warning should
not be considered for property
damage accidents unless person-
al injury risk is present.
OSHA Heading
Description
5. SAFETY AND OPERATION PRECAUTIONS
5.1 PRECAUTIONS AND MARKINGS
Because an air dryer is pressurized and contains mechanical parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in
operation or maintenance is hazardous to personnel. In addition to the many obvious
safety rules that should be followed with this type of machinery, the safety precautions
as listed below must be observed:
NOTICE
CAUTION
NOTICE
WARNING
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5.2 SAFETY CONSIDERATIONS FOR DRYER INSTALLATION
ZEKS ZBA series blower purge desiccant dryers are designed to regenerate the towers in
an up-flow configuration. The heated regeneration air is exhausted from the tower through
a dedicated full flow purge exhaust valve that is provided for each tower. The exhaust
valves are located on the upper manifold and are positioned to discharge the hot regener-
ation air stream vertically above the dryer.
During the regeneration cycle, the temperature of the air exiting the valve and the surface
temperature of the tower undergoing regeneration & the associated purge piping will
exceed 200°F. The regeneration cycle may last up to 3.75 hours during a normal cycle.
The following safety considerations must be taken into account by the customer during the
installation process:
Proper ventilation:
The unit shall be installed in an area with sufficient means to properly exhaust the heat
emitted during the regeneration process. This is required in order to prevent unnecessary
heat build-up during unit operation. The installer shall be responsible for ensuring the ven-
tilation system complies with building codes that are recognized both nationally and locally.
Heated surfaces during regeneration process:
Additional field installed provisions such as additional insulation may be field provided for
the vessels and purge piping to safeguard against hot surface contact during unit opera-
tion. Proper training must be provided to on-site personnel by the installer and equipment
owner.
Purge Exhaust Vent Lines (Optional):
The left and right tower full flow purge exhaust valves can be vented to an external loca-
tion. This can be accomplished via a field supplied and installed piping system. The exter-
nal piping system will aid in minimizing the heat load on the space during the regeneration
cycle. The following must be taken into consideration for this option:
• The exhaust valves for each tower can be piped into a common header or be piped
separately.
• All exhaust risers should have a drip leg to collect condensate. A ball valve must be
provided to allow the condensate to properly drain and not collect within the piping.
The ball valve should be rated for this temperature.
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• The piping must be sized appropriately in order to prevent additional pressure drop to
the blower and the piping shall be properly rated for the temperature of the regenera-
tion exhaust airstream. The temperature of the air exiting the full flow purge valve will
exceed 350°F near the end of the regeneration step. Plastic piping cannot be used
for this application.
The blower is not designed to incur additional pressure drop due to external pip-
ing. The length of the external piping shall be kept to a minimum and it must be
sized such that the additional piping pressure drop will not exceed 0.1 PSI.
• Vertical pipe penetrations through a roof structure: Vertical pipes extending beyond
the roof shall be transitioned with an elbow and a section of horizontal piping (15 pipe
diameters) at a minimum to prevent water ingress back into the piping section. It is
recommended that the end section of the horizontal pipe be terminated with a 45
degree angle. An additional elbow can also be added to direct the outlet air down-
wards towards the roof.
• For pipe penetrations that extend horizontally beyond the building, the pipe should be
allowed to extend vertically above the roof line and vent onto the roof via a 90 degree
elbow. The exhaust piping shall never be piped to allow the exhaust air to be directed
to a ground location due to safety considerations.
Proper Personal Protective Equipment (PPE) should be worn in the vicinity of
compressed air equipment.
The equipment should only be installed and serviced by authorized personnel.
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6. PRINCIPLES OF OPERATION
6.1 INTRODUCTION
As described in SECTION 1, water vapor is removed from compressed air by diverting
air flow alternately between two towers filled with activated alumina desiccant. While one
tower processes the compressed air stream adsorbing water vapor, the opposite tower
regenerates by desorbing the water vapor and venting it to atmosphere.
ZEKS Blower Purge Dryers are equipped with ZEKS’ Bi-Mode feature. The DPC™
Controller provides the ability to select between blower purge or heatless regeneration.
Both blower purge and heatless regeneration methods are described in the following
sections. Refer to SECTION 8.2 for details on switching the dryers operation between
Blower Purge and Heatless Pressure Swing operation.
6.2 DRYING CYCLE
Saturated compressed air enters the dryer and is diverted to the appropriate tower by the
Inlet Flow Valves (Refer to the Process and Instrumentation Diagram). The Right Tower
Flow Valve is actuated to a closed position to prevent air flow from entering the regenerat-
ing tower. Simultaneously, the Left Tower Flow Valve is actuated to an open position allow-
ing air flow to the drying tower. During this time, the Left Tower Purge Valve is actuated to
a closed position, preventing the compressed air from venting to atmosphere. As the com-
pressed air flows through the desiccant material in the left tower at pressure, removal of
water vapor from the air stream begins to occur through adsorption. In the adsorption
process, the desiccant material draws water vapor out of the compressed air and “holds”
it until the left tower drying cycle is complete. Compressed air flows out of the tower for
delivery to the process use. The Outlet Flow Check Valves provide air flow diversion to
the outlet air connection of the dryer.
6.3 REGENERATION CYCLE
Previously adsorbed moisture removed from the process stream gets stripped or desorbed
from the desiccant material in the regeneration process. The first stage of regeneration is
tower de-pressurization. After the Inlet Flow Valves are switched to divert air flow away
from the regenerating tower, the Depressurization Valve opens and the tower will be
depressurized. Through depressurization, a significant portion of the previously adsorbed
water vapor is stripped off of the desiccant material and exhausted to atmosphere.
The DPC™ Controller must be in the OFF position prior to changing the mode
(blower / heatless) of the dryer. After the change is made and the DPC™ is subse-
quently turned ON, the dryer will be in the new mode of operation.
NOTICE
Any time the dryer is switched between two operating modes, care must be taken
to ensure the purge adjustment valve is adjusted correctly. Refer to the specifica-
tion sheet in this manual for proper gauge setting.
CAUTION
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6.3.1 Blower Purge Regeneration
In the blower mode, there is no dry compressed air used for regeneration. Ambient
air is drawn into the blower intake and then discharged through the purge heater
and through the regenerating tower. After tower depressurization, the heater and
blower operate for 3 hours, 44 minutes. The blower continues to operate for ten
minutes to cool the heater element.
6.3.2 Blower Purge Regeneration with Optional Compressed Air Cooldown
With the Compressed Air Cooldown feature, which uses a portion of dried com-
pressed air to cool the bed at the end of the regeneration cycle, the heater and
blower operate for 2 hours and 57 minutes. The blower continues to operate for
an additional ten minutes to cool the heater. The Repressurization Valve is then
opened, allowing dry compressed air to pass through the regenerating tower for
48 minutes.
6.3.3 Heatless Pressure Swing Regeneration
In the heatless mode, following depressurization, regeneration uses approximately
15% of the dry compressed air, expanded to atmospheric pressure to complete the
desorption process. As shown in the P & ID, the compressed air exits the drying
tower and a portion of the air flows through the Purge Adjustment Valve and the
Purge Orifice. Once the air has passed through the Purge Orifice, it expands to
atmospheric pressure and continues the regeneration process. Desorption occurs
as the desiccant releases water vapor into the regeneration air and is exhausted
through the Purge Valves. Note that in the Heatless Pressure Swing Mode, proper
setting of the purge flow is necessary to achieve optimum dryer performance.
Setting the purge flow too high will waste compressed air and if set too low, the
dryer will not achieve dew point performance. The purge adjustment manifold con-
sists of the purge adjustment valve, purge pressure gauge, and the purge orifice.
Manually adjust the purge adjustment valve until the reading on purge pressure
gauge matches the purge pressure setting listed on the specification sheet in the
front of this manual as well as the tag attached to the gauge.
6.4 TOWER REPRESSURIZATION
Upon completion of tower regeneration, and prior to changing the Inlet Flow Valve position
to switch towers, the regenerated tower must be repressurized.
Failure to repressurize prior to tower switchover will result in shocking the desiccant
material and cause premature desiccant dusting.
NOTICE
When operating dryer in standard Blower Purge mode, dryer may exhibit high dis-
charge temperatures at tower switchover (300°F) and dew point spikes (+20°F).
This is considered normal operation for this equipment. Operator must insure that
equipment located downstream of dryer be capable of tolerating these conditions.
NOTICE
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6.4.1 Blower Purge Repressurization
Three minutes prior to tower switch-over, the blower will be shut off and the Purge
Valves and Depressurization Valves will close. The Repressurization Valve will then
open, allowing air from the outlet of the dryer to pressurize the tower prior to switch-
over. During normal tower regeneration, the Repressurization Valve is closed, so that
the blower supplies the only source of regeneration air.
6.4.2 Blower Purge Repressurization with Optional Compressed Air Cooldown
Three minutes prior to tower switch-over, the Purge Valves and Depressurization
Valves will close. The Repressurization Valve will then open, allowing air from the
outlet of the dryer to pressurize the tower prior to switch-over.
6.4.3 Heatless Pressure Swing Repressurization
45 seconds prior to tower switch-over, repressurization is accomplished by closing
the appropriate Purge Valve and the Depressurization Valve. When the Purge Valve
closes, the regeneration air begins to pressurize the tower. In addition, the
Repressurization Valve opens, allowing additional air from the outlet of the dryer to
assist the purge air and to ensure adequate pressurization. During normal tower
regeneration, is held closed so that the only source of air for regeneration passes
through the purge adjustment assembly.
6.5 VALVES
Actuated valves are two-way valves that are switched using double acting actuators. Each
valve is actuated by a four-way Solenoid Valves as shown on the P & ID.
The Inlet Flow Valves are connected as normally open valves. When the dryer is de-ener-
gized, the solenoid valves for these valves supply air the “OPEN” port on the appropriate
valve actuator.
Purge Valves are connected as Normally Closed valves. When the dryer is de-energized,
the solenoid valves for these valves supply air the “CLOSED” port on the appropriate valve
actuator.
On 2,500 SCFM dryers and smaller, switching valves are provided as two-way normally
closed pilot air operated valves. Control air is supplied by solenoid valves in order to open
valves as required. On 3,000 SCFM and larger dryers, these valves are “Actuated Valves”
as described above and are operated by four-way Solenoid Valves.
Outlet Check Valves, as well as Purge Check Valves, are single direction check valves that
will allow flow in the direction shown on the P&ID but not allow flow in the opposite direc-
tion. Valve positions must be changed accordingly for the appropriate mode selected.
Actuated valves require 75 psi min. pressure for proper operation.
NOTICE
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6.6 CONTROLS
6.6.1 DPC™ User Interface
The DPC™ display provides the user with the operating parameters and their cor-
responding values. When power is supplied to the dryer, the DPC™ will illuminate
and default to the “Standby” mode, displaying the “Press ON” prompt.
The following illustration summarizes the keypad functions.
PRESS ON
BUTTONS
• ON
Initiates PLC program. Begins system monitoring and
On dryers equipped with both the Moisture Load Control option as well as Power Saver,
the dryer may be operated in an extended heating mode. In this mode, the heating cycle
is extended while the Moisture Load Control function prolongs the drying cycle. This feature
is particularly useful when operating the dryer with new desiccant. As described earlier in
this manual, new desiccant has the ability to adsorb more moisture than the dryer can
desorb in a fixed regeneration cycle. With the Extended Heating operation, the Moisture
Load Control feature can be used immediately without the need to age the desiccant. This
feature is provided only when the dryer is equipped with both the Moisture Load Control
and Power Saver options. To enable the Extended Heating mode, perform the following
keystrokes:
Depress the +/- button until the desired set point is
displayed. Pressing SELECT DISPLAY saves the
current selection.
Depress the SELECT DISPLAY button until the
EXTENDED HEATING screen is displayed.EXTENDED HEATING
OFFSELECTDISPLAY
+-
EXTENDED HEATINGON
8.8 POWER SAVER (OPTIONAL, BLOWER PURGE MODE)
On dryers equipped with Power Saver, the temperature of the purge exhaust is monitored
and displayed on the DPC™ Controller. After a tower switch-over, and at the beginning of
tower regeneration, the purge exhaust temperature will be relatively low (normally 90°F - 110°F).
The purge exhaust temperature will increase as desiccant regeneration progresses. As
nearly all of the previously adsorbed moisture is driven off of the desiccant, the exhaust
temperature will begin to rise. The timing for the temperature change will vary depending
on moisture loading on the towers. When the purge exhaust temperature reaches 195°F,
which indicates that the desiccant heating is complete, the DPC™ Controller will remove
power to the heater and subsequently the blower. On standard units, the towers will then
repressurize and remain repressurized until the tower switchover sequence is initiated. On
dryers with the optional Compressed Air Cooldown feature, the Compressed Air Cooldown
routine will commence. After cooling, the Purge Valves close and the Repressurization
Valve opens. The off-line tower remains pressurized until the tower switchover sequence
is initiated. Activation of the Power Saver feature is through the DPC™ Controller.
27
8.10 HIGH HUMIDITY ALARM (OPTIONAL)
8.10.1 Description and Activation
As described in SECTION 7.5, the High Humidity Alarm can be configured
in two ways. Without the Moisture Load Control / Dew Point Display option,
the High Humidity Alarm is triggered by a humidistat. When the dryer is
equipped with the optional Moisture Load Control / Dew Point Display fea-
ture, the dew point sensor transmits the dew point to the DPC™. Should
the outlet pressure dew point exceed the customer specified set point,
High Humidity Alarm will activate.
Depress the +/- button until the desired set point is
displayed. Pressing SELECT DISPLAY saves the
current selection.
Depress the SELECT DISPLAY button until the HIGH
HUMIDITY screen is displayed.HIHUMID ALARM:
OFFSELECTDISPLAY
+-
The following illustrates the method of activating the High Humidity Alarm
feature:
HIHUMID ALARM:ON
28
The High Humidity Alarm set point should not be drier than the Moisture Load Control
set point. Failure to do so will result in an alarm indication. ZEKS recommends setting
the High Humidity Alarm at least 10°F wetter than the Moisture Load Control setpoints.
NOTICE
8.10.2 Setpoint Adjustment
On dryers equipped with the optional Moisture Load Control / Dew Point
Display, the High Humidity Alarm setpoint can be adjusted as follows. Note
that on dryers equipped with the High Humidity Alarm but not the Digital Dew
Point Display, manipulating these values will have no effect on the High
Humidity Alarm operation.
To enter a negative number, depress the +/- button.
Otherwise, proceed to the next step.
Depress the SELECT DISPLAY button until the HIGH
HUMIDITY SET POINT screen is displayed.SELECTDISPLAY
+-
The following illustrates the method of adjusting the setpoint for the High
Humidity Alarm feature:
Depressing ENTER saves the selected set point.
SETPressing the SET button permits the value of the HIGH
HUMIDITY ALARM SETPOINT to be changed
ENTER
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the MLC setpoint.2
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the HIGH HUMIDITY
ALARM setpoint.
1
HIHUMID SETPOINT-20°F (-28°C)
HIHUMID SETPOINT- °F (-28°C)
HIHUMID SETPOINT_20°F (-28°C)
HIHUMID SETPOINT-2 °F (-28°C)
HIHUMID SETPOINT-21°F (-28°C)
HIHUMID SETPOINT-21°F (-29°C)
29
When the Program Jog is initiated in the middle of the heating cycle, advancing the
program without allowing normal tower cool down will result in an outlet air tempera-
ture that may exceed 300°F. As such, proper precautions must be taken to protect
downstream equipment from high temperature exposure.
During the Program Jog routine, the display may show intermediate steps in the
program that are not active in the current program set up. This should be considered
normal operation.
NOTICE
Depress the SELECT DISPLAY button until the JOG
MODE display appears. The WAIT prompt will appear
should the program not be able to advance at this stage.
SELECTDISPLAY
Depress the SELECT DISPLAY button until the JOG
MODE display appears. The PRESS ENTER prompt will
appear, along with the current step and remaining time,
should the program be able to advance at this stage.
JOG: ENT TO JOGSTEP 6 TIME10699
8.11 PROGRAM JOG
All Eclipse heated purge and blower purge dryers come equipped with a Program Jog
feature that is accessible via the DPC™ Controller. This feature allows the dryer cycle to
be accelerated for troubleshooting and routine inspection purposes. By accessing the
Program Jog routine in the DPC™, the customer can advance the program to the next
program step. Note that the program advance feature will not advance through all steps
of the program
To exit the TECHNICIAN MODE, press the “Select Display” key to the initial “SET
OPMODE” screen or “BEGIN TECHNICIAN MODE” screen and depress the � button
to return to the CUSTOMER MODE
NOTICE
Should the program be at a stage whereby the DPC™ permits the jog feature, the following
will be displayed:
Depressing the ENTER button advances the program to
the next step. The display will indicate the next step has
been initiated.
JOG MODESTEP 8 TIME00550
ENTER
The DPC™ Controller will only permit the jog function during specific stages of the program.
Should the program be at a stage where the program can not advance, the following will
be displayed:
The Program Jog advances steps #6, #8, #20 & #22, which are the longest program
steps. The balance of the steps are not advanced in Program Jog Mode.
NOTICE
WARNING
JOG: WAITSTEP 4 TIME 0
30
The standard dryer is not rated for any gas other than air.
9. INSTALLATION AND START-UP
9.1 APPLICATION AND CHECK ANALYSIS ZEKS ECLIPSE Regenerative air dryers are shipped complete with desiccant up to and including model 2100ZBA. On larger units, the desiccant is packaged separately for ease in handling. Refer to SECTION 10.6 for desiccant fill procedures.
To achieve the best dryer performance, carefully check that the design and installationrequirements outlined below are satisfied.
ZEKS dryers are available with an operating range from 75 -150 PSIG. Air available for your usage will vary with operating pressure. The maximum design pressure of thestandard Eclipse Dryers is 150 PSIG. For units that require higher operating pressures,consult your ZEKS representative.
Dryers are sized according to flow and pressure drop, not pipe size. The difference
between the inlet and the outlet flow is the amount of purge air required. This air is
exhausted to atmosphere and is not available for use downstream. Make certain air
supply to dryer meets air demand plus purge air requirements.
9.2 LOCATING AND MOUNTINGThe dryer must never be installed where process air and/or ambient temperature exceeds 120°F or drops below 50°F. Locate dryer to avoid extremes of heat and cold from ambient or other conditions. If the dryer is exposed to ambient conditions below 50°F, dryer must be equipped with provisions for low ambient operation. Where applicable, dryer towers may be insulated to reduce heat loses. Avoid locating dryer outside or where it is exposed to the elements.
The dryer, or any air system component, must be located to avoid exposure to pulsation in the compressed air as well as possible surges due to fluctuating demand. In addition,care must be used to minimize exposure to vibration transmitted through mounting padsor piping.
Provide adequate space around the dryer for normal maintenance requirements and
service.
NOTICE
ZEKS recommends that the mufflers be cleaned after initial start-up to remove any
desiccant dust generated during shipment. After running dryer for initial 30 minute period,
de-energize / depressurize dryer and remove mufflers. Disassemble and clean the
removable insert inside the muffler core. Reinstall mufflers prior to operating dryer.
NOTICE
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If the dryer is shipped with the desiccant packaged separately, install the desiccant
after locating and mounting. Desiccant has been provided separately to minimize
handling difficulty and placing unnecessary stress on the dryer assembly.
Bolt the dryer to the foundation using the bolt holes provided in the base frame.
Anchor bolts should project a minimum of 3.5 inches above the foundation and allow
proper nut and washer assembly.
9.3 PIPING
Pipe the compressed air lines to the inlet and outlet connections. Locate the
prefilters as close as possible to the dryer. Ensure the positioning allows for ease
of servicing.
Note that the wet air inlet is located at the dryer’s upper manifold and the dry outlet air is
located at dryer’s lower manifold. In situations where air supply is required 24 hours a day
(it is undesirable to interrupt the airflow), a three-valve bypass system is recommended to
bypass the dryer. To keep pressure drop at a minimum, use the fewest elbows necessary.
Once all piping has been connected, all joints, including those on the dryer, should
be soap-bubble tested at line pressure to ensure no joints have been damaged in
transit and site placement.
9.4 FILTRATION
It is important that a prefilter and an afterfilter be provided in your dryer installation.
It is recommended that a mechanical separator be installed immediately preceding
the prefilter to remove the bulk liquid and entrained water.
Coalescing prefilters, located before the dryer, protect desiccant beds from
desiccant life. Locate prefilters as close to dryer as possible. FAILURE TO PROVIDE
AND MAINTAIN A HIGH EFFICIENCY COALESCING PREFILTER WILL VOID DRYER
WARRANTY.
Afterfilters, located after the dryer, help eliminate the possibility of desiccant dusting
carrying over into the air system.
All dryers must have proper filtration. Liquid water and oil must be removed before the
air enters the dryer. Ensure separators, prefilters and drains are in good working order.
Failure to do so will void warranty.
High temperature filters must be used to prevent rupture possibility in the event dryer
failure should occur. Consult your ZEKS representative for appropriate filter selection.
NOTICE
WARNING
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9.5 ELECTRICAL CONNECTION
Refer to wiring diagram for all electrical connections. Electrical connection must be
hard piped with an external fused disconnect switch with proper overload protection.
Size field connection knock-out for the conduit fitting required by the NEC.
Service wires must be sized according to the minimum circuit ampacity shown on
the dryer serial nameplate and the requirements of the NEC.
The power connections are marked L1, L2 and L3.
9.6 START-UP
• With dryer de-energized, slowly pressurize the dryer. When the dryer reaches full oper-
ating pressure, check the system for air leaks. Soap test all joints and fitting. To main-
tain desired dew point, any leaks detected must be repaired, especially those on the
outlet side of the dryer.
• Turn on dryer disconnect switch to apply power to the dryer.
• Verify all actuated valves are in their failsafe position.
• Using a voltmeter, check the power connections for the correct voltage shown
on the dryer serial nameplate
• Close and secure all electrical panel covers.
• Ensure that the purge adjustment valve is in the open position.
• The sequence will initiate proper Inlet and Purge Valve positioning and tower
depressurization.
Dryer must be grounded with the full sized ground wire connected to an earth ground.
Initial dryer start-up must be in the Blower Purge Mode
NOTICE
NOTICE
Once power is applied to the dryer and after a brief
initialization sequence, the PRESS ON prompt will
be displayed.
PRESS ON
Depress the ON button to initiate the dryer program.
The DPC™ Controller will display the first CUSTOMER
MODE screen
LT DRY RT REGENON
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• If the dryer has been in storage or off for an extended period of time, the Blue Moisture
Indicator may be gray, the High Humidity Alarm (if equipped) may be activated and the
Dew Point Display (if equipped) may indicate a high dew point. Depending upon the
duration of idle time, it may take anywhere from one to twelve hours for the alarm to
deactivate, the BMI to return to its normal blue state and dew point to drop.
• For dryers equipped with Moisture Load Control, refer to SECTION 8.6 regarding the use
of this option on new equipment.
9.7 SHUT DOWN PROCEDURES
The following procedures must be followed to properly shut down the dryer to avoid damage
to the unit and preserve dryer performance. The dryer requires compressed air to actuate
the valves. Removing the compressed air supply prior to shutting down the dryer will
result in improper valve positioning. In addition, the dryer must complete a specific
Shutdown Sequence prior to being turned off. Should power be removed from the dryer
or air pressure removed from the dryer prior to the completion of the Shutdown Sequence,
damage to the dryer may occur. Lastly, the inlet valves are configured to open on a loss
of power and the purge valves configured to close (fail safe). Should a valve open to a
depressurized tower, as would be the case if the dryer were stopped in mid-cycle, a rapid
pressurization will occur.
The force of repeated rapid pressurizations will damage the dryer.
NOTICE
Dryer should not be shut down during the heating cycle. Doing so may cause the
Heater High Temperature alarm to activate, which will require the user to manually
reset the Heater High Temperature safety in the control enclosure. If the dryer must
be shut down during the heating cycle, advance the program via the Program Jog
function (see SECTION 8.12) to the end of the heating cycle prior to initiating the
Shutdown Sequence.
CAUTION
On dryers equipped with Moisture Load Control (MLC), merely leaving the unit in
MLC without a compressed air supply is not advised, as it is likely that the system
pressure will decay over time. Should this occur, the unit will go into a FTS alarm as
well as risk misalignment of valves should switchover occur prior to reinstating the
air compressor.
NOTICE
34
For all Blower Purge Dryers that will be routinely shut down and restarted, ZEKS recom-
mends that an isolation valve be installed at the dryer outlet. Upon restarting the dryer, it
is likely that the pressure downstream of the dryer will have decayed. When starting the
dryer without the valve (or with the valve in the fully open position), the high velocities of
the air through the towers could damage the desiccant, as well as provide unprocessed
air down stream.
Shut Down Procedure:
• Maintain a compressed air source to the dryer and a supply of power
to the DPC™ Controller.
• Permit the dryer to complete the full SHUTDOWN SEQUENCE (90 seconds)
• De-energize the dryer
• Shut down air compressor or bypass dryer
• Close Isolation Valves (if equipped)
NOTE: On the subsequent Start-up, the outlet isolation valve should be in the
closed position. Slowly open the valve to build pressure downstream.
Prior to removing power or compressed air from the dryer, depress the OFF but-
ton on the DPC™. This initiates the Shutdown Sequence, which closes the purge
valves, repressurizes the off-line tower and opens the flow valves. DO NOT
REMOVE POWER OR COMPRESSED AIR FROM THE DRYER DURING THE
SHUTDOWN SEQUENCE.
NOTICE
Depress the OFF button to initiate the SHUTDOWN
SEQUENCE.SHUTDOWNSEQUENCE
OFF
Once the PRESS ON Prompt is displayed, the dryer has
completed the SHUTDOWN SEQUENCE. Power and air
may be safely removed from the dryer.
PRESS ON
35
10. MAINTENANCE AND SYSTEM CHECK
10.1 SCHEDULED MAINTENANCE
Daily Maintenance Functions:
• Check and record inlet pressure, temperature and flow.
Verify that it is within specifications.
• Check tower pressure gauge readings within operating tolerance.
• Check tower pressure gauges for proper dryer cycling.
• Check that prefilter condensate drains are functioning properly
• Verify that pressure in purging tower is 5 PSIG or less.
• Verify that prefilter and afterfilter differential pressure is within operating limits.
A filter with 0 psig pressure may indicate a damaged element.
Monthly Maintenance Functions:
• Check your operating conditions: inlet flow, inlet pressure, and inlet temperature.
• Check prefilter(s) and afterfilter(s) differential pressure and drains.
• Check dryer cycle and sequence of operations (i.e. drying,depressurizing,
regenerating).
Quarterly Maintenance Functions:
• Replace prefilter(s) and afterfilter(s) cartridges.
• Check pilot air filter element and replace as needed.
Semi-Annual Maintenance Functions:
• Check outlet dew point.
• Check amp draw on heater.
• Replace blower intake filter
Annual Maintenance Functions:
• Check desiccant and replace if necessary.
• Inspect and clean solenoid valves and check valves. Replace worn
or damaged seats and parts as required.
• Test lights and switches, replace as necessary.
• Test electrical components, replace as necessary.
• Check and repair any air leaks, loose bolts, flanges and fittings.
Every Two Years:
• Change check valves
• Change control solenoid valves
• Check and change temperature probes
Every Five Years:
• Replace desiccant.
Refer to SECTION 9.7 for the proper way to shut down the Blower Purge Dryer.
NOTICE
36
10.3 MUFFLER CHANGE-OUT PROCEDURE
• Turn control power off per shutdown procedures described in SECTION 9.7.
• Once the dryer has been depressurized, replace the muffler.
• Follow normal start-up procedures as described in SECTION 9.
Should the drying system be overloaded and/or malfunctioning causing high
pressure drop, afterfilters will prematurely plug. This problem can be avoided by
frequent inspection and cleaning of cartridges.
To avoid injury, depressurize dryer before performing any service
NOTICE
10.4 SOLENOID VALVES
Periodically clean all solenoid valves. Cleaning can be accomplished by removing
the solenoid, removing the mufflers and removing the valve bodies from the mani-
fold. Check and replace O-rings as necessary. If the solenoid valves fail to operate,
check the following:
• Control Circuit - Verify that the solenoid is receiving electric current.
• Burned out solenoid coil.
• High/low voltage - Voltage should be +/- 10% of nameplate readings.
• Solenoid valve leaking - Disassemble, clean and repack or replace.
10.5 PILOT OPERATED ACTUATOR
Should the actuator fail to rotate, disconnect the pilot lines to check if the actuator
is receiving pilot pressure.
If the actuator is receiving pressure:
• Verify that control pressure is 75 psig min.
• Ensure the inlet valve is not plugged.
10.2 PREFILTERS and AFTERFILTERS
Prefilter cartridges must be changed as often as required to prevent contamination
of the regenerative dryer’s desiccant bed.
Prefilter drains must be checked daily. Failure to drain condensed liquid from the
sump of the filter housing will result in carry over and damage to the desiccant
material. Afterfilters are used to prevent desiccant dust particulate contamination
from migrating downstream into plant processes. Elements should be changed as
pressure drop increases to an undesirable level.
WARNING
37
10.6 DESICCANT CHANGEOUT PROCEDURE
• Eclipse™ dryers are furnished with fill and drain ports on each desiccant tower.
Remove the caps on both ports.
• To assist in getting the desiccant to flow from the tower, insert a small rod in to the
drain port as necessary. This may be required as the desiccant is packed into the
towers which may interfere with the desiccant flow from the towers.
• Retainer screens, located at the inlet and outlet piping connections of the tower, are
removable on all models. It is suggested that these screens be removed and cleaned
at the time of desiccant changeout. These screens can be accessed by disconnecting
the upper and lower manifolds from the dryer towers.
• After cleaning the retainer screens, replace screens and reattach the outlet port plug.
• With the fill port plug removed, fill the dryer tower with the appropriate grade and size
desiccant. The level and grade of the desiccant should be consistent with the Desiccant
Fill Chart.
• Once the towers have been filled, replace the fill port plug on each tower.
• Any connections disturbed in the desiccant changeout process should be leak tested
prior to re-commissioning the dryer.
To avoid injury, depressurize dryer before performing any service.
Be sure to wear respiratory protection during the draining and filling process to mini-
mize inhalation of desiccant, as desiccant will produce dust during this procedure.
CAUTION
Desiccant quantity, positioning and grades must match the corresponding values in
the Desiccant Fill Chart. Failure to do so may result in poor dryer performance.
CAUTION
WARNING
38
DESICCANT FILL CHART
39
Check purge flow settings.
Check purge piping for obstruction.
Clean purge piping and muffler.
Check pressure source.
Check flow rate and cause for
increased demand.
Check aftercooler, clean and service
as necessary.
Check air/moisture separator and
prefilter. Replace dryer desiccant if
necessary.
Install suitable prefilter. Replace dryer
desiccant.
Check flow rate and cause for
increased air demand.
Check pressure source.
Check inlet valve. Verify inlet valve
is closed to purging tower (0 PSIG
tower).
Check gauge against tower gauges
when in switching sequence.
Replace gauge as required.
Insufficient purge rate
Inlet air/gas pressure below
design condition.
Flow rate higher than design
condition.
Inlet temperature above design
condition.
Entrained water entering
desiccant bed.
Desiccant contaminated by oil.
Excessive flow rate.
Inlet pressure below design
condition.
Air is leaking across valve.
Improper calibration
Elevated dew point
Excessive pressure
drop in dryer
Excessive back pres-
sure in regenerating
tower (Above 5
PSIG).
Excessively high
pressure at the
purge gage (Blower
and Heatless Modes)
11. TROUBLESHOOTING
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
40
Check power input.
Check solenoid valve.
Check pilot air line. Check that control
air line filter is clean. Check regulator
setpoint.
Check switch. Open pressure: >65
psig; close pressure: <40 psig
Check purge valve and its solenoid
valve.
Check that repressurization circuit is
sending control signal.
Check solenoid valve. Repair and
replace if necessary.
Replace contactor.
Replace thermocouple.
Replace temperature control.
Contact ZEKS Distributor/Factory
No input power
Defective solenoid valve
No pilot air / Low pilot air
pressure
Defective pressure switch
Faulty purge valve
Purge valve does not open.
Purge valve stuck in closed
position.
Contactor stuck closed.
Defective thermocouple
Defective temperature control
Valve switching failure
Failure to Shift
(Switching Failure)
Failure to Shift
(Dryer fails to
pressurize.)
Failure to Shift
(Dryer fails to
depressurize.)
Heater High Temp.
Alarm (Heater runs
continuously)
Heat High Temp.
Alarm (Loss of flow
across heater)
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
The Heater High Temperature Alarm halts the DPC™ program. Prior to reinstating
dryer, note the position of all valves. This is critical in determining the possible
cause of the alarm condition.
NOTICE
To reset the Heater High Temperature Alarm, reset the DPC™ Controller using the
RESET button and manually reset the Heater High Temperature safety in the con-
trol enclosure.
NOTICE
41
INNOVATIVE COMPRESSED AIR SOLUTIONS
ZEKS Compressed Air Solutions
Web: www.zeks.com
Oil carryover from oil-lubricated compressors is common in today’s compressed air systems. Lubricant aerosols combine with water vapor that is present in the compressed air. When cooled in downstream equipment such as aftercoolers, dryers, filters and separators, the aerosols and vapors condense to form a liquid mixture that needs to be removed from the compressed air stream. The presence of lubricants in the liquid condensate may render it unsafe for discharge into surface water, sanitary sewers and wastewater treatment plants. Using absorption technology, ZEKS OS Oil/Water Separators remove over 99% of oil content (mineral, synthetic, semi-synthetic, and polyglycol 1) and stable emulsions from the discharged condensate. Replaceable filter element bags trap lubricants within the OS Separator but allow water to pass through. The conditioned water meets stringent EPA guidelines and conforms to State and local codes. Testing shows lubricant carryover in the separated water to be 10ppm or lower. Disposal as stated by local and State guidelines is necessary for only the oil soaked elements. The multi-tower units have no moving parts and require no electrical hookup. Seamless molded-plastic construction will not crack or leak while removable lids provide easy access for periodic element replacement. Units can remain in service during the simple element replacement procedure. A port for collecting samples for visual inspection of outgoing wastewater is conveniently located. Four OS models are available. Model selection is based on total air compressor capacity and lubricant type. Multiple sources of condensate can be connected simultaneously. Refer to the Technical Specifications chart to choose the model that meets or exceeds the total compressor volume (scfm). Installation requires positioning of the unit for collection of condensate from all sources, and connection to inlet and outlet piping. Effective In All Compressed Air Systems • Separates mineral, synthetic and semi-synthetic lubricants, stable emulsions and polyglycol • Requires no electricity • Receives condensate discharged by intelligent drains, timed solenoid drains, manual drains or float style drains • Easy to install and maintain • Operates with all makes of compressors
1 Special Polyglycol elements required for Polyglycol Lubricated compressed air systems. Polyglycol units denoted with ‘PG’ suffix on model number.
OS Oil/Water Separators Separate Lubricant Carryover From Air Treatment Condensate
See reverse side for Technical Specifications.
OS2501/OS2501PG
To conform to available space, the 3-tower OS 2501 can be configured in-line or at a right angle.
Inlet Connections: OS 300 (2) OS 751 (2) OS 1251 (4) OS 2501 (4)
H
W D
Stable Emulsions
Stable Emulsions
Stable Emulsions
OS 1251 separation capacity can be expanded at any time through addition of an OS EXT carbon finishing tower. Technical specifications, as well as installation and maintenance procedures then match those for the OS 2501.
1302 Goshen Parkway West Chester, PA 19380 Phone: 610-692-9100 Fax: 610-692-9192 Web: www.zeks.com
Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication was approved for reproduction. The company reserves the right to change specifications, discontinue models, equipment or design without notice and without incurring obligation. The information set out in this brochure is for preliminary information only and is not intended to constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.
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Installation & Maintenance Instructions
OSB Oil/Water Separators
GENERAL OPERATION The OSB Oil/Water Separator Series separates oil from condensate generated by compressed air systems. OSB Oil/Water Separators achieve separation of oil from condensate by directing the condensate through multiple separation stages. As condensate flows in to the OSB Oil/Water separator, oil is filtered out through multiple filtration elements. The first oil absorbing element has a clever saturation indicating feature, offering the user visual indication of operating status at a distance. The replaceable elements are designed to combine various types of absorption technologies resulting in less than 10 ppm oil residue values at the output stage. The final separation stage includes specially selected activated carbon that removes any contaminants that may remain following the two absorption stages.
SAFETY AND PROPER USAGE To ensure safe and long lasting operation of this product, the operator must comply strictly with the instructions enclosed herein. Non-compliance with instructions or improper handling of the product will void the product warranty! Usage of this product in conditions not specified in this Manual or that are contrary to the instructions provided is considered IMPROPER. The manufacturer will not be held liable for any damages resulting from improper use of the product.
SAFETY & WARNING INSTRUCTIONS
ATTENTION
• Observe valid and generally accepted safety rules when planning, installing and using this product.
• Take proper measures to prevent unintentional operation of the product or damage to it.
• Do not attempt to disassemble this product or lines in the system while they are under pressure.
• Always depressurise the compressed air system before working on the system.
It is important that personnel use safe working practices and observe all regulations and legal requirements for safety when operating this product. When handling, operating or carrying out maintenance on this product, personnel must employ safe engineering practices and observe all local health & safety requirements & regulations. International users refer to regulations that prevail within the country of installation. Most accidents that occur during operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. Often an accident can be avoided by recognising potentially dangerous situations. Improper operation or maintenance of this product could be dangerous and result in an accident causing injury or death. The manufacturer cannot anticipate every possible circumstance that may represent a potential hazard. The WARNINGS in this manual cover the most common potential hazards and are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by the manufacturer, he must ensure the product will not be damaged or made unsafe and that there is no risk to persons or property.
3
EXPLODED VIEW AND IDENTIFY ALL COMPONENTS DIAGRAM
Overflow Indicator Test Bottle Lid 2 Absorption Element 2 Carbon Element Outlet Port OSB Housing Test Drain Supporting Bracket Service Drains (2X)
Element Indicator
Lid 1
Inlet Ports (2X)
Absorption Element 1
Depressurising
Pad
Inner Depressurising
Pad
Name Plate
Screws (3x)
4
INSTALLATION INSTRUCTIONS
IMPORTANT NOTICE
Before installing this product, make sure it complies with the
order and that it suits the application!
1. Unpack the unit and inspect it for transport damage. Do not install if damage is detected.
2. Depressurise the compressed air system before installation or maintenance of the ZEKS OSB Oil/Water Separator
3. Locate the OSB Oil/Water Separator within the compressed air system near a suitable waste water drain. The unit is designed to fit easily against a wall. Condensate collection pipe
4. Remove the lids from Tower 1 and Tower 2.
5
INSTALLATION INSTRUCTIONS
5. Remove the plastic bag that is placed on top of Absorption Element 2 inside Tower 2.
6. Remove the white Absorption Element from Tower 1 and Tower 2.
7. Connect condensate piping to the OSB Oil/Water Separator inlet(s).
8. Connect the OSB Oil/Water Separator Outlet Port to a suitable waste water point. Make sure the condensate always flows in a downward direction.
9. Before filling the unit with water make sure the Test Drain and Service Drains are closed. �
10. Fill the unit by pouring water into Tower 1 until both towers contain water and water flows out of the Outlet Port. Tip: To prevent carbon dust from spreading, spray water over the black Carbon Element in Tower 2 before filling the unit.
6
INSTALLATION INSTRUCTIONS
11. Make sure the black element rests on the bottom of the tower by pushing it down.
Push the element down until all trapped air is forced out of the Carbon Element.
12. When both towers are filled with water and the black Carbon Element is resting on the bottom of Tower 2, both white Absorption Elements can be put into position: tall element in Tower 1, short element in Tower 2.
13. Replace each lid on Tower 1 and on Tower 2. The lid on Tower 2 will force Absorption Element 2 into the correct position.
Make sure both lids are positioned and secured properly.
14. The OSB Oil/Water Separator is now fully operational.
7
SERVICE INSTRUCTIONS
OSB Oil/Water Separators require period replacement of the two Absorption Elements and the Carbon Element. When the top of the White Visual Indicator that normally protrudes above Tower 1 retracts to lid level, replace Absorption Element 1, Absorption Element 2 and the Carbon Element. (Refer to the dedicated Maintenance Instructions supplied with the Service Kit.) See REPLACEMENT PARTS list for Item Numbers. If the Red Visual Indicator that is normally retracted within the Tower 2 lid rises to become visible, check for blockage of flow downstream of the OSB Oil/Water Separator.
MAINTENANCE CHART
Date Description Name
8
TECHNICAL SPECIFICATIONS
Max. Oil Absorption Elements (Approximate element absorption capacity)
Inlet Connections ½” (2x) Outlet Connections 1” Test Valve Yes Service Drain Yes (2x) Element Life Indicator Yes Overflow Indicator Yes Housing Material PE Total Recyclable Yes Housing Color Black Lid Color Gray Mineral Lubricants Yes Synthetic Lubricants Yes Stabile Condensate Emulsions Yes Polyglycol Yes (consult factory) Max. Air Compressor capacity (Based on a single 8-hour shift)
OSB175 – up to 175 SCFM OSB350 - 176 to 350 SCFM OSB750 - 351 to 750 SCFM OSB1250 - 751 to 1250 SCFM
REPLACEMENT PARTS Order Replacement Elements based on OSB Model Number. Replacement Element Kits include: Pre-Absorption Element #1, Pre-Absorption Element #2, Carbon Finishing Element. Pre-Absorption Pre-Absorption Carbon Finishing Replacement OSB Model Element #1 Element #2 Element Element Kit OSB175 684743 684751 684759 684763 OSB175PG 684744 684752 684759 684764 OSB350 684745 684753 684760 684765 OSB350PG 684746 684754 684760 684766 OSB750 684747 684755 684761 684767 OSB750PG 684748 684756 684761 684768 OSB1250 684749 684757 684762 684769 OSB1250PG 684750 684758 684762 684770
The EZDB 2 is a motorized ball valve drain that is designed to discharge highly viscouscondensate in compressed air applications at pressure ratings up to 720 psi. It has beenengineered specifically for use in compressed air systems and is reliable and simple to installand set-up for effective timed discharge of condensate. Valve OPEN and CLOSED adjustmentsare made through a touchpad on the front of the valve body. There are seven EZDB 2 models withfeatures that make them the ideal timed electric drain valve for many compressed air applications.
EZDB 2 Features:
• Microprocessor controlled• External touchpad controls• Programmable 10-cycle control• Remote contact connection• Anti-blockage protection of gear mechanism• LED indicates valve ON (OPEN)• LCD displays program CYCLE NUMBER• Manual TEST button• 720 PSI maximum pressure• Stainless steel ball; Nickel-plated brass valve• Power failure protection – battery back-up (batteries not included)• Weatherproof
Air compressor, air dryer, filter, and receiver performanceIs dependent on reliable drain valve operation.
Count on the EZDB 2 Motorized Ball Valve to dependablydischarge condensate from your compressed air system!
See reverse side for Technical Specifications.
jlreid
Sticky Note
Zeks EZDB-2 motorized Drain Valves for each Air Tank Receiver
EZDB 2Motorized Ball Valve
Technical Specifications
• Microprocessor controlled• External push-button controls• Programmable 10-cycle control
Interval time OFF (CLOSED) – 4 min. – 24 hrs.Discharge/ball rotation time ON (OPEN) – 7 sec. – 14 min./53 sec.
• Remote contact connection• Anti-blockage protection of gear mechanism• FPM O-rings and PTFE seals• Voltage: 115 VAC and 230 VAC; 50/60 Hz• ½” NPT connection size with ½” internal orifice diameter• Ball rotation: 180º in 7.5 seconds• Manual TEST button• 720 PSI maximum pressure• Stainless steel ball; Nickel-plated brass valve• Power failure protection – battery back-up (4, AA, 1.5V batteries not included)• Weatherproof
Model Connection WorkingNumber Size Voltage Pressure Weight
Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication was approved for reproducto change specifications, discontinue models, equipment or design without notice and without incurring obligation. The information set out in this brochuand is not intended to constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.
6.14”5.25”
2.72” 1.42
2.9
3.77
”5.
59”
6.30
”
1”
tion. The company reserves the rightre is for preliminary information only
”
jlreid
Highlight
TOP VIEW
REV
TYPE
DRAWING NOCHECKEDDRAWN
E22
A10333
TITLE
DMM
SIZE: B SHEET 1 OF 1
KAT
9/14/2016 10/10/2016
STOCK
VERTICAL AIR RECEIVER
ASME
CUSTOMER
(BUILT IN ACCORDANCE WITH LATEST EDITION OF SECTION VIII DIV 1 ASME CODE)
THIS DRAWING & SPECIFICATIONS ARE PROPERTY OF SPVG AND MAY NOT BE
COPIED, REPRODUCED, OR USED IN WHOLE OR PART, AS A BASIS FOR DESIGN
MANUFACTURE OR SALE WITHOUT PRIOR PERMISSION FROM SPVG.
E22 ISSUED
REV DESCRIPTION BY DATE
DESIGN INFORMATION
SPECIFICATION VALUE
DIAMETER O.D./I.D.
60 O.D.
MAWP 150 PSI AT 400°F
MDMT -20°F AT 150 PSI
CAPACITY APPROX 2000 GALLONS
SHIPPING WEIGHT 3503 LBS
CRN L6794.56801234T9YN
NOZZLE CHART
NOZZLE ID NPT SIZE
N1
1/4
N2 1
N3
1 1/4
N4 3
N5 6
N6 MANWAY
34
8
72
110
148
182
N4
N1
N3
N3
N3
N6
N5
N2
N5
11/16 X 1 1/2 SLOTS 4-PLACES
EQUALLY SPACED
ON A 43 13/16 DIA BC
46
jlreid
Sticky Note
AR-2 Air Receiver Dry Samual Pressure Vessel Model A10333-2000 GALLON VERTICAL ASME RECEIVER WITH 8" BASE RING, RATED AT 150 PSI. PROVIDE WITH SAFETY RELIEF VALVE AND PRESSURE GAUGE Kit PN# 2200/MCTK-19MHH150
GENERAL ARRANGEMENT400 & 500 ZBA
FILTER PACKAGE ''A''
510167
06/23/06SAJ
1 OF 1NTS
12.19
40.50
33.00
2.00 (TYP)
2.00 (TYP)
(4) .56'' O MTG. HOLES
HEATER INSULATION
OPTIONAL TOWER INSULATION(SHOWN THIS VIEW ONLY)
DPC CONTROLLER & DYNOPTIC PANEL(SEE DETAIL)
1) DRYER ON/OFF CONTROL2) DRYER ALARM3) HEATER OPERATION & TEMP CONTROL4) HIGH HEATER TEMP ALARM5) HEATER FAILURE ALARM6) LEFT/RIGHT TOWER DRYING7) LEFT/RIGHT TOWER REGEN8) FAILURE TO SHIFT ALARM9) REGEN SEQUENCE STATUS10) BLOWER OPERATION CONTROL11) HIGH HUMIDITY ALARM (OPTIONAL)12) MOISTURE LOAD CONTROL WITH DEW POINT DISPLAY (OPTIONAL)
DPC LCD DISPLAY
DESICCANT FILL PORT
TOWER PRESSURE GAUGE
TOWER TEMPERATURE GAUGE
DESICCANT DRAIN PORT
56.50
82.50
PURGE PRESSURE GAUGE
PURGE ADJUSTMENT VALVE
ELECTRICAL ENCLOSURENEMA 4
40.50
11.50
73.38
40.00
PILOT AIR SHUT-OFF VALVE
RELIEF VALVE
DEPRESSURIZATIONMUFFLER
DEPRESSURIZATIONVALVE
INLET FLOW VALVE
HEATER
2'' FPT AIR OUTLETCONNECTION
OUTLET FLOW VALVES
INLET PURGE CHECK VALVESL
C OF INLETL
2'' FPT AIR INLETCONNECTION
C OF OUTLETL
C OF INLETL
*NOTES: 1) MAXIMUM WORKING PRESSURE - 150 P.S.I. 2) SAFETY RELIEF VALVE SETTING - 165 P.S.I 3)PILOT AIR LINES NOT SHOWN FOR CLARITY 4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE'S LATEST REVISION.
PILOT AIR FILTER
BLUE MOISTURE INDICATOR
ZTF TYPE ''G''AFTERFILTER
20.81
27.50 @ 500 ZHA26.25 @ 400ZHA
FACE OF INLET
26.25
SIZE SCALE DWG NO REVSIZE
UNLESS OTHERWISE SPECIFIEDDIMENSION ARE IN INCHES
TOLERANCES ARE:
APPROVED
CHECKED
DRAWN
DATEAPPROVALS
MATERIAL
FRACTIONS±
DECIMALS .XX ± .50.XXX ±
ANGLE±
REV ECO DATE APPROVED
BSHEET
NOTICE: THIS DRAWING EMBODIES ACONFIDENTIAL PROPRIETARY DESIGNOWNED BY ZEKS AND ALL PATENTRIGHTS AND DESIGN AND CAN NOT BEALTERED IN ANY WAY. MANUFACTUR-ING THE SAME ARE EXPRESSLY RE-SERVED TO ZEKS. THIS DRAWING ISSUBMITTED UNDER A CONFIDENTIALRELATIONSHIP FOR A SPECIFIED PUR-POSE AND THE RECIPIENT HEREOF BYACCEPTING THIS DRAWING ASSUMESCUSTODY THEREOF AND AGREES NOTTO DISCLOSE ANY INFORMATION RE-GARDING IT TO ANY UNAUTHORIZEDPERSON OR TO INCORPORATE THISPROPRIETARY DESIGN OR THE SUB-STANCE OF IT EITHER IN WHOLE OR INPART IN ANY EQUIPMENT, NOR USE ITFOR THE MANUFACTURE OF ANYPARTS.