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ECLlPSpM DESICCANT DRYERS ZHA HEATED PURGE MODELS
TABLE OF CONTENTS
1. INTRODUCTION 2. ABBREVIATED WARRANTY 3. NOMENCLATURE 4 RECE
IVING AND INSPECTION 5. SAFETY AND OPERATION PRECAUTIONS 6.
PRINCIPLES OF OPERATION 7. ALARMSAND INDICATORS 8. TECHNICIAN MODE
9. INSTALLATION/INITIAL START-UP
10. MAINTENANCE AND SYSTEM CHECK 11 . TRQUBlESHOOTING
ATIACHMENTS
A. B. C D. E.
GENERAL ARRANGEMENT DRAWING WIRING OIAGRAM P & 1 0 DIAGRAM
ENGINEERING SPECIFICATIONS PARTS LIST
ZEKS Compressed A ir Solutions 1302 Goshen Parkway
West Chester, Pennsylvania 19380
PAGE
1 1 2 3 4 5
12 15 24 29 33
Class ~ Sub class SA LocatIOn A ~.9 Documontat:oo " Cert ;f,w
l") rl
610-692-9 100 800-888-2323 FAX 610-692-9192 VW"'NZEKS.COM
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1 INTRODUCTION
2.
ZEKS Ecl ipselM Hea! Reac!ivated Desiccant Dryers are designed
to adsorb moisture from compressed air. The dryers are cOrl$tructed
with two towers, each containing desiccanl beads, that alternate
between on-line (drying) and offl ine (regenerating) modes,
yielding a continuous stream of dry a ir atthe dryer's outlel.
During normal operation, wet air passes through the on line
tower and waler vapor from the air is adsorbed (collected) on the
desiccant beads. Whi le air is being adsorbed in the on-line tower,
the moisture on the desiccanl in the offline lower is removed by a
process called des-orption (regeneration) ln standard heat
reactivated operation, afler an initial rapid depres-surizalion , a
port ion of dried air from the on-line tower passes through a
heater and over the desiccant bed and carries the moisture off the
bed and out the dryer's exhausl. With the dryer's Bi-Mode feature,
the dryers may also be operated in a Heatless mode, which uses more
purge air but does not require use of the heater.
The continuous, alternating pro cess of adsorption and
desorption is controlled using a Programmable Logic Controller that
switches the towers in a specifie timed sequence. Very dry
compressed air dew points are achieved through the continuous
switching and operation of Ihis dryer. ZEKS offers heat react
ivated dryers to provide either -40' F or - 1 OO"F pressure dew
point ou! lel air.
ABBREVIATED WARRANTY
ZEKS Eclipse heat reactivated desiccan! dryer products are
warran!ed la be free from defects in material and workmanship for a
period of 12 months from the original date of shipment from Ihe
factory. To allow the warranly la be in effect for 12 months from
the date of equipment slart-up, the Warranty Registration Card must
be compleled and returned 10 ZEKS. Alternately, the Warranty
Registration Card may be completed on-line al W\VW.zeks.com. The
lotal warranly period cannot exceed 18 months from the original
date of shipment from the faclory.
Equipment musl be ins!alfed and operaled in accordance wilh
ZEKS' recommendations. ZEKS liability is limited to repair of,
refund of purchase priee paid for, or replacement in kind al ZEKS'
sole option, during the warranty time period stated above. IN NO
EVENT SHALL ZEKS BE LlABLE OR RESPONSIBLE FOR INCIDENTAL OR
CONSEQUENTIAL DAM-AGES, Even if the possibility of such incidental
or consequential damages has been made known 10 ZEKS Compressed Air
Solutions ln addition, the usual maintenance and replace-ment type
producls are nol covered by this warranty
The warranties expressed above are in lieu of and exclusive of
ail other warranlies. There are no other warrant ies, expressed or
implied, except as stated herein. There are no implied warranties
of merchantability or fitness for a particular purpose, which are
specifically dis-claimed .
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3. HEAT REACTIVATEp DRYER NQMENCLATURE
NOMINAL FlQW SCFM* TYPE { DESIGN SERIES
150 200 250 300 400 500 600 800 1000 1200 1500 1800 2100 3000
4000 5000 6000 8000
ZHA= HEAT REACTIVATED
He: NEMA 4, 150 psig Ee: NEMA 4,300 psig F= NEMA 4XF, 150 psig
Je: NEMA4XF, 300 psig S= NEMA4XS, 150 psig U= NEMA 4XS, 300
psig
1 0= STANDARD P'" NON STANDARD PlC R '" REMOTE START STOP E '"
NON-FUSED
DISCONNECT F'" FUSED DfSCONNECT
ElECTRICAL pOWER
4 = 460-3-60 (-40 F pdp) D = 460-3-60 (-100 F pdp) 5'" 230-3-60
(-40 F pdp) E '" 230-3-60 (-100 F pdp) 6'" 575-3-60 (-40 F pdp) F
'" 575-3-60 (-100 F pdp)
1 0- STANDARD B = HIGH HUMIDITY M '" MOISTURE lOAD
CONTROL P '" POWER SAVER T = HIGH OUTLET TEMP
0= STANDARD 3'" TOWER INSULATION
OPTIONS
9 '" SS CONTROL AIR U NES G '" INlET 1 OUTlET TEMP
2
AND PRESS GAUGES S '" STEAM HEAT
REACTIVATION
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4. RECEIVING AND INSPECTIQN
4.1 INSPECTION Upon receiving your ZEKS air dryer, please
inspect the unit closely. Visually check the dryer to make certain
that ail air lines and electrical connections are securely fastened
and were not damaged in transit If rough handling has been
detected, please note il on your delivery receipt, especial ly if
the dryer will not be immediately uncrated. Obtaining the delivery
person's signed agreement to any noted damage wil l facilitate any
insurance claim.
4.2 UNPACKING AND HANDLING Refer ta the General Arrangement
drawing for the appropriate means for lifting or moving the dryer.
For Ihose dryers thal indicale lifting via the structural skid,
forks should exlend ali lhe way Ihrough the skid to reduce
unnecessary forces to the dryer during moving. VVhen lifting the
dryer, ensure that no stress is applied to the piping or valving.
Refer 10 Section 7.2 for locating and mounling of dryer.
NOTtCE Under no circumslances should any person atlempt to lift
heavy objects wilhoul prop-er lifting equipment (ie. , crane,
hoist, slings or fork truck.) Lift ing any unit without proper
lifting equipment can cause serious in jury.
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5. SAFETY AND QPERATION PRECAUTIONS
Because an air dryer is pressurized and contains mechanical
parts, the same precautions should be observed as with any piece of
machinery of th is type where carelessness in operation or
maintenance is hazardous 10 personnel. In addition to the many
obvious safety rules that should be fol lowed with this type of
machinery, the safety precautions as listed below must be
observed:
1. Only qualified personnel shall be permitted to adjust,
perform maintenance or repar this dryer.
OSHA Heading Description
2. Read ail instructions completely before operating unit.
3. Pull ma in electrical disconnect switch and discon-nect any
separate controllines, if used, before attempting to wol1l or
perform maintenance on the unit.
'_''' "~ ,o_", r.n. ","ou._ w""'"' , .. ","'" prob ..,.,. 01 d
... ., '" " ",,,lnft.
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6. pRI NClplES OF OPERATION
6.1 INTRODUCTION As deSCfibed in Section 1, waler vapor IS
removed from compressed air by diverting air now allernalely
between two towers fille(! wilh aclivaled alumina desiccanl. While
one tower processes Ihe compressed air slream adsorbing waler
vapor, the opposite tower regenerates by desorbing the water vapor
and venting it 10 atmosphere.
ZEKS Heat Reactivated Dryers are eq uipped with ZEKS' Bi-Mode
feature. The OPC , .. Controller provides the ability 10 select
between heated or heatiess regeneration. Both heated and heatless
regenerat ion methods are described in the following sect ions.
Reler to Section 8.2 for details on switching dryer operation
between Heated Purge and Heatless Pressure Swing operation.
NOTICE The OPC TM Controlrer must be ln the OFF position prior
to changing the mode (heated purge 1 heatless) 01 the dryer. Aller
the change Is made and the OPC '" is subsequently tumed ON, the
dryer will be in the new mode of operation.
6.2 DRYING CYCLE Salurated compressed air enlers the dryer and
is diverted to the appropriate lowar by the Inlet Flow Valves.
(Refer to the Process and Instrumentation Diagram.) The Right Tower
Flow Valve is actuated to a closed position 10 prevenl air now Irom
entering Ihe regenera!-ing lower. Simultaneously, lhe left Tower
Flow Valve is aeluale
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6.3.1 Setting the Regeneration Air Flow Proper sett ing of the
purge flow is necessary ta achieve proper dryer performance in the
heatless and exlernally healed modes. Setting the purge f10w tao
high will waste compressed air and if set 100 low, the dryer wil l
nol achieve dew point per-formance. The purge adjustment manifold
consists of the purge adjustment valve, purge pressure gauge, and
the purge orifice. The purge pressure gauge is located between the
purge adjustment valve and purge orifice. Manually adjust the purge
ad just me ni valve until the reading on purge pressure gauge
matches the purge pressure sett ing listed on the specification
sheet in the front of this manual as weil as the tag attached to
the gauge. Note that there are two purge gauge values
cor-responding with each mode of operation.
6.3.2 Heated Purge Regeneration ln the heal reactivaled mode,
the process described in section 6.3.2 is repealed using 7.5% of
dry compressed air expanded 10 atmospheric pressure. However, after
air expansion through the Purge Orifice, the purge air is passed
through the purge heater. This expanded, heated purge air is then
passed through the regener-aling tower and exhausted out to
atmosphere. Afler a three minute delay, the heat-ing process occurs
for 2 hours and 57 minutes. During the heating process the electrie
heater is cycled on and off by ZEKS' AceuTemp Solid state relay.
This advaneed control ler precisely monitors purge air tempe rature
and adjusts the heater temperatu re accard ingly. This results in a
regeneration air temperature that remains w ithin 3 oF from the
heater setpoint for the entire regeneration cycle, elimi-nating
temperature swings assoeiated with contactor-based heating system.
Upon complet ion of the three-hour heating period, the e lectric
heater turns off. The dry regeneration air continues to flow for 57
minutes in order ta cool down the desie-cant bed.
6.3.3 Heatless Pressure Swing Regeneration ln the heatless mode,
following depressurization , regeneration uses approximale-Iy 15%
of the dry compressed air expanded 10 atmospheric pressure ta
complete the desorption process. As shown on the P & ID, the
compressed air exits the dry-ing tower and a portion of the air f1
0ws through the purge adjustment valve and the Purge Orifice. Once
the air has passed through the Purge Orifice, il expands la
atmospheric pressure and continues the regeneration process.
Desorption occurs as the desiecant releases waler vapor into the
regeneration air and is exhausled Ihrough the Outlet Purge
Valves.
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.
Repressurizat ion is accomplished by closing the appropriate purge
valve. Closing the Purge Valve allows the regeneration air to
pressurize the lower.
NOTICE Failure 10 repressurize prior ta IOlVer switchover will
result in shocking the desiccant material and cause premature
desiccant dusting.
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6.4.1 Heated Purge Repressurization Three minutes prior to tower
switchover, repressurizat ion is accomplished by clos-ing the
appropr iate Purge Va lve. When the Purge Valve closes, the
regeneration air begins to pressurize the tower. If the dryer is
supplied with the optional repres-surizalion piping , the
Repressurization Valve opens, allowing some additional air Irom the
outiet of the dryer 10 assis! the purge air and to ensure adequate
pressur-ization. Ouring norma l tower regeneration, the
Repressurization Va lve is held closed so that the only source of
air for regeneration passes through the purge adjustmen!
assembly
6 .4.2 Heatless Pressure Swing Repressurizal ion 45 seconds
prior to tower switch-over, repressurization is accomplished by
closing the appropriate Purge Valve. When the Purge Valve closes,
the regeneration air begins to pressurize the tower. If the dryer
is supplied with the optional repres-surization piping , the
Repressurizat ion Valve opens, allowing some addit ional air from
the outlet of the dryer ta assis! the purge air and 10 ensure
adequate pressur-izalion. During normal lower regeneralion, the
Repressurizat ion Valve is held closed so that the only source of
air for regeneration passes through the purge adjustment
assembly.
6.5 VALVES Flow and Purge Valves are wo-way valves that are
switched using air-operated double--acting ac!ua!ors. Each valve is
actuated by a four-way solenoid valve as shawn on the P &
ID.
NOTtCE Actualed valves require 75 psi min. pressure for proper
operation.
The Inlet Flow Valves are connected as normally open valves.
\Nhen the dryer is de-ener-gized, the solenoid valves for the Inle!
Flow Valves supply control air ta the 'open" port on the
appropriate valve actuator.
Purge Valves are connected as normally closed valves. \Nhen the
dryer is de-energized, the solenoid valves for the Purge Valves
supply control air 10 the "closed" port on the appropriate valve
actuator.
Oulle! Check Valves, as weil as Purge Check Valves are
single-direction check valves that w ill allow flow in the
direction shawn on the P & ID, but not allow flow in the
opposite direction.
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6.6 CONTROLS
6.6.1 OPCT'" User Interface The OPCw display provides the user
with the operating parameters and lheir cor-responding values.
\f\Ihen power is suppl ied to the dryer, the DPC w wi ll illuminate
and default to the 'Standby" mode, displaying the "Press ON"
prompt.
The fo llowing illustration summarizes the keypad funclions.
Fll)Ilre 1 OPC'" Control er
BUITQNS
0' tn itiates PLC program. Begin. system monitoring and valve
Gwitching lunctions.
0" Stop. PLC program Stops vaille switching fu nctions.
Initiates Shutdcwn Sequence. Opens Inlet Flow Vatveo Closes Purge
Vailles.
SELECT DISPlAY Aliows the user 10 = 11 Ihrough the ~.ailable
di.pla)'s. The last display seleded wil l rema;n displayed a. the
de/au lt display.
" Anows user to incasc sm pooint values Set point val_ ues cycle
th rough a fixed range. AI. n a~ow. "!lt",ing negatllle numbcr.; in
Technido n.
9 or 'blank" hcrlton AlklI", uscr 10 step b~C~W3rd$ 10 the
F't"ev,ous le.e l of the menu.
8
RESET Pressing on"" deaf'IT Permils the adjustment 01 p"famcters
in TECHNICtAN
ENTER Used 10 acepl changed pa",meters ~ nd set pooint val
.......
TEST Not used in Oesicmnt Dry"" app l;cnlion.
; Re.tricted l evel ~=.s br factory use onty.
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6.6.2 DynOptic Panel User Interface The OynOptic T" Panel
provides clear indication of dryer status via bright LED ind
icators. The following il lustrat ion summarizes the panel 's
features:
DryerON (G ;,,",),~
Let! Tower
"
Left Tower (Ye''''' Figure 2 - DynOplic"" P~oel
Tower
Heate, Operation
',~:,::,;;w" Drying ( Il
NOTE: ZEKS AccuTemp solid state temperature controller modulates
the heater repeat-edly during the heating cycle. Pulsating of the
heater LED will occur as a result and should be considered normal
dryer operation .
6.6.3 DPCT,", Display Parameters The DPCT,", Controller is
capable of displaying a number of system parameters in the default
CUSTOMER MODE. The following summarizes the parameters that can be
accessed by depressing the SELECT DISPLAY butlon from the DPC""'
Controller. (Note that sorne displays are optiona! and may not
appear on ail models):
Tower Status {LT DRY 1 RT REGEN or LT REGEN 1 RT DRY}: Provides
visual confirmation of tower dl)'ing and regenerating status.
Step Timer {ie STEP 4 TIME 120}: Information screen displaying
the current step in the program and the time remaining for the
displayed step.
Dew Point Temperature (OPTIONAL) - {DEW POINTTEMP: XX}: When
equipped with the optional Dew Point Display feature, provides
accurate display of dl)'er oullet pressure dew point
Heater status (HEATED PURGE MODE ONL Y) - {ON f OFF}: Indicates
thatthe heater is being given a signal to heallhe purge air
Heater Temperature (HEATED PURGE MODE ONLY) - {HEATER TEMP: XX}
Indicates the current temperalure of the healer.
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Purge Oullet Temperature (OPTIONAL) - {PURGE OUT TEMP}: When
equipped with the optional MLC, indicates the temperature of the
purge air.
Alanns {ALARM LIST - PRESS ENTER}: Depressing at th is prompt
per-mits viewing of current a larm status and alarm history, which
includes the time and date of the alarm occurrence.
Operating & Purge Times - {OPERATING TIMES - PRESS ENTER}:
Dep ressing al this prompt provides access to the operating and
purge hours of opera-tion.
Operating Mode {OPERATING MODE: HEATLESS f HEATED PURGE}: ZHA
dl)'-ers are capable of operating in Heated Purge and Heatless
Pmssure Swing modes. This display indicates mode of operation for
dryer.
Once the last screen is displayed, depressing the SELECT DISPLAY
butlon will return the display 10 the lop of the lis!'
6.7 TIMING SEQUENCE Ali t iming functions are performed by ZEKS'
DPCTIA Contro))er, an advanced micro PLC designed exclusively for
ZEKS Eclipse'" dryers. The DPC"" Controller is completely
pro-grammed at the factol)' and does not require any further
adjuslmenl. The standard timing cycle switches the Inlet Flow
Valve, which alternates the drying tower. At the same time as the
Inlet Flow Valve opens, the appropriate tower Purge Valve opens to
begin the purge flow generation. Once the pu rge regeneration flow
portion of the dl)'er cycle is complete, tower repressurization
begins as previously described.
6.7.1 Heatless Pressure Swing rimer Cycle ln the heatless
operating mode, the DPCT'" controls a ten-minute cycle. The tower
switch-over occurs every five minutes. Ten seconds after tower
switch-over occurs, the regenerating tower depressurizes and tower
regeneration occurs for four min-utes and 15 seconds. At that time,
tower repressurization begins.
6.7.2 Heated Purge Tlmer Cycle ln the externally healed
operating mode, the DPe T'" controls an eight-hour cycle. The tower
switch-over occurs evel)' four hours. Ten seconds after switch-over
occurs, the regenerating tower depressurizes for 50 seconds. After
depressuriza-tion, heated regeneration begins and extends for 2
hours and 58 minutes. The heating supply is turned off and the
purge air fiaI'.' continues for the next 58 min-utes. The purge air
supply during th is lime is used ta cool down the hot desiccant
After the cool down stage, a repressurization slage repressurizes
the offline tower for 3 minutes
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6.8 RESTART MODES The DPC TM Control ler includes a Shutdown
Sequence that is acl ivated when the dryer OFF butlon is depressed.
This feature positions the valves to their failsafe position and
resets the program and is the recommended method of shutling down
the dryer. When the dryer is subsequently energized, the dryer is
ready to run at the start of the program. Should, however, power be
eut to the dryer before the Shutdown Sequence has been init i-ated,
as would be the case from a power failu re, the dryer can be
configured to restart in one of Iwo restart modes. Note that access
to the settings to change the restart mode for the dryer are
located in the TECHNICIAN MODE. Refer to Section 8.8 for a
description of the restart-modes found in the TECHNICIAN MODE. Note
that when the dryer is shut down using the OFF butlon, the dryer
will require user intervention ta restart the dryer.
6.8.1 Manual Mode (ZERO) ZEKS dryers are shipped from the
factory in the Manual Mode. Afler power is re-supplied ta the
dryer, the user will be presented with the ' PRESS ON' display. The
valve switching and timing operations will only start once the ON
bulton is depressed. In this configuration, la restart the dryer,
the user must manually depress the ON button on the DPC's control
panel.
6.8.2 Auto Reslart Mode (LAST) ln this mode, the dryer w ili
re--start automatically once power is applied ta the dryer. In
TECHNICIAN MODE, th is operating mode is aclivated when the '
RESTART" prompt is set to "LAST". The OPcn .. will pick up where il
left off in the program once power is applied.
6.9 OPERATING TIMES ln the CUSTOMER MODE, the DPCru Controller
provides access ta the following operat-ing hours of the dryer:
"O"P5
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7.0 ALARMS AND INOICATORS
7.1 MOISTURE INOICATOR (Standard) The moisture indicator senses
a sample of the control air whlch is taken from the dryer oulle!.
The indicator provides a gross indication of dew point
deterioralion at the oulle! of the dryer. Under normal operating
conditions, the indicator is blue. In the event of a dryer
malfunction or prolonged dryer shut down, it wililum gray in the
presence of moisture.
7.2 HEATER HIGH TEMPERATURE ALARM WlTH INTERLOCK (Standard) The
Heater High Temperature Alarrn monitors the internai temperatu re
of the heater hous-ing. Should a component fa ilure occur or system
conditions result in the heater tempera-ture rising aboya the alarm
set point, the dryer wi ll alarm. Ouring the alarrn condition, the
healer is prevented from operating. the OPC'M halls the program at
the point where the alarrn occurred and d isplays lhe condition in
the OPC'" LCD display. The dryer will be unable 10 be resel
untillhe temperature of the heater has fallen below the alarrn
poin!. To reinstate the dryer, depress the RESET button on the
OPC'" Controller ANO manually resel the Heater High Temperature
Safety in the electrical enclosure. Note that the alarm condition
will return should proper correct ive action not be taken.
7.3 HEATER FAILURE ALARM (Standard) This feature produces an
alarrn should the heater failto generate heat atlhe beginning of
the heating cycle. Ouring the initial ten minutes of the heating
cycle, the OPC '" Controller monilors the heater temperature.
Should the heater temperature fail 10 rise to 150 OF within the ten
minule period, the Heater Failure Alarm will he trlggered. During
this alarm
cond~ion, power to the heater is removed and the program is
halted. Oepresslng the RESET butlon on the OPC '" COfitroller wi ll
reinstate the program and provided the heater problem has been
remedied, continue with normal operation.
7.4 FAILURE TO SHIFT ALARM (Standard) ZEKS Failure To ShiflAlarm
monitors the dryer sequencing functions to insure proper dryer
operation by sensing the pressure in each lower via tower pressure
switches. Should one of the following conditions occur, the OPC'"
Cootroller will communicate the alarm condition. There are several
types of switching failure modes that can be detecled by the
Failure To Shift Alarrn feature. They are as follows:
7.4.1 Failure 10 Repressurize At the end of the repressurization
stage of the dryer operation, both lowers should be at line
pressure. Should the pressure switches indicale that both towers
are not at line pressure, the Failure to ShiftAlarm will activate
and the OPC'" will stop the program at ifs current position in the
program. The user must depress the RESET button at which time the
OPC~" Control!er will resume operation from the last step in the
program.
7.4.2 Failure 10 Oepressurize At the end of the depressurization
stage of the dryer operation, the regenerating tower should be al
atmospheric pressure. Should the pressure switches indcate thal
this is not the case, the Failure to Shifl A1arm will activate and
the OPC'''' will stop the program at ifs current position in the
program. The user musl depress the RESET button at which time the
OPC TM Conlroller wi ll resume operation trom the last step in the
program.
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7.5 HIGH HUMIOITY ALARM (Optional) The High Humid ity A larm
communicates an alarm condition in the event that outlet dew point
deterioration occurs. One of tv.Ia maisture sensars are used ta
sample the outlet air moisture content. VVhen a dl)'er is provided
withaut Moisture Load Control' Oew Point Display option , a
humidistat w ith a re lative humidity sensor is preset 10
communicate a High HumidityAlarm condition when the dew point rises
abave _1 0F (for -40 oF dl)'ers). Refer ta Section 8.10 for details
on enabling' disabling the High Humid ity alarm on dl)'ers equipped
wilh this feature.
When a dl)'er is pravided with Moisture Load Control' Dew Point
Display option, a dew point sensar is used ta delect this alarm
condition The dew point sensor transmits the outlet pressure dew
point ta the OPCT" Cantral ler. The OPC T" Controller compares the
dew point ta the custamer specified set point. Shauld the dew point
be greater than the set point, a High Humidity Alarm will be
initiated. Refer ta Section 8.10 for details on set-ting the High
Humidity Selpoint for dl)'ers equipped w ith the Moisture Load
Control' Oew Point Display feature.
7.6 HIGH OUTLET TEMPERATURE (Optianal) This option provides
continuaus monitoring of the the dryer discharge air temperature
via a thermostat tha! senses the outlet air temperature during
dryer operation. Shauld a high oullet temperature condition exist,
the ala rm is displayed on the DPC"" Cantroller ta aler!
maintenance personnel of a malfunction. This alarm does not
in!errupt the dryer p ro-gram. Oepressing the RESET button will
clear the alarm provided the alarm condition as been addressed.
Note Ihat the alarm will clear automatically once the high
temperature condition is corrected.
7.7 DEW POINT TRANSMITTER FAULT (Optional w! MLC) When operating
the dryer with the Moisture Load Control (MLC) activated , should
the OPC TM Cantral ler deteel a tault with the Oew Point
Transmitter, the Contraller will display the message, "ALARM - MLC
OFF' . When Ihis alarm indication appears, the MLC feature is
automalical ly disabled. Once the source of the fault is detected
and remedied, the user MUST REACTIVATE the MLC feature in TECHNIC
IAN MODE. Note that provided the High Dew PointAlarm feature has
been activated in TECHNICIAN MODE, depressing the RESET button
without remedying the prablem will display the message "OP SENSOR
FAUL T' after a brief delay. OtherNise, the dryer will continue to
operale in the standard timed drying cycle.
Note that with the MLC fealure off and the High Dew Point Alarm
activated in TECHN I-ClAN MODE, should the Controller delect a
fault \Vith the Dew Point Transmitter, the DPCTM Controller will
display the message, "OP SENSOR FAULT". As with the other alarms,
pressing RESET without addressing the source of the fau lt wil l
result in an new alarm after a brief delay
7.8 ALARM LIST The DPCTM Controller stores the 20 most recent
alarm cond itions. These alarms are stored with the type of alarm
as weil as the dale and time the alarm occurred . This list can
greatly faci litate troubleshooting the dryer and provide an
indication of dryer operation during unattended service. The
following describe the method to access and review the alarms
slored in the DPCTM Controller:
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(SELECT] 1
ALARM LIST 1
Oepresslhe SELECT DISPLAY buttoo....ml thotAl..ARM ~, PRESS
ENTER UST display appeat'S.
El 1 BEGIN ALARMS 1 Depress.,g the ENTER buItQn en1eN; the MARM
LIST ...... nu. ( SELECT]
1
ALARM OFF 1
Depressing th e SELECT OIS PLAY buHO
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8.0 TECHN ICIAN MOpE The DPC provides a protected TECH NICIAN
MODE to manipulate several parameters not accessible by the casual
operator. Below is a list of parameters that can be accessed and
manipulated by the technic ian in the TECHNICIAN MODE:
NOTE: Setpoints indicated are adjustable ONLY when dryer is
equipped w ith the Moisture Load Control' Dew Point Display option.
Setpoints are non-adjustable on dry-ers w ithout this option
8.1 ENTERING TECHNICIAN MODE
TECHNICIAN MODE should only be entered by qualified service
personnel Altering the sel points in TECHNICIAN MODE will have a
significanl effect on the operation of the dryer. Incorrect set
points may damage dryer and cause potenlial serious in jury.
To enter the TECHNICIAN MODE, perform Ihe following
keystrokes:
00 BEIjIN TECHNICIAN i'~ODE :;;;.~~ OPMuDE
HEATLESS
8.2 OPERATING MODE (BI-MODE)
Pre;~in g th" "2" and "3' butt""s simultaneously enters the
TECHNICIAN MODE.
Deprcsslflg SELECT DISPlAY scro lls throu gh the a.a il ~ble
p~rameter~ .
As described in Section 6, Eclipse ZHA Heat Reaclivated Dryers
come standard with the Bi-Mode feature, permining the dryer to
operate in a heated purge mode as weil as a heatless pressure swing
mode. To change the operation mode of the dryer, perform the
following keystrokes'
15
-
SET OPMODE HEATED PURGE
SET OPMODE HEATLESS
Dep
-
8.4 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE ONLY) The
DPCfl,IConlroller permils the user 10 adjusllhe lemperalure of the
heater, thereby allering lhe regeneralion temperature in the heated
purge mode.
The user is advised to only aller the regeneralion lemperature
after being inslrucled 10 do 50 by ZEKS factory personnel. Improper
or inappropriate manlpulalion of Ihe heater temperature can result
in degraded dryer performance, equipment damage and serious in
jury. Notify ZEKS Compressed Air Solutions prior 10 altering the
heater temperature.
The following il lustrates the method of adjusting the setpoint
for the heater temper-alure:
1
SET HTR TEMP . 375 0 F (190 0 C)
Depres$ the SELECT OISPLAY buItoo unti Ille HEATER TEMPERATURE
SET POINT..:reen ~
-
8.4 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE ONLY) The
DPCTMConlroller permits the user to adjust the lemperature of the
healer, thereby allering the regeneration temperature in the heated
purge mode_
The user is advised 10 only alter the regeneration tempe rature
afler being instructed to do so by ZEKS factory personnel. Improper
or inappropriate manipu lation of the heater lemperature can result
in degraded dryer performance, equipment damage and serious in
jury. Notify ZEKS Compressed Air Solutions prior to allering the
heater temperature_
The fol lowing illustrates the method of adjusting the setpoint
for the healer temper-ature:
~LEY DISPU.Y
G o o o ( '"'" 1
375',T/T~ I~0 c;. HTR TEl'lP SET
-375" F (1 '30 " C) HTR TEMP SET
3 oF
-
NOTICE On dryers equipped with the optional Moisture Load
Control feature, the PurgeMizer MUST be set to 100% in order for
the Moisture Load Control to operate properly.
8.6 MOISTURE LOAD CONTROL 1 DEW PO INT DISPLAY (OPTIONAL) The
Moisture Load Control { Dew Point Display option includes a dew
point sensor that transmits the outlet pressure dew point to the
DPCTM Controller. The DPC'" Controller displays the out let
pressure dew point in real-lime. This option package also includes
Moisture Load Control, an energy savings feature that matches
moisture load ing and regeneration energy usage. Drying equipment
is typically operated below full flow rating and/or below maximum
water loading capacity of the desiant bed . The Moisture Load
Control feature utilizes the data communicated from the dew point
sensor and exlends the normaltimed switching sequence in proportion
to the moisture loading on the dryer.
When the Moisture Load Contro l feature is turned off, ai l
switching sequences occur as described in Section 6.7. When the
Moisture Load Control feature is activated, the drying sequence is
governed by the outlet pressure dew point as measured by the dew
point sensor. When the sampled outlet dew point registers below the
customer set point (_43F default for _40F dryers; _1 02F on _100F
dryers), an immediate change in dryer opera-tion w ill not be
noticeable. The dryer will continue its normal regeneration process
through tower re-pressurization. Once the tower is re-pressurized,
both lowers wi ll be al line pres-sure but air will only f10w
through the tower indicated by the DynOptic'" Panel Tower switch
over sequence is delayed until the dew point elevales above the
Moisture Load Control setpoint, at which point tower switch over
will our.
NOTICE
New desiccant has a moisture holding capacity higher than the
dryer's design regen-eration capacity. The desiccant ages in a
three- to six- month lime period at which point it stabil izes to
an "aged" state. During this aging process at initial start-up or
after desiccant replacement, the Moisture Load Control feature
should be deactivated.
8.6.1 Enabling 1 Disabling Moisture Load Control
o
The following illustrates the method of accessing and adjusting
the Moisture Load Control feature:
MOI :::TURE LOAD CONTROL: OFF
CONTROL: ON
18
Depress the SELECT DtSPU\Y bunon until l ile MOtS TURE LOAD
CONTROL screen is displayed
Depre .. th e
-
8.6,2 Set Point AdJustment On dryers equipped with the optional
Digital Dew Point Display, the Moisture Load Control setpoint can
be adjusted to match the dryers requirements la the desired
pressure dew point. Note thal on dryers equipped with Moislure load
Control but not the Digital Oew Point Display, manipulaUng Ihese
val-ues will have no effect on Moislure Load Control operation.
The following illustrales Ihe method of adjusting the setpoint
for the Moisture Load Control fealure:
1 MLC SET POINT 1
. -43"F (-41"0 . r.;;l 1 MLC SET PO 1 NT 1 L.::..J . -43' F
(-41' C) .
O. l::::;;"';;:L;;C=S;;;T:::;;P;;:O;;IN;;T;=1 ~ OF (-41"C) , O 1
f>lLC SET POINT 1 - 4 OF (-410 . O MLC""", ~T -41 FL.
(:4~~IC> ( _] l_'1~L=-C~S_E_T-,--,P..::O_I N",T----,
. _ 41F (-40"C)
Depron tne SELECT QtSPlAY bu\t0)/'l u~lillhe MLC S ET POINT ~
III di$played,
Pre01;Oig the SET burton ~ lhII VIIlue Dl the MLC SETPOINT to be
thlllIQOd
To ente< Il negaIive ""mber, dep-en the . ,. button.
0Iherwise, proed 10 the ne.t Slep.
U", lhe nOOlI>llrs 0)/'1 the k8)'~d to ente< the
desire
-
8.7 POWER SAVER (OPTIONAL, HEATED PURGE MODE) On dryers equipped
with Power Saver, the temperature of the purge exhaust is monilored
and displayed on the DPCTM Controller. After a lower switch-over,
and allhe beginning of tower regeneration, the purge exhaust
temperature wi ll be re latively low (normally 90 10 110"F). The
purge exhaust temperature will increase as desiccant regeneralion
progress-es. As nearly ail of the previously adsorbed moisture is
driven off of the desiccanl, the exhaust lemperature will begin 10
rise . The timing for the temperature change will vary depending on
moisture loading on the lowers . When the purge exhaust lemperature
reaches 195"F, which ind icales that the desiccant heating is
complete, Ihe OPCTM Controller wil l remove power to the heater.
Once the heater is tumed off, Ihe tower cool down process begins
and continues for 57 minutes. Purge air will continue 10 exhaust
and the exhaust air tempe rature w ill cont inue to rise (25QoF is
not uncommon) as it removes the heat from the regeneraled desiccant
material. As the cool down progresses, the exhaust temperature wil
l beg in to decrease. After cooling. Ihe Purge Valves close and the
optional Repressurization Valve (if equipped) opens. The off-line
tower remains pres-surized unti l the tower switchover sequence is
initiated . Activation of the Power Saver feature S via the OPC T'"
Controller.
The following illustrates the method of accessing and activaling
Ihe Power Saver feature:
PuWER :jAVER: OFF
0 1 ~-----' PuWER ::;;AVER : ON 8.8 RESTART MODE
Depress the SELECT DISPLAY blJtton until the POWER SAVER sereen
Is displayed.
Dep",s.lhe +/. bull"" umil the desircd set point il;
dis-play"",. Pressing SELECT DISPLAY saves the CUITent
seleclioo.
ZEKS' Eclipse TM dryers can be configured to restart in one of
Iwo operating modes. As described in Section 6.8, the dryer rnay be
configured for Manual operation (fac-tory defaull) or Auto Restart,
which permits the dryer to operate automatically once power is
re-applied 10 the dryer afler a power fai lure. The following
illustrates the method of accessing and adjusting the differenl
start modes for the dryer:
REST ART : ZERO
De~r~" Ih~ SELECT DISPLAY butto~ ""Iii the START MODE screen is
displayM
O. l __ R_'E"C",",--'R,--'T_' __ . L A':;T Tc char>ge the
star! mode l,om its clment selection ta the allemate setting.
depress th
-
8.9 EXTENDED HEATING (OPTION Al) On dryers equipped with both
the Moisture load Control option as weil as Power Saver, the dryer
may be operaled in an extended healing mode. In Ihis mode, the
heating cycle is extended while the Moisture load Control function
prolongs the drying cycle. This fea-lure is particularly useful
when operating the dryer with new desiccant. As described earli-er
in this manual, new desiccant has the abi!ity ta 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
desic-cant. 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:
EXTENDEO HEATING OFF
o LI_EA_'T_E_N_D_E o:::D N~H_E_AT_I N_G-l 8.10 HIGH HUMIOITY
ALARM (OPTIONAl)
6.10.1 Description and Activalion
Oe~* \!MI SELECT OISPLAY bull"" un~11/MI EXTEIIO-EO HEATING
8Cl"Mn is cIit.pI.rTe1tC teledion.
As described in Section 7.5, the High Humidity Alarm can be
configured in two ways. Without the Moisture load Control f Dew
Point Display option, the High Humidity Alarm is triggered bya
humklistat. lNhen the dryer is equipped with the optional Moisture
load Control f Dew Point Display fea-ture, the dew point sensor
transmits the dew point to the DPC TU. Should the outlet pressure
dew point exceed the customer specified set point, High Humidity
A1arm will activale.
The foliowillQ illustrates the method of activatillQ the High
Humidity Alarm feature:
HIROMID ALARM OFF
o LI_H_I_H_O_M-=~cc~~,-A_L_A_R_M---,
21
Oep re$. lhe SELECT DISPLAY button uni, the HIGH HUMIOITY sa...,
i$ d"rsplflyed.
Depre the . /_ button unli the desir&d sel point i.
dis-play&d. Pressi "ll SELECT OISPLAY oavel lhe ",,"ent
selection.
-
8.10.2 Setpoint Adjustment On dryers equipped with the optional
Moisture Load Control 1 Dew Point Display, the High Humidity Alarm
setpoint can be adjusted as folfows. 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.
The following illustrates the method of adjusting the setpolnt
for the High Humidity Alarm feature:
1 HIHUMID SETPOINT 1
. _20 4 F (_28 C) .
r.;;l l_H=I H::O::M-,I_D---,S-,E::TP,-O-,I"N_T---,I t....::..J .
20F (-28C) .
O 1 HIHUMID SETPOINT : L ____ 0_F __ '_-2_8_0_C_)--" o H UM ID
:.:.ETP -2 OF (_28C) O 1 HIHUMID SETPOINT . -21F (-2S0C)
'---- - -----'
[ ~._~ J IL_H_IH::U,-M...:I_D--,-S..:T:.:P,-O-,I-=N_T--, ","'~ .
- 21F (_29C)
NOTICE
Depress!he SELECT DlSPlJ\Y botlon untiIlM HIGH HUMIDrTY SET
POINT Weetl il dlsplayed.
Pressing !he SET buIton p8m'111 the v_ of !he HIGH HUMIDrTY
ALARM SETPOINT 10 be changed
To enter a negative number, tlef>ren the .. ,. bu!ton
OIherwise , pr-oOO to the ne.t .Iep.
Use 111" numbers on the keypad 10 &nier the desireUse !he
nurrbers on !he keypad 10 enle< the d~ pressure dew pQnI
\enIpefahn lof the HIGI-l HUMIDITY
""'"'-
The High Humidity Alarm sel point should not be grealer Ihan the
Moisture Load Control set point. Failure 10 do so will resutt in an
alarm indication. ZEKS recom-mends settlng the High Humidity Alarm
at leasl 1 O~F wetter than the Morsture Load Control setpoints.
22
-
8.11 PROGRAM JOG Ali Eclipse heated purge and blower purge
dryers come equipped with a Program Jog fea-ture tha! is accessible
via the OPC T'" Controller. This feature allows the dryer cycle to
be accelera!ed for troubleshooting and routine inspection purposes.
By accessing the Program Jog routine in the OPC ..... , the
cus!omer can advance the program to the nex! program step. Note
that the program advance feature will no! advance through ail steps
of the program
When the Program Jog is initiated in the middJe of the heating
cycle, advancing the program without aUowing nOtmal tower cool down
will result in an oullet air tempera-ture that may exceed 300F. As
such , proper precautions must be taken to protect downstream
equipment from high temperature exposure.
NOTICE
Ouring the Program Jog routine, the display may show
intermediate steps in the pro-gram that are not active in the
current program set up. This should be considered normal
operation.
The OPC"" Controller will only permit the jog function during
speciftc stages of the pro-gram. Should the program be at a stage
where the program can not advance, the follow-ing will be
displayed:
JOG, WAtT STEP 4 TIME 0
DItp
-
9. INSTALLATION AND START-UP
9.1 APPLICATION AND CHECK ANALYSIS ZEKS ECLIPSE Regenerat ive
air dryers are shipped complete with desiccant up ta and including
model 2000ZHA. 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 installation requirements outlined below are
satisfied
ZEKS dryers are avai lable w ith an operating range from 75 -
150 PSIG. Air available for your usage w ill vary with operating
pressure. The maximum design pressure of the stan-dard Eclipse
Dryers is 150 PSIG For units that require higher operating
pressures, con-suit your ZEKS representalive.
Dryers are sized according ta 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 ta atmosphere
and is not available for use downstream. Make certain air sup-ply
ta dryer meets air demand plus purge air requirements.
NOTfCE The standard dryer is not rated for any gas other than
air.
NOTICE
ZEKS recommends that the mufflers be cleaned afler initial
start-up ta remove any des-iccant dust generated during shipment.
After running dryer for initial 30 minute period, de-energize /
depressurize dryer and remove mufliers. Disassemble and clean the
removable insert inside the muffler core. Reinstall mufflers prior
ta operating dryer.
9.2 LOCATING AND MOUNTING The dryer must never be installed
where air and/or ambient lemperature exceeds 120"F or drops below
+35F. Locate dryer to avoid extremes of heat and cold Irom ambi-ent
or other cond itions. If the dryer is exposed 10 ambient conditions
below 32F, protec-tion must be provided againsl condensation and
freez ing as described in SecUon 6.15. VVhere applicable, dryer
tower1> may be insulated ta reduce heat loses. Avoid locating
dryer outside or where it is exposed ta the el ements.
The dryer, or any air system componenl , must be located to
avoid exposure ta pulsation in the compressed air as well as
possible surges due to fluctuating demand. In addition, care must
be used to minimize exposure to v ibration Iransmitted through
mounting pads or piping.
Provide adequate space around the dryer for normal maintenance
requirements and serv-ice.
24
-
If the dryer is shipped with the desiccant packaged separately,
install the desiccant after locating and mounting. Desiccant has
been provided separately la minimize handling difficulty and
placing unnecessary stress on the dryer assembly.
Boit the dryer 10 the foundation using the boit holes provided
in the base frame. Anchor bolts should project a minimum of 3.5
inches above the foundation and allow prop-er nut and washer
assembly.
9.3 PIPING Pipe the compressed air lines ta the inlet and oullet
connections. Locate the prefilters as close as possible ta the
dryer. Ensure the positioning allows for ease of servicing
Note that the wet air inlet is located al the dryer's upper
manifold and the dry oullet air is Iocated at dryer's lower
manifold. In situations where air supply is required 24- hours a
day (it is undesirable ta interrupt the airflow) , a three-valve
bypass system is recommend-ed ta bypass the dryer. Ta keep pressure
drop al a minimum, use the fewest elbows nec-essary
Once a il piping has been connected ail joints, including those
on the dryer, should be soap bubble tested at line pressure ta
ensure no joints have been damaged in transit and site
placement.
9.4 FILTRATION Il is important that a prefilter and an afterfi
ller be provided in your dryer installation.
NOTICE
Ai l dryers must have proper fittration. Liquid water and oil
must be removed before Ihe air enlers the dryer. Ensure separalors
, prefilters and drains are in good working order. Fai lure la do
sa will void warranty.
It is recommended Ihat a mechanical separalor be inslalled
immediately preceding the prefllter ta remove the bulk liquid and
enlrained wate r,
Coalescing prefilters, located before the dryer, proteet
desiceant beds from contamination by ail , enlrained waler, pipe
scale, etc , thereby, extending dryer desiceant life. Locate prefi
llers as close la dryer as possible
Afterfi lters. located after the dryer, help eliminate the
possibility of desiccant dusting carrying over inlo the air
system.
High temperalure fillers must be used 10 prevent rupture
possibil ity in the event dryer failure should occur, Consult your
ZEKS represenlalive for appropriate filler selection.
25
-
9.5 ELECTRICAl CONNECTION Refer to wiring diagram for ail
electrical connect ions. Electrical connection must be hard piped w
ith an external fused disconnect switch w ith proper overload
protection.
Size field connection knock-out fo r the conduit fitting
required by the NEC.
Service wires must be sized according to the minimum circuit
ampacity shown on the dryer seriai nameplate and the requirements
of the NEC.
The power connections are marked L 1, L2 and L3.
NOTICE Dryer must be grounded w ith the full sized g round w ire
connected to an earth ground.
9.6 START-UP
NOTICE Initial dryer start-up must be in the Heated Purge
Mode
With dryer de-energized , slowly pressurize the dryer. When the
dryer reaches full oper-at ing pressure, check the system for air
leaks. Soap test ail joints and fitting. To main-tain desired dew
point, any leaks detected must be repaired, especially those on the
oullet side of Ihe dryer.
Turn on dryer d isconnect switch to apply power to the
dryer.
PRESS ON Once pOwer i$ applied to the dryer " 00 " fter" brief
in itiat i.zatiorl sequ",",,,,,. the PRESS ON prompt wig ""
dis-ptayed.
Verify ail actuated valves are in their failsafe position.
Using a voltmeter, check the power connections for the correct
voltage shown on the dryer seriai nameplate
Close and secure ail electrical panel covers.
Ensure that the purge adjustment valve is in the open
position.
El 1 LT DRY RT REliEN ! Depress the ON button 10 initiale lhe
dryer P"'9r1!1m The DPC 'M Coolroller wi~ display lhe fi rsl
CUSTOMER MODE screen
The sequence will initiale proper Inle! and Purge Valve
positioning and tawer depressur-ization.
26
-
. If the dryer h"s been in storage or off for an extended period
of time, the Blue Moislure Indicalor may be gray, Ihe High Humidity
Alarm (if equipped) may he acti-vated and the Dew Point Display (if
eQuipped) may indicale a high dew point Depending upon the duration
of idle lime, il may take anywhere from one to twelve hours for the
alarm 10 deactivale, the BMlio relum to its normal blue state and
dew point to drop .
. For dryers equipped with Molsture load Control, refer to
Section 8.6 regarding Ihe use of this oplion on new equlpment.
NOTICE -100 F dryers require flow through Ihe dryer 10 lower the
pressure dew poinl to design levels. Failure to permit air flow
through the dryer (dead-heading) will result in elevaled outJet dew
points. Once air is permittecl to flow through the dryer, the
pressure dew poinl will gradually reduce to design levels.
9.7 SHUT DOWN PROCEDURES
The following procedures musl be followed 10 properly shut down
the Heat React iv" ted Dryer to avoid damage to the unit and
preserve dryer performance. The dryer requires compressed air 10
"cluate the valves. Removing the compressed air supply prior 10
shul-ting down the dryer will resul! in improper valve positioning
. In addition, the dryer musl complete a specifie Shutdown Sequence
prior 10 being turned off. Should power be removed from the dryer
or air pressure removed from Ihe dryer prior 10 the completion of
the Shuldown Sequence, damage 10 the dryer may cccur. laslly, the
inlet valves are con-figured 10 open on a loss of power and the
purge valves configured to close (fail safe). Should a valve open
10 a depressurized lower, as would be the case if the dryer were
slopped in mid-cycle, a rapid pressurization will occur.
NOTICE The force of repeated rapid pressurizations wlll damage
the dryer.
NOTICE On dryers eQuipped wlth Moisl\Jre load Control (MlC),
merely leaving II"Ie unit in MlC without " compressed air supply is
nol advlsed, as it is likely that the system pressure will decay
over lime. Should Ihis occur, Ihe unit will go into a FTS alarm as
weil as risk misalignment of valves should swilchover occur prior
10 reinstating the " ir compressor.
27
-
CAUTION
Oryer shouklnot be shut down during the heating cycle. Ooing 50
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. 11) to the end of the heating cycle prior
to init iating the Shutdown Sequence.
For ail Heat Reaclivated Oryers that will be routinely shut down
and restarted, ZEKS ree-ommends that an isolation valve be
installed atlhe dryer oullel. Upon restarting the dryef, it is
likely tha! the pressure downstream of the dryer will have decayed.
V\lhen starting the dryer withoutthe valve (or w i!h the valve in
the fully open position), the high velocities of the air through
the towers could damage the desiccan!, as weil as provide
unprocessed a ir down stream.
NOTICE Prier 10 removing power or compresseShut Down
Procedure:
Mainla in a compressed air source to the dryer and a suppty of
power to the OPC .... Controller.
SHUTDOWN SEQUENCE
Depress the OFF bunon 10 niUale 'M SHUTOOWN SEQUENCE.
Permit the dryer to complete the full SHUTDOWN SEQUENCE (30
seconds)
PRESS ON
Oe-enorglze the dryer
Once the PRESS ON PrompI I displayed. the dtyer hM ~ted the
SHUTOOWN SEaUENCE. Power end air "'~y be sa!ely remoYed ' rom '
'''' clrrer,
Shut down air compressor or bypass dryer
Close Isolat ion Valves (if equlpped)
Note: On the subsequent Start-up, the outlet isolation valve
should be in the closed position. Slowly open the valve to build
pressure downstrearn.
28
-
10. MAINTENANCE AND SySTEM CHECK
10.1 SCHEOUlED MAINTENANCE Daily Maintenance Functions: o Check
and record inlet pressure, temperature and flow. Verify that it is
with in
specifications. o Check lower pressure gauge readings within
operating tolerance. o Check tower pressure gauges for proper dryer
cycling. o Check tha! prefiller condensale drains are functiooing
property o Verity that pressure in purging lower is 5 PSIG or less.
o Verity that prefilter and afterfilter d ifferen!ial pressure is
wilhin operating limits.
Monthly Maintenance Functioos: o Check your opera!ing
conditions: inlet flow, inle! pressure, and inle! !emperarure. o
Check prefilter(s) and afterfilter(s) differentiaJ pressure and
drans. o Check dryer cycle and sequence of operations (i.e.
drying,depressurizing, regen-
era!ing).
Quarterly Maintenance Functions: o Replace prefillar(s) and
afterfilter(s) cartridges . Check pilai air filler element and
replace as needed.
Semi-Annuel Maintenance Functions: o Check oullet dew point. o
Check amp draw on heater.
Annual Mainteoance Functions: o Check desiccant and replace if
necessary. o Inspect and clean solenoid valves and check valves.
Replace worn or damaged
seats and parts as required. o Testlights and switches, replace
as necessary. o Test electrical components, replace as necessary .
Check and repair any air leaks, Ioose bolts, flanges and
fittings.
Every Two Years : o Change check valves o Change control
solenoid valves o Check and change lemperalure probes
Every Five Years: o Replace desiccant.
NOTtCE Refer to Section 9.7 fot the proper way 10 shut down Ihe
Heat Reactivated Oryer.
29
- 10.2 PREFllTERS andAFTERFILTERS Prefilter cartridges must be
changed as often as require
-
10.6 DESICCANT CHANGEOUT PROCEDURE
To avoid in jury, depressurize dryer before perlorming any
service.
CAUTION
Be su re to wear respiratory protection during the draining and
filling process to mini-mize inhalation of desiccant, as desiccant
will produce dus! during this procedure.
Eclipse dryers are furnished wi!h fill and drain ports on each
desiccant tower. Remove the caps on both ports.
Ta assis! in getling 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 tow-ers 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 ail models. It is
suggested that these screens be removed and cleaned al the l ime 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
reatlach the outlet port plug.
With the fill port plug removed, fi ll the dryer tower wi\h the
appropriate grade and size desiccant. The level and grade of the
desiccant should be consistent with the Desiccant Fill Chart.
CAUTION
Desiccant quantity, positioning and grades must match the
corresponding values in the Desiccant Fill Chari. Failure to do sa
may result in poor dryer perlormance.
Once the towers have been fi lled, replace the fill pori plug on
each tower.
Any connections disturbed in the desiccant changeout process
should be leak tested prior to re-commissioning the dryer.
31
-
1>,ll", ~,-,." 'Mo" Gl,OO"
lWI""iZ'" -,- .:. . 00."- ,....,- , .. ". ,.=. .. -~"""'" ,-
M.r..- J7."- l'ooz"v_ , S~_ ~ 01:.00-~,- ,,- ~-","- .., . .,- ~""".
, .,,- f' .",,. 'J."--'''-'Il''' ,,- fl_"- ... ..,- ..:wlOZ...." ..
u.., , . ", . ., 00" ,"""',,,-/," N',' " """. "W >oocz ..... II
.. , .- . 00- Of co' --
Ho' " . ..,- ..... ~. -V' ~, ~,
,~- -.!II)' .. - N_"'" .. ....,.. ~, ~, ."
pESICCANT Eill CHART
32
-
11 . TROUBLESHOOIING
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
Elevated dew point Insumclent purge rate I l Check purge now
settings.
Check purge piping for obstruction.
Clean purge piping and muffler.
Inlet air/gas pressure below Check pressure source. design
condition.
Flow rate higher than design Check now rate and cause for
condition. increased demand.
Inlet temperature above design Check aftercooler, clean and
service condition. as necessary.
Entrained water entering desic- Check airlmoisture separalor and
pre-cant bed. filler. Replace dryer desiccant If nec.
essary.
Desiccanl contaminaled by oil. Install suitable prefi lter.
Replace dryer desiccant.
Excessive pressure Excessive flow rate. Check flow raie and
cause for drop in dryer incressed air demand.
Inlel pressure below design Check pressure source.
condition.
Excessive back pres- Air is leaking across valve. Check in lel
va lve. Verify inle! valve 18 sure in regenerating closeExcessively
high Improper calibration Check gauge agains! lower gauges pressure
al the when in switching sequence. purge guage (Heat Replace gauge
as require33
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PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
Failure la Shift No inpul power Check power input. (Switching
Failure)
Defective solenoid valve Check solenoid valve.
No pilot air 1 Law pilot air pres- Check pilot air line. Check
that con-sure lrol air line filler is clean. Check regu-
lalor setpoint.
Defecl ive pressure switch Check switch. Open pressure: > 65
psig; close pressure: < 40 psig
Failure to Shift Faulty purge valve Check purge valve and its
solenoid (Dryer fails 10 valve. pressurize.)
Check that repressurizat ion circuit is sending control
signa!.
Fai lure 10 Shift Purge valve does not open. Check solenoid
valve. Repair and (Oryer fai ls to Purge valve stuck in closed
replace if necessary. depressurize.) posrtion.
Heater High Temp. Contactor stuck closed. Replace contactor.
Alann (Healer runs continuously) Defective thermocouple Replace
thermocouple.
Defective tempe rature control Replace tempe rature control.
Heat High Temp. Valve switching fai lure Contact ZEKS
Distributor 1 Factory Alarm (Loss of fl ow across heater)
NOTICE
The Heater High Temperature A larm halts the OPC T" program.
Prior ta reinstating dryer, noie Ihe position of ail valves. This
is critical in determining the possible cause of Ihe alarm condit
ion .
NOTICE
To rese! the Heater High Temperature Alarm, resellhe opeT'"
Conlroller using the RESET button and manually reset the Heater
High Temperature safety in the con-trol enclosure.
34
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35
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ZEKS ENGINEERING SPECIFICATIONS
MODEl NUMBER'
DATE OF MANUAL
GENERAl ARRANGEMENT WIRING DIAGRAM; PROCESS &
INSTRUMENTATION DIAGRAM:
" CAPACITY G 100 psig 1 100 'F inlet cor>dilioos OPERATING
PRESSURE INLET TEMPERATURE ourLET OEWPOINT
600ZHA6HTOOO M!t2,2008
~~~~ SCFM AIR P$IG ~ 0 l00PSIG Oryer cap.",ily redicated_ The
... ~ ..... U be conWered appropria!e lot the relerenced drye<
ana m.v d.n ... rmm the $t8nda'd inIofmabon found in the Techniall
M-..r.
-
ZEKS COUfflEss.(n . .. Rll.1I'1(IH$
SPARE PARTS LIST 600ZHA6HTOOO
""
NO TE : The Spares Parts List above has been generaled for the
dryer indlCClled. This parts Iost was made .. 1 the Wnll 01
manufllClullI and st\31 be oonsidered apPfopriat8 for the
rererenced dryer and may dlffe, from \he standard information round
in the TechnCal Manua!.