ZEKS 1000HSFA400, 1200HSFA400, 1600HSFA400, 1200HSFW400, 1600HSFW400 Technical Manual

TECHNICAL MANUAL

HeatSink

True-Cycling Refrigerated

Compressed Air Dryers

HSF Models

1000-1600 SCFM

ZEKS Compressed Air Solutions

1302 Goshen Parkway

West Chester, PA 19380

Phone: [phone]

800-888-2323
Fax: [phone]
Web: www.zeks.com

Form: TM 1000-1600HSF-DPC-0513

DPC

Patent No.: 6,186,223

NOTICE

Those operating the machine or performing
maintenance should read and understand the
decals positioned on the machine and
contents of this Technical Manual.

Ensure that this Technical Manual is not
removed permanently from the machine.

TM

TABLE OF CONTENTS PAGE

1. INTRODUCTION 2

2. ABBREVIATED WARRANTY 2

3. REFRIGERATED DRYER NOMENCLATURE 3

4. RECEIVING AND INSPECTION 4

5. SAFETY AND OPERATION PRECAUTIONS 5

6. PRINCIPLES OF OPERATION 6

7. INSTALLATION AND INITIAL STAR T-UP 15

8. SCHEDULED MAINTENANCE 18

9. TECHNICIAN MODE 20

10. TROUBLESHOOTING 23

11. WIRING DIAGRAMS 25

12. GENERAL ARRANGEMENT 31

13. PARTS IDENTIFICATION 32

14. ENGINEERING SPECIFICATIONS 33

TECHNICAL MANUAL

HeatSink

True-Cycling Refrigerated Compressed Air Dryers

HSF Models

1000-1600 SCFM

Patent No.: 6,186,223

TM

ZEKS Compressed Air Solutions

1302 Goshen Parkway

West Chester, PA 19380

Phone: [phone]

800-888-2323
Fax: [phone]
Web: www.zeks.com

2. ABBREVIATED W

ARRANTY
ZEKS refrigerated dryers 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 online 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.

REFRIGERANT COMPRESSORS
A prorated warranty for the replacement of the refrigerant compressor will be extended to
a maximum of 60 months (5 years) from the original date of shipment from the factory.
Following the standard warranty terms, the available prorated compressor warranty is as
stated below. This prorated warranty applies to replacement compressor only and does
not cover any labor expenses.

Prorated coverage of price from date of shipment from the factory:

19 to 24 months 70%
25 to 36 months 50%
37 to 48 months 30%
49 to 60 months 10%

2

1. INTRODUCTION
The ZEKS HeatSink refrigerated air dryer removes moisture, oil vapor, and other contami-

nants from compressed air. These contaminants are detrimental to pneumatically
operated appliances, controls, instruments, machinery and tools. This is accomplished by
cooling the air with a refrigeration unit to a temperature at which moisture in the air is
condensed and separated from the airstream. The temperature the air is cooled to,
normally between 36 and 40°F, is known as dew point. This dryer can be easily installed
into various pneumatic systems in which dry air is required or desired. Please refer to
Principles of Operation for complete operating details.

3

HEAT EXCHANGERS
Dryers that utilize CFX heat exchanger technology (HSF, HSG, NCE & NCG) are covered
for a total of 10 years from the original date of shipment from the factory. Following the
standard warranty terms the available warranty is as stated below. The exchanger
warranty applies to the replacement exchanger only and does not cover any labor
expenses.

Prorated coverage of prices from date of shipment from the factory:

18 to 48 months 100%
49 to 60 months 70%
61 to 72 months 50%
73 to 84 months 30%
85 to 96 months 20%
97 to 120 months 10%

Freight and labor coverage varies internationally. Refer to Distributor Warranty Guidelines
for limitations and detailed explanation of warranty coverage.

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.

3. REFRIGERA

TED DRYER NOMENCLATURE

NOMINAL
FLOW DESIGN CONDENSER
SCFM

TYPE SERIES TYPE POWER OPTIONS

1000, 1200 HS= HeatSink F A=Air Cooled 4=460-3-60
1600 W=Water Cooled 5=230-3-60

6=575-3-60

O = STANDARD O = STANDARD
H = NEMA 4 Z = SPECIAL
W = WEATHERPROOF 8 = DPC-8
F = AMBIENTAIR FILTER

4. RECEIVING

AND INSPECTION

4.1 INSPECTION
Upon receiving your ZEKS air dryer, please inspect the unit closely. If rough handling
has been detected, please 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 damages will facilitate any insurance claims

4.2 UNPACKING AND HANDLING

Under no circumstances should any person attempt to lift heavy
objects without proper lifting equipment (i.e., crane, hoist, slings or
fork truck). Lifting any unit without proper lifting equipment, can
cause serious injury.

All dryer packages have been mounted on a base which provides for forklifting
between the two base channels to facilitate handling during shipment. Forks should
extend all the way through forklift channels to reduce unnecessary forces to the dryer
during moving. Slings can be used to lift the crates, but spreader bars must be used
to prevent the slings from exerting a force against the sides of the crates.

4

WARNING

5

5. SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating parts, the same precautions

should be observed as with any piece of machinery of this type where carelessness in
operation or maintenance could be hazardous to personnel. In addition to obvious safety
rules that should be followed with this type of machinery, safety precautions as listed
below must be observed:

OSHA

Heading Descriptions

1. Only qualified personnel shall be permitted to adjust,

perform maintenance or repair this air dryer.

2. Read all instructions completely before operating unit.

3. Pull main electrical disconnect switch and disconnect

any separate control lines, if used, before attempting to
work or perform maintenance on the unit.

4. Do not attempt to service any part while machine is in

an operational mode.

5. Do not attempt to remove any parts without first relieving

the entire air system of pressure.

6. Do not attempt to remove any part of the refrigeration

system without removing and containing refrigerant in
accordance with the EPA and local regulations.

7. Do not operate the dryer at pressures in excess of its

rating.

8. Do not operate the dryer without guards, shields and

screen in place.

9. Inspect unit daily to observe and correct any unsafe

operating conditions.

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 may result in
personal injury 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 observance of this list will
prevent all personal injury or equipment damage.

“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
personal injury risk is present.

“Notice” is used to indicate a
statement of company policy
as the message relates directly
or indirectly to the safety of
personnel or protection of
property. Notice should not be
associated directly with a
hazard or hazardous situation
and must not be used in place
of “Danger,” “Warning,” or
“Caution.”

CAUTION

“Caution” is used to indicate a
hazardous situation which may
result in minor or moderate
injury.

NOTICE

NOTICE

WARNING

6

6. PRINCIPLES OF OPERATION

6.1 INTRODUCTION
ZEKS HEATSINK™ dryers remove moisture from compressed air by cooling the air
temperature to between 36° and 40°F (2 and 4°C). This causes vapors to condense
into liquid droplets which can then be easily removed from the air. The major
systems of the dryer which contribute to its operation are the Air System, the Moisture
Removal System, the Refrigeration System, the Thermal Mass Circulating System
and the Controls. The following paragraphs describe each of the systems in greater
detail.

6.2 AIR SYSTEM

The air system consists of the dryer components which are in contact with the
compressed air. Referring to Figure 1 and following the bold “

AIR FLOW,” hot saturated

air from the compressor enters the precooler/reheater where the air temperature is
reduced prior to entering the chiller by the cool air exiting the air/moisture separator.
This precooling allows for the use of a smaller refrigeration system. The air then
goes into the chiller section where it is further cooled to the desired dew point by a
thermal mass fluid. The temperature of the thermal mass fluid is maintained by the
refrigeration circuit and controls. The air continues to the separator where moisture is
removed, thereby, allowing the cool, dry air to return to the precooler/reheater to be
heated by the incoming moist hot air. The air exiting the “reheater” portion of the
dryer should be approximately 15°- 20°F lower than the inlet air temperature based
on standard conditions at full rated flow.

FIGURE 1

FLOW DIAGRAM

DRAWING 500161

7

6.3 MOISTURE REMOVAL SYSTEM
Liquid droplets are removed from the air stream in the separator. As the air and
liquid mixture passes through the separator it spins, slows down and then changes
direction. This causes the condensate to fall out of the air stream and collect in the
bottom of the separator. The collected liquid is removed from the separator by a
solenoid valve. The solenoid valve is controlled by the microprocessor controller as
described in Section 6. For adjustment please note the following:

• To obtain the optimum time values for operation of the solenoid drain valve, set
the off-time to three minutes and the on-time ten seconds via the controller.

• After running the unit under full rated flow for approximately 30 minutes, verify that
when the solenoid drain opens, all of the accumulated liquid is discharged and then
a small burst of air.

• If a small amount of liquid and a large amount of air is discharged, decrease the on­time setting or increase the off-time setting. If there is all liquid and no air has been
discharged, increase the on-time setting or decrease the off-time setting.

• The on/off time settings will vary according to seasonal operating conditions. During
the summer when more moisture is present in the air system a shorter on-time,
increasing the valve opening frequency, is required. A longer valve off-time may be
used during the winter months when moisture levels are lower.

6.4 REFRIGERATION SYSTEM
The Refrigeration System consists of all the components which handle refrigerant.
This is a hermetically sealed closed-loop system. Referring to Figure 1 and following
the phantom “

REFRIGERANT FLOW,” refrigerant is shown leaving the evaporator section

where, in the process of removing heat, it is changed from a low pressure liquid into
a low pressure gas. This gas enters the suction side of the compressor where it is
compressed into a high pressure gas. The high pressure gas is cooled in the air
cooled or water cooled condenser section until it becomes a high pressure liquid. It
then goes through a permanent filter dryer that ensures the refrigeration system is
free of contaminants. A thermostatic expansion valve meters the refrigerant for
introduction into the evaporator. The refrigerant pressure is reduced upon entering
the evaporator where as it evaporates, heat is removed from the thermal mass fluid.
A solenoid valve in the liquid line eliminates the possibility of flooded starts.

6.5 THERMAL MASS CIRCULATING SYSTEM

The thermal mass fluid in a ZEKS HEATSINK™ dryer is continuously circulated in a

closed pump loop system. Referring to Figure 1 and following the dashed “

THERMAL

MASS FLUID” line, the heat is removed from the fluid in the evaporator by the refrigera-

tion system. The thermal mass reservoir is sized to minimize refrigeration cycles
during reduced air load periods. The thermal mass fluid is pulled from the bottom of
the reservoir and pumped through the chiller, removing heat from the air and returned
to the evaporator. The pump utilized on ZEKS’ HEATSINK™ dryer is a maintenance­free, quiet cartridge circulator pump similar to those used in residential water
systems. While the refrigeration system cycles on and off based on loading
conditions, the circulating pump runs continuously to maintain flow through the chiller
at all times.

6.6 CONTROLS
ZEKS’ 1000-1600HSF Refrigerated Compressed Air Dryers are equipped with the

Digital Performance Controller (DPC™). This advanced microprocessor-based
controller has been engineered by ZEKS exclusively for use with ZEKS’ Compressed
Air Dryers.

The DPC™ cycles the refrigeration system based on the dryer's Chiller Temperature.
A temperature sensor samples the thermal mass temperature as it enters the chiller
exchanger. The Chiller Temperature Set point is a user adjustable set point that is
used to set the Refrigeration Compressor Off temperature. Once the Chiller
Temperature has fallen below the Chiller Temperature Set point, the refrigeration
compressor will de-energize. The Operating Temperature Differential is factory set at
4°F above the Chiller Temperature Set point. Therefore, if a user adjusts the Chiller
Temperature at 36°F, the Refrigeration Compressor On temperature will be 40°F.

In addition to the operation of the HeatSink™ dryers as described above, the DPC™
permits monitoring of dryer parameters and enunciation of alarm conditions.

The list below summarize the features the DPC™:

• 2 X 16 Character Backlit LCD Display - Easy-to-read display provides continuous

indication of dryer default parameter. Standard backlight permits viewing of critical
information in low light environments.

• Electronic Drain with On/Off Time Adjustment: Included with DPC™-equipped

HeatSink™ and NonCycle dryers is a solenoid drain valve. Control of the open and
close time of the valve is set via the DPC™ Controller.

• Remote Start / Stop: DPC™-equipped dryers offer a unique remote start / stop

feature. This feature allows the dryer to be operated via a remote user-supplied
switch.

• Remote Alarm Contact: DPC™-equipped dryers include a remote alarm contact to

provide indication of any of the dryers alarms described later in this manual.
Contact rated for 2A / 120V max.

The DPC™ Controller features three levels of access. The default level CUSTOMER
MODE permits adjustment of dryer parameters to address seasonal variations for
drain timing and pressure dew point temperature. Aprotected TECHNICIAN MODE
permits access to and manipulation of additional parameters to address the initial
machine set up. Apassword protected FACTORY MODE is also included for use with
ZEKS Service Personnel for troubleshooting the dryer.

8

The DPC™ controller includes a digital readout for monitoring the discharge pressure
of the refrigerant gas exiting the compressor. This reading will vary dependent upon
condenser type as indicated below:

• For air-cooled applications, condensing fans are cycled on and off by the DPC
based on the refrigerant discharge pressure. Primary fan(s) are cycled on at 235
psig and off at 195 psig. Should the discharge pressure continue to climb above
265 psig, the secondary condensing fans will cycle on. As discharge pressure is
reduced below 210 psig, the secondary fan(s) will cycle off. On 1000 and
1200HSF models, two condensing fans are utilized. The 1600HSF has three
condenser fans. For the 1600HSF, the center fan is the primary controlled fan
the outside fans are the secondary controlled fans.

• Water cooled condensers utilize a water regulating valve (Note Figure 2). The
water regulating valve comes pre-adjusted from the factory at 250 psig discharge
pressure. To compensate for water temperature variation, it may be necessary to
adjust the water regulating valve to maintain a 250 psig discharge pressure.
Adjustment can be done by rotating the adjusting screw counterclockwise for an
increase in discharge pressure. For conditions where low water temperature
and/or high water pressure are expected it is advisable to install a water pressure
regulator ahead of the condenser.

ADJUSTMENT SCREW

FIGURE 2

WATER REGULATING VALVE

Drawing 600562

9

10

6.6.1 BASIC USER INTERFACE
The DPC™ display provides the user with the operating parameters and their
corresponding values. The following illustration summarizes the keypad functions.

BUTTONS

• ON
Places the dryer "On Line"; Energizes glycol pump on
HeatSink™ dryers. For HeatSink™ models, the
compressor will operate based on temperature;

• OFF
Places the dryer "Off Line"; Stops all automatic functions,
including circulating pump operation on HeatSink™ dryers.

• SELECT DISPLAY
Allows the user to cycle through the available displays.
The last display selected will remain displayed as the
default display.

• + / ­Allows user to increase set point values. Set point values
cycle through a fixed range. Also allows entering negative
numbers in FACTORY MODE.

• TEST
Allows user to manually activate the drain solenoid valve.

• RESET
Pressing once clears the local alarm indication and de­energizes the remote alarm contact. Should the alarm
condition persist, the alarm will return after the alarm
inhibit time has expired.

• SET
Permits the adjustment of parameters in TECHNICAN
and FACTORY MODES. In CUSTOMER MODE, allows
user to back through displays,

• ENTER
Used to accept changed parameters and set point
values.

• i
Restricted Level access for factory use only. Not used
for basic dryer functions. Not to be used by customer or
service technician.

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