Zeks Eclipse TECHNICAL MANUA

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ECLIPSE™ DESICCANT DRYERS

ZPA HEATLESS MODELS

TABLE OF CONTENTS PAGE

1. INTRODUCTION 1

2. ABBREVIATED WARRANTY 1

3. HEATLESS DRYER NOMENCLATURE 2

4. RECEIVING AND INSPECTION 3

5. SAFETY AND OPERATION PRECAUTIONS 4

6. PRINCIPLES OF OPERATION 5

7. INSTALLATION / INITIAL START-UP 7

8. SCHEDULED MAINTENANCE 13

9. TROUBLESHOOTING 17

10. PURGE CHARTS 19

A

TTACHMENTS

A. GENERAL ARRANGEMENT DRAWING
B. WIRING DIAGRAM
C. FLOW DIAGRAM
D. SPARE PARTS LIST
E. ENGINEERING SPECIFICATIONS

ZEKS Compressed Air Solutions

1302 Goshen Parkway

West Chester, Pennsylvania 19380

610-692-9100 800-888-2323 FAX [phone]

WWW.ZEKS.COM

COMPRESSED AIR SOLUTIONS

TM

ZPATM 90-5000 V0107

1

1. INTRODUCTION

ZEKS Eclipse™ Heatless Desiccant Dryers are designed to adsorb moisture from
compressed air. The dryers are constructed with two towers, each containing desiccant
beads, that alternate between online (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
online tower, the moisture on the desiccant in the offline tower is removed by a process
called desorption (regeneration). After an initial rapid depressurization, a portion of dried
air from the online tower passes over the desiccant bed and carries the moisture off the
bed and out the dryer’s exhaust.

The continuous, alternating process of adsorption and desorption is controlled using a
timer 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. ZEKS
offers dryers to provide either -40°F, -80°F or -100°F pressure dew point outlet air.

2. ABBREVIA

TED WARRANTY

ZEKS Eclipse™ heatless 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 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.

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.

Valves – After the Basic Warranty noted above expires the diaphragm valves on the ZPA
heatless dryers are warranted (parts only) for a total of 5 years from the date the dryer is
shipped from the ZEKS factory. The following applies to this warranty:

a. Check valves are excluded
b. Not applicable to dryers provided for -80 and -100 degree F dewpoint applications
c. Valves must be rebuilt every two years. Refer to Section 8. of this manual
d. Control line air filter element must be replaced once per year.

2

3. HEATLESS DRYER NOMENCLATURE

NOMINAL
FLOW
SCFM*

TYPE / DESIGN SERIES ELECTRICAL POWER OPTIONS

90 ZPA= Pressure Swing 1 = 115-1-60 (-40°F)
120
160
200
250
300
400 0= NEMA 1 0= STANDARD
500 H= NEMA 4 A= FAIL TO SHIFT
600 B= HIGH HUMIDITY
800 C= A + B

1000 M= MOISTURE LOAD
1200 CONTROL + A
1500 N= M + B
1800
2100
2700
3300
4000
5000

* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature

and 100 psig compressed air pressure..

Nomenclature shown above represents standard price sheet options. Other options are
available, refer to nomenclature insert specific to your dryer for details.

NOTICE

3

4. RECEIVING AND INSPECTION

4.1 INSPECTION

Upon receiving your ZEKS air dryer, please inspect the unit closely. If rough
handling has been noticed, 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

Refer to labels on the dryer 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.

NOTICE

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.

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5. SAFETY AND OPERATION PRECAUTIONS

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:

1. Only qualified personnel shall be permitted to adjust, perform
maintenance or repair this air dryer.

OSHA Heading

Description

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 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.

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
observance of this list will prevent all personal injuries or equipment damage.

NOTICE

“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

“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.

WARNING

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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 desiccant. While one tower
processes the compressed air stream, adsorbing water vapor, the opposite tower is
regenerated by desorbing the water vapor and venting it to atmosphere. Refer to the
Process and Instrumentation Diagram (P&ID) for a visual representation of the drying
and regenerating cycles.

6.2 DRYING CYCLE

Saturated compressed air enters the dryer and is diverted to the appropriate tower
by the Inlet Flow Valves. Referring to the Process and Instrumentation Diagram
(P&ID), the Left Inlet Flow Valve is actuated to a closed position to prevent air flow
from entering the regenerating tower. Simultaneously, the Right Inlet Flow Valve is
actuated to an open position, allowing air flow to the right hand tower. During this
time, the Right Tower Purge Valve is actuated to a closed position, preventing the
compressed air from venting to atmosphere. As the compressed air flows through
the desiccant material 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 right 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. The Right Outlet Flow Check Valve allows air flow through to the outlet
connection of the dryer while The Left Outlet Flow Check Valve checks off to prevent
flow back to the regenerating tower.

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 depressurization. After the Inlet Flow Valves are switched to
divert air flow away from the regenerating tower, the appropriate Purge Valve will be
opened and the tower will be depressurized. Through rapid depressurization, a
significant portion of the previously adsorbed water vapor is stripped off of the
desiccant material and exhausted to atmosphere.

The second stage of regeneration uses a portion of the dry, compressed air,
expanded to atmospheric pressure to complete the desorption process. As shown on
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 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 Muffler.

Eclipse Heatless Dryers may be equipped with an optional Downstream Purge
feature. By adding additional check valves to the upper manifold, a dryer equipped
with the Downstream Purge option is able to use air from a downstream source to
purge the regenerating tower. This optional feature is useful for applications with
downstream (dry) storage tanks, as pulling air from a downstream source can
minimize cycling of the air compressor.

6

6.4 SETTING THE REGENERATION AIR FLOW

Proper setting of the purge is necessary to achieve proper dryer performance.
Setting the purge flow too high will waste compressed air and if set too low, the dryer
will not achieve proper dew point performance.

The purge adjustment manifold consists of the Purge Adjustment Valve, the Purge
Pressure Gauge and the Purge Orifice. When the right tower is the drying tower
(pressurized) and the left tower is depressurized (0 PSIG), manually adjust the
Purge Adjustment Valve until the gauge reading on the purge pressure gauge
matches the Purge Pressure Gauge setting listed on the laminated tag affixed to
the Orifice Plate Assembly.

6.5 TOWER REPRESSURIZATION

Upon completion of tower regeneration, and prior to the Inlet Flow Valves changing
position to switch towers, the regenerated tower must be repressurized.

Repressurization is accomplished by closing the appropriate Purge Valve. Closing
the Purge Valve allows the regeneration air to begin to pressurize the tower. In
addition to the regeneration air, the Repressurization Valve, (standard on -80°F and

-100°F dew point and high pressure dryers; optional on -40°F dew point dryers)
opens allowing some additional air from the outlet of the dryer to ensure adequate
pressurization. During normal tower regeneration, the Repressurization Valve is
held closed so that the only source of air for regeneration passes through the purge
adjustment assembly.

Failure to re-pressurize prior to tower switchover will result in shocking the
desiccant material and cause premature desiccant dusting.

NOTICE

The right tower must be the drying tower for proper purge adjustment setting.
When the left tower is the drying tower, the Purge Adjustment Gauge will read
close to line pressure.

NOTICE

On dryers equipped with the optional NEMA 4 / DPC™ Package or when using the
optional Moisture Load Control feature, the purge valve MUST be set to the factory
set point to insure proper operation of these features.

NOTICE