ZEKS Eclipse 120ZPA, Eclipse 300ZPA, Eclipse 200ZPA, Eclipse 160ZPA, Eclipse 400ZPA Technical Manual

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TECHNICAL MANUAL
ZPA Heatless Purge
Desiccant Compressed Air Dryer
90-5000 scfm
NOTICE
Those operating the machine or performing maintenance should read and understand the decals positioned on the machine and the contents of this Technical Manual.
Ensure that this Technical Manual is not removed permanently from the machine.
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, PA 19380
Phone: 610-692-9100 800-888-2323
Fax: 610-692-9192 Web: www.zeks.com
Form: ZEKS ZPA NEMA 1 V0813
TABLE OF CONTENTS
SECTION CONTENT PAGE
1. INTRODUCTION ............................................................................................. 2
2. ABBREVIATED WARRANTY .......................................................................... 2
3. ZPA HEATLESS DRYER NOMENCLATURE .................................................. 3
4. RECEIVING AND INSPECTION ..................................................................... 3
5. SAFETY AND OPERATION PRECAUTIONS ................................................. 4
6. PRINCIPLES OF OPERATION ....................................................................... 5
7. ALARMS AND INDICATORS .......................................................................... 7
8. INSTALLATION/INITIAL START-UP ................................................................ 8
9. SCHEDULED MAINTENANCE ....................................................................... 10
10. TROUBLESHOOTING .................................................................................... 13
11. PURGE CHARTS ............................................................................................ 14
12 GENERAL ARRANGEMENT DRAWINGS ...................................................... 18
13 WIRING DIAGRAMS ....................................................................................... 21
14 FLOW DIAGRAM ............................................................................................ 23
15 FILTER FLOW ................................................................................................. 25
16 FILTER ARRANGEMENT ................................................................................ 26
17 REPLACEMENT PARTS DIAGRAM ............................................................... 27
18 REPLACEMENT PARTS LIST ........................................................................ 30
ZEKS Eclipse ZPA 90-5000 Desiccant Dryers
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1
1.0 INTRODUCTION
ZEKS Eclipse™ Heatless Desiccant Dryers are designed to adsorb moisture from compressed air. The dryers are constructed with two towers, each containing desiccant­beads, that alternate between online (drying) and offl ine (regenerating) modes, yielding a continuous stream of dry air at the dryer’s outlet.
During normal operation, wet air passes through the online 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 offl ine tower is removed by a process called desorption (regen­eration). After an initial rapid depressurization, a portion
2.0 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. See SECTION 9.
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 specifi c 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.
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 fi tness for a particular purpose, which are specifi cally disclaimed.
Valves – After the Basic Warranty noted above expires, the diaphragm valves on the ZP A 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°F and
-100°F dewpoint applications
C. Valves must be rebuilt every two years. Refer to
SECTION 9 of this manual
D. Control line air fi lter element must be replaced
once per year.
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3.0 NOMENCLATURE
Nominal Flow Type/Design Voltage Electrical
SCFM* Series (Dew Point) NEMA Option 90 ZPA = Pressure Swing 1 = 115-1-60 (-40°F) 0 = NEMA 1 0 = Standard
120 G = 115-1-60 (-80°F) H = NEMA 4 A = Failure-To-Shift (FTS) 160 B = 115-1-60 (-100°F) S = NEMA 4X B = High Humidity (HH) 200 2 = 230-1-60 (-40°F) Stainless Steel C = FTS + HH 250 C = 230-1-60 (-100°F) E = Dew Point Display 300 3 = 220-1-50 (-40°F) + MLC (NEMA 4/4X) 400 E = 220-1-50 (-100°F) G = Dew Point Display + MLC 500 + FTS (NEMA 4/4X) 600 M = Moisture Load Control (MLC) 800 + FTS (NEMA 1 only) 1000 N = MLC + HH (NEMA 1 only) 1200 1500 1800 2100 2700 3300 4000 5000
* Nominal Flows indicated are
for 100F inlet temperature, 100
°F ambient temperature and
100 psig compressed air pressure.
! NOTICE
Nomenclature shown above represents standard price sheet options. Other options are available ­refer to nomenclature insert specifi c to your dryer for details.
4.0 RECEIVING AND INSPECTION
4.1 INSPECTION
Upon receiving your ZEKS air dryer, please inspect the unit closely. If evidence of rough handling is detected, please note it on your delivery receipt, especially if the dryer will not be uncrated immediately. Obtaining the delivery per­son’s signed agreement to noted damages will facilitate submission of insurance claims.
4.2 UNPACKING AND HANDLING
! 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.
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 when moving. When lifting the dryer, ensure that no stress is applied to the piping or the valves. Refer to Section 8.2 for locating and mounting of dryer.
ZEKS Eclipse ZPA 90-5000 Desiccant Dryers
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5.0 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 qualifi ed 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 dryer is in an operational mode.
5. Do not attempt to remove any parts without fi rst reliev- ing 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.
OSHA Heading Descriptions
! WARNING
“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.
! CAUTION
“Caution” is used to indicate a hazardous situation which may result in minor or moderate injury.
! 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.”
! NOTICE
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.
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ZEKS Eclipse ZPA 90-5000 Desiccant Dryers
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6.0 PRINCIPLES OF OPERATION
6.1 INTRODUCTION
As described in Section 1, water vapor is removed from compressed air by diverting air fl ow alternately between two towers fi lled with desiccant. While one tower process- es 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.
Timing of the drying and regenerating cycles is automati­cally controlled by a Solid State Timer (SST). An optional programmable dryer controller is available.
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 P&ID, the Left Inlet Flow Valve is actuated to a closed position to prevent air fl ow from entering the regen- erating tower. Simultaneously, the Right Inlet Flow Valve is actuated to an open position, allowing air fl ow 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 fl ows through the desiccant material at pres- sure, 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 fl ows out of the tower for de- livery to the process use. The Outlet Flow Check Valves provide air fl ow diversion to the outlet air connection of the dryer. The Right Outlet Flow Check Valve allows air fl ow through to the outlet connection of the dryer while The Left Outlet Flow Check V alve checks off to prevent fl ow 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 fi rst stage of re- generation is tower depressurization. After the Inlet Flow V alves are switched to divert air fl ow away from the regen- erating tower, the appropriate Purge Valve will be opened and the tower will be depressurized. Through rapid de­pressurization, a signifi cant portion of the previously ad- sorbed 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 fl ows through the Purge Adjustment Valve and the Purge Orifi ce. Once the air has passed through the Purge Orifi ce, 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 Muffl er.
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.
6.4 SETTING THE REGENERATION AIR FLOW
It is necessary to manually set the purge air fl ow to achieve proper dryer performance. Setting the purge fl ow too high will waste compressed air and if set too low, the dryer will not achieve proper dew point performance.
! 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.
The purge adjustment manifold consists of the Purge Ad­justment Valve, the Purge Pressure Gauge and the Purge Orifi ce. When the left tower is the drying tower (pressur- ized) and the right 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 affi xed to the Orifi ce Plate Assembly.
! 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 ensure proper operation of these features. See Appendix A-6.
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6.0 PRINCIPLES OF OPERATION
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.
! NOTICE
Failure to re-pressurize prior to tower switchover will re­sult in shocking the desiccant material and cause pre­mature desiccant dusting.
Repressurization is accomplished when the appropriate Purge Valve closes. 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.
6.6 VALVES
Solenoid valves are used to actuate the Flow Valves, Purge Valves and the optional Repressurization Valve on Eclipse Heatless Dryers. The Inlet Flow Valves and op­tional Repressurization Valve are normally open valves, while the Purge Valves are connected as normally closed valves. This arrangement permits air to fl ow through the dryer during periods of loss of power.
Outlet Check V alves are single direction check valves that will allow fl ow in the direction shown on the P&ID, but not allow fl ow in the opposite direction.
6.7 TIMING SEQUENCE
All timing functions on NEMA 1 dryers are performed by the Solid State Timer (SST) and on NEMA 4 dryers by ZEKS DPC™ Controller. Regardless of controller, the tim­ing of ZEKS -40°F, -80°F and -100°F dryers is as follows:
6.7.1 TIMING CYCLE FOR -40°F DEW POINT DRYERS
The standard timing cycle for -40°F operation switch-
es the Inlet Flow Valve position every fi ve minutes which alternates the drying tower. At the same time as a tower Inlet Valve opens, the appropriate tower Purge V alve opens to depressurize the regenerating tower. Tower regeneration occurs for 4 minutes and 15 seconds, at which time the Purge V alve closes to initiate repressurization.
6.7.2 TIMING CYCLE FOR -80°F AND -100°F DEW POINT DRYERS
The standard timing cycle for both -80°F and -100°F
operation switches the Inlet Flow Valve position ev­ery 2 minutes which alternates the drying tower. At the same time a tower Inlet Valve opens, the appro­priate tower Purge Valve opens to depressurize the regenerating tower. Tower regeneration occurs for 1 minute and 50 seconds, at which time the Purge Valve closes to initiate repressurization. The Re­pressurization Valve opens to assist tower repres­surization for the last 10 seconds prior to Inlet Flow Valve switching.
PRINCIPLES OF OPERATION for dryers equipped
with the optional NEMA 4/DPC Package.
6
Refer to Appendix A6,
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7.0 ALARMS AND INDICATORS
7.1 MOISTURE INDICATOR
The Blue Moisture Indicator (BMI) analyzes a sample of the control air supply which is taken from the dryer outlet. The BMI provides an indication of dew point deterioration at the outlet of the dryer. Under normal operating condi­tions, the BMI appears blue. In the event of a dryer mal­function or prolonged dryer shut down, it will turn gray in the presence of moisture.
7.2 FAILURE-TO-SHIFT ALARM (Optional)
The Failure-to-Shift Alarm provides an indication of switch­ing failure in one of the dryer switching valves. The Fail­ure-to-Shift Alarm uses a pressure switch to monitor the pressure in each tower.
At “0” PSIG the switches are normally closed which sends a signal to the controller. When the towers pres­surize, the switches open, thus removing the signal to the controller. The controller anticipates the appropri­ate open and closed switch position based on its timing sequence. On dryers equipped with NEMA 1 electrics, if either switch is in an incorrect position, the Failure­to-Shift Alarm light will illuminate. The alarm light will remain illuminated and the dryer will continue the operat­ing sequence until the problem is corrected.
sample of dried air from the control line across a sensing element. If the sensing element is exposed to air with a dew point of -10°F or higher (for -40°F dryers), the sen­sor sends a signal to the humidistat. On NEMA 1 dryers, power is then supplied to the red alarm light on the enclo­sure. This light will remain illuminated until the problem is corrected and the sensing element has dried out.
On dryers equipped with the optional NEMA 4/DPC Package, Refer to Appendix A7, ALARMS AND INDI­CATORS for description and explanation of alarms.
7.4 MOISTURE LOAD CONTROL (Optional)
The Moisture Load Control (MLC) feature is designed to minimize the loss of purge air during low fl ow or low wa- ter loading conditions. On -40°F units, a sensor samples the moisture content from the online tower and provides a signal to a humidistat. As long as the humidistat fi nds that the air in each tower is dry , it will not allow the control­ler to open the Purge Valves. Once the moisture content in either tower is found to reach the threshold point, the humidistat sends a signal to the controller and initiates the regeneration cycle. For -80°F and -100°F dryers, a digital dew point monitor is used in place of the humidistat.
On dryers equipped with the optional NEMA 4/DPC Package, Refer to Appendix A7, ALARMS AND INDI­CATORS for description and explanation of alarms.
7.3 HIGH HUMIDITY ALARM (Optional)
The purpose of the High Humidity Alarm is to provide the operator an indication if the equipment fails to supply air at its designed dew point. This is accomplished by passing a
Refer to Appendix NEMA 4 / DPC™ Package for cor­rect operation of NEMA 4-equipped dryers with the DPC™ Microprocessor Controller.
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8.0 INSTALLATION AND START-UP
8.1 APPLICA TION AND CHECK ANAL YSIS
To achieve the best dryer performance, you should care­fully check that the design and installation requirements outlined below are satisfi ed.
! NOTICE
The standard dryer is not rated for any gas other than air.
Operating pressure of ZEKS Eclipse dryers can range from 75 -150 PSIG. Air available for your usage will vary with operating pressure. The maximum allowable working pressure of the standard Eclipse ZPA Heatless Dryer is 150 PSIG. Consult your ZEKS representative for units re­quiring a higher operating pressure.
The dryer must never be installed where 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. Avoid locating the dryer outside or where exposed to the elements.
! NOTICE
ZEKS recommends the muffl ers be cleaned after initial start-up to remove any desiccant dust generated during dryer shipment. After running the dryer for the initial 30 min­ute period, de-energize/depressurize the dryer and remove the muffl ers. Disassemble and clean the removable insert inside the muffl er core. Reinstall the muffl ers prior to oper- ating dryer.
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 during site placement. All installed piping must be self-supported.
8.4 FILTRATION
It is important that a prefi lter and an afterfi lter be provided in your dryer installation.
! NOTICE
All ZPA dryers must have proper fi ltration. Liquid water and oil must be removed before compressed air enters the dryer. Ensure separators, prefi lters and drains are in good working order. Failure to do so will void war­ranty.
Coalescing prefi lters, located before the dryer, protect desiccant beds from contamination by oil, entrained wa­ter, pipe scale, etc., thereby, extending dryer desiccant life. Locate prefi lters as close to dryer as possible.
It is recommended that a mechanical separator be in­stalled immediately preceding the prefi lter to remove bulk liquid and entrained water.
Particulate afterfi lters, located after the dryer, help elimi- nate the possibility of desiccant dust carryover into the air system.
8.2 LOCATING AND MOUNTING
Lift the dryer only by the lifting points indicated by the lift­ing labels on the dryer.
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. Refer to section 12, General Arrangement Drawings, for details.
8.3 PIPING
Pipe the compressed air lines to the inlet and outlet con­nections. Locate the prefi lters as close as possible to the dryer. Ensure the positioning allows for ease of servicing. Refer to the General Arrangement drawing.
Note that the wet air inlet is at the dryer’s lower manifold, while the dry air outlet is at the dryer’s upper manifold. In situations where air supply is required 24 hours a day (where it is undesirable to interrupt the airfl ow), a three valve by-pass system is recommended to bypass the dryer. Use the fewest elbows necessary to keep pressure drop at a minimum.
8.5 ELECTRICAL CONNECTION
Make all electrical connections to the dryer as shown on the wiring diagram. Care must be taken to connect the proper voltages.
! NOTICE
Dryer must be grounded with the full size ground wire connected to an earth ground.
! NOTICE
Dryer must be fused according to NEC with the size fuse listed on the dryer serial nameplate, or on specifi cation sheet in Technical Manual.
Size fi eld connection knock-out for the conduit fi tting re- quired by the NEC.
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8.0 INSTALLATION AND START-UP
8.6 DESICCANT LEVEL VERIFICATION
Remove desiccant fi ll port at the top of each vessel (tower) and check desiccant level. The level should be consistent with the level depicted on the Desiccant Fill Chart on page 12 of this Technical Manual.
8.7 START-UP
! NOTICE
For dryers equipped with the optional NEMA 4/DPC™ Package, refer to the NEMA 4/DPC™ Package Appendix in this Technical manual prior to starting dryer.
• Slowly pressurize the dryer. When the dryer reaches full operating pressure, check the system for air leaks. Soap test all joints and fi tting. To maintain desired dew point, any leaks detected must be fi xed, especially those on the outlet side of the dryer.
• Make sure that the purge adjustment valve is open and air outlet shut off valve (if equipped) is closed.
• For dryers equipped with a dew point monitor, remove the dew point monitor sensor from the electrical enclo­sure and install in the sensing block, located beside the enclosure and attach the sensor cable to the sensor.
• Close and secure all electrical panel covers.
• When the dryer is energized, the Power-On Light and Right Tower Drying Light will illuminate. When the electri­cal circuit is energized, the Solid State Timer will start au­tomatically. See Section 6 for logic operating sequence. For units equipped with NEMA 4 / DPC Package, after initialization, the On button must be pressed.
• Following depressurization of the left tower , adjust purge valve as described in Section 6.4.
! NOTICE
At initial start-up, check the dryer operation for one or two cycles, especially at the time of the tower shift. Ver­ify that all systems are operating in their proper order and sequence. If the dryer is not functioning properly, contact distributor or ZEKS Technical Service.
• If the dryer has been in storage or off for an extended period of time, the Blue Moisture Indicator (BMI) 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 condition to clear, the BMI to return to its normal blue color state and the dew point to drop to design levels.
• On dryers equipped with the Moisture Load Control (MLC) option, access the option through the DPC Con­troller to verify that MLC is OFF to allow standard cycling at start-up.
• Turn on dryer disconnect switch (supplied by customer) to apply power to the dryer.
• For the fi rst 30 seconds that the dryer is energized, both purge valves will remain closed. After 30 seconds, the purge valve will be opened and depressurization will oc­cur.
• With a voltmeter, check the power connections for the correct voltage shown on the dryer serial nameplate.
• Slowly open the outlet valve to gradually pressurize the down stream piping.
! NOTICE
When opening the outlet valve, insure drying tower gauge maintains line pressure. Allowing pressure to drop in the dryer will result in an overfl ow condition.
• On dryers equipped with Moisture Load Control, the Moisture Load Control switch may be turned “ON” to save purge air as described in Section 7.4.
! NOTICE
-80°F and -100°F dryers require fl ow through the dryer to lower the pressure dew point to design levels. Failure to permit air fl ow through dryer (deadheading) will re- sult in elevated outlet dew points. Once air is permitted to fl ow through the dryer, the pressure dew point will gradually reduce to design levels.
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