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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1.0 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.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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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.

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.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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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.

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.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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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.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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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.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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9.0 MAINTENANCE AND SYSTEM CHECK

9.1 SCHEDULED MAINTENANCE

DAILY MAINTENANCE FUNCTIONS:

• Check and record inlet pressure, temperature and ﬂ ow. Verify that it is within speciﬁ cations.

• Check tower pressure gauge readings within operating tolerance.

• Check operation for proper dryer cycling, depressurization and repressurization.

• Check that the preﬁ lter drain is operating properly and that there is no condensate discharged from purge mufﬂ ers.

• Verify that pressure in purging tower is 10 PSIG or less. If higher, mufﬂ er replacement is recommended. See SEC- TION 10.

• Verify that preﬁ lter and afterﬁ lter differential pressure is within operating limits. Replace elements and/or cartridges as required. See SECTION 9.1 Semi-Annual Maintenance.

9.2 PREFILTERS AND AFTERFILTERS

PREFILTERS - The cartridges of the preﬁ lter must be changed as often as required to prevent contamination of the regenerative dryer’s desiccant bed.

The preﬁ lter and automatic drain must be checked daily. To prolong ﬁ lter cartridge life, it is recommended that a mechanical air / moisture separator be placed immediately before the preﬁ lter.

AFTERFILTERS - The purpose of the afterﬁ lter is to re- move residual desiccant dust. Depending upon equipment application and usage, frequency of ﬁ lter element change will vary . It is recommended that, at the minimum, the ﬁ lter element be changed every six months.

! NOTICE

Should the drying system be overloaded and/or malfunctioning, causing high pressure drop, afterﬁ lters may prematurely plug. This problem can be avoided by frequent inspection and proactive replacement of cartridges.

• Check the Blue Moisture Indicator. Make sure air is bleeding through the indicator. The indicator will be blue when air is dry.

SEMI-ANNUAL MAINTENANCE FUNCTIONS:

• Check outlet dew point.

• Check pilot air ﬁ lter element and clean or replace as

required.

• Replace preﬁ lter and afterﬁ lter elements and/or cartridges.

ANNUAL MAINTENANCE FUNCTIONS:

• Check desiccant and replace if necessary.

• Inspect and clean pilot air control solenoid valves, check valves and diaphragm valves. Rebuild and / or replace as required.

• Test lights and switches, replace as necessary.

• Test electrical components, replace as necessary.

EVERY TWO YEARS:

• Replace diaphragm and seal kits on purge and switching

diaphragm valves.

9.3 PILOT AIR CONTROL SOLENOID VALVES

The length of time the pilot air valves can reliably operate without replacement is dependent upon the type of dryer and the dryer’s operation. On ZEKS -40°F dewpoint dryers, replacing the valves every 60 months is recommended. Given the difference in cycle times for -80°F and

-100°F units, these dryers should have their pilot valves replaced every 30 months.

PILOT AIR FILTER ELEMENT IDENTIFICATION AND REPLACEMENT

To determine the correct replacement element for the Pilot Air Filter on the dryer, visually identify the ﬁ lter that is mounted on the right side of the Electrical Enclosure and compare it to the options shown below. Select the replacement element that matches the Pilot Air Filter and use the corresponding Part Number when ordering.

EVERY THREE-TO-FIVE YEARS:

• Rebuild purge and switching diaphragm valves (Preventative).

• Replace Check Valves (Preventative).

Use Replacement Element

Part No.: E15H

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Use Replacement Element

Part No.: 104424

9.0 MAINTENANCE AND SYSTEM CHECK

9.4 MUFFLER CHANGEOUT PROCEDURE

! WARNING

To avoid injury, depressurize dryer before performing any service.

• Depressurize the dryer turn control power off.

• Replace mufﬂ er.

• Follow Start-up procedure described in SECTION 8.7.

• Turn control power back on.

9.5 PURGE AND SWITCHING DIAPHRAGM VALVES

These valves have two control ports; one on top and the other on the back side.

• Normally Open (N.O.) Valves: For N.O. inlet or repressurization valves, control air is supplied to the top port. The back side port exhausts out the bottom side of the diaphragm. If air leaks continuously when control air is supplied to the valve, the internal seals are leaking and must be replaced.

• Normally Closed (N.C.) Valves: For N.C. purge valves, the top port is plugged. Control air is supplied to the back port. If air vents out of the back port continuously when the solenoid is de-energized, it will exhaust through the top of the solenoid. If this condition is observed, the internal seals are leaking and must be replaced.

9.7 DESICCANT CHANGEOUT PROCEDURE

When it becomes necessary to replace the desiccant in the towers, or on units that are shipped without the desiccant installed, observe the following procedure:

! WARNING

To avoid injury, depressurize dryer before performing any service.

! CAUTION

Desiccant will produce dust during the changeout procedure. Be sure to wear respiratory protection during the draining and ﬁ lling process to minimize inhalation of desiccant dust.

• The standard units are furnished with ﬁ ll and drain ports on each desiccant tower. Remove the caps on both ports.

• To assist in getting the desiccant to ﬂ ow from the tower, insert a small rod into the drain port as necessary. This may be required as the desiccant is packed into the towers which may interfere with the desiccant ﬂ ow from the towers.

• Retainer screens, located at the inlet and outlet piping connections of the tower, are removable on all models. It is suggested that these screens be removed and cleaned at the time of desiccant changeout. These screens can be accessed by disconnecting the upper and lower manifolds from the dryer towers.

• After cleaning the retainer screens, replace screens and reattach the outlet port plug.

9.6 OUTLET CHECK VALVES

Outlet check valves sealing can be veriﬁ ed by depressur- izing the dryer and slowly applying pressure to the outlet. The valves should seal and prevent air from pressurizing the towers. If a tower begins to pressurize, the check valve on that side requires replacement.

• With the ﬁ ll port plug removed, ﬁ ll the dryer tower with the appropriate grade and size desiccant. For those dryers that are shipped without desiccant installed, using the ﬁ ll kit provided with the dryer will facilitate ﬁ lling the desic- cant in the tower. The level of the desiccant should be below the top retainer screen as shown on the Desiccant Fill Chart on the following page.

• Once the towers have been ﬁ lled, replace the ﬁ ll port plug on each tower.

• Any connections disturbed in the desiccant changeout process should be leak tested prior to re-commissioning the dryer.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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9.0 MAINTENANCE AND SYSTEM CHECK

-40oF DRYERS -100oF DRYERS

ACTIVATED ALUMINA (AA); 4-8 mm

DESICCANT FILL INSTRUCTIONS

ACTIVATED ALUMINA (AA); 4-8 mm

MOLECULAR SIEVE (MS)

(AA) (AA) (MS) DIMENSIONS (INCH) -40oF -100oF MODEL DRYERS DRYERS A B C lbs./Dryer lbs./Dryer 90 23.00 10.50 30.00 100 75 25 120 17.00 6.50 20.38 134 101 34 160 22.00 8.50 28.75 192 144 48 200 14.00 3.00 21.50 236 177 59 250 23.00 10.50 28.00 290 218 73 300 12.00 6.00 21.25 344 258 86 400 11.00 6.00 22.25 470 353 118 500 27.00 12.75 34.75 638 479 160 600 17.50 7.75 29.00 748 561 187 800 34.00 13.50 41.00 900 675 225 1000 23.00 7.50 31.50 1100 825 275 1200 10.00 2.00 23.75 1270 953 318 1500 12.00 2.75 23.25 1600 1200 400 1800 35.00 15.50 45.75 2000 1500 500 2100 22.00 10.75 38.50 2340 1755 585 2700 6.00 2.50 26.00 2928 2196 732 3300 16.25 8.00 35.25 4000 3000 1000 4000 7.75 3.50 29.00 4250 3150 1100 5000 9.00 4.25 28.00 5600 4200 1400

NOTE: Desiccant weight shown is per-dryer.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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10.0 TROUBLESHOOTING

For troubleshooting procedures, refer to maintenance descriptions in Section 9 as required.

PROBLEM

Elevated dew point

Blue Moisture Indicater (BMI) indicates high moisture level.

Excessive pressure drop in dryer

PROBABLE CAUSE

Insufﬁ cient purge rate.

Inlet air pressure below design condition. Flow rate higher than design condition.

Inlet temperature above design condition (120F). Entrained water entering desiccant bed.

Desiccant contaminated by oil. Elevated dew point.

BMI wet.

Excessive ﬂ ow rate. Inlet pressure below design condition.

CORRECTIVE ACTION

Check purge ﬂ ow settings. Check purge piping for obstruction. Clean purge piping and mufﬂ er . Check pressure source and system for leakage. Check ﬂ ow rate and cause for increased demand.

Correct ﬂ ow rate condition. Check aftercooler. Clean and service as necessary. Check air/moisture separator, preﬁ lter and drains.

Replace dryer desiccant if necessary. Install suitable preﬁ lter. Replace dryer desiccant. Refer to “Elevated Dew Point” corrective actions

shown above. Depending on degree of saturation of the desic-

cant, the BMI may take a week or more of continuous use to switch back to its blue (dry) state.

Check ﬂ ow rate and cause for increased air demand. Check pressure source.

Failure to shift

Dryer fails to pressurize.

Dryer depressurizes too rapidly.

Dryer fails to purge.

Excessive back pressure in regenerating tower (above 5 psig).

No input power. Defective solenoid valve. No pilot air.

Pilot-operated diaphragm valve seat failure. Faulty purge valve.

Purge valve does not close; dryer repressurizing through inlet valve.

Purge valve does not open. Purge valve stuck in closed position.

Purge mufﬂ er does not pass air.

Purge mufﬂ er passes too much air. Air is leaking across valve.

Check power input. Check solenoid valve. Check pilot air line. Check that control air line

ﬁ lter is clean. Inspect seals and replace as required. Check that repressurization circuit is sending

control signal. Check purge valve and its solenoid valve. Check purge valve and its solenoid valve.

Check purge valve and its solenoid valve. Repair and replace if necessary.

Check that repressurization circuit is sending control signal.

Purge mufﬂ er is dirty; replace.

Check inlet valve and outlet check valves. Verify inlet valve is closed to purging tower (0 psig tower).

Right tower excessively high pressure at the purge gauge.

Improper calibration.

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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Reset when right tower is online.

11.0 PURGE CHARTS

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 9/64"

90ZPA Setting - 48 psig @ 14 SCFM

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 5/32"

120ZPA Setting - 53 psig @ 19 SCFM

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 3/16"

160ZPA Setting - 50 psig @ 26 SCFM

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 7/32"

200ZPA Setting - 42 psig @ 30 SCFM

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 1/4"

50ZPA Setting - 42 psig @ 40 SCFM

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 9/32"

300ZPA

Setting - 40 psig @ 48 SCFM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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11.0 PURGE CHARTS

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 5/16"

400ZPA

Setting - 45 psig @ 65 SCFM

100

110

120

130

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 3/8"

500ZPA

Setting - 35 psig @ 81 SCFM

100

110

120

130

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 3/8"

600ZPA

Setting - 41 psig @ 93 SCFM

100

120

140

160

180

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 7/16"

800ZPA

Setting - 46 psig @ 130 SCFM

100

120

140

160

180

200

220

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 1/2"

1000ZPA

Setting - 43 psig @ 162 SCFM

120

150

180

210

240

270

300

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 9/16"

1200ZPA

Setting - 41 psig @ 195 SCFM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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11.0 PURGE CHARTS

120

150

180

210

240

270

300

330

360

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 5/8"

1500ZPA

Setting - 41 psig @ 243 SCFM

120

150

180

210

240

270

300

330

360

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 5/8"

1800ZPA

Setting - 51 psig @ 292 SCFM

100

150

200

250

300

350

400

450

500

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 3/4"

2100ZPA

Setting - 40 psig @ 340 SCFM

100

150

200

250

300

350

400

450

500

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 3/4"

2700ZPA

Setting - 53 psig @ 438 SCFM

100

150

200

250

300

350

400

450

500

550

600

650

700

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 7/8"

3300ZPA

Setting - 47 psig @ 535 SCFM

100

200

300

400

500

600

700

800

900

1000

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 1"

4000ZPA

Setting - 44 psig @ 649 SCFM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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11.0 PURGE CHARTS

100

200

300

400

500

600

700

800

900

1000

0 10203040506070

Purge Air Flow - SCFM

Purge Meter Setting - psig

Purge Orifice - 1"

5000ZPA

Setting - 56 psig @ 811 SCFM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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12.0 GENERAL ARRANGEMENT

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

12.0 GENERAL ARRANGEMENT

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

12.0 GENERAL ARRANGEMENT

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

13.0 WIRING DIAGRAM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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13.0 WIRING DIAGRAM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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14.0 FLOW DIAGRAM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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14.0 FLOW DIAGRAM

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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15.0 FILTER FLOW

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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16.0 FILTER ARRANGEMENT

FILTER

MODEL

ABCDEF

DIMENSIONS(INCH)

ZTF 100 * 4. 50 14.00 6.00 1.50 1.25 3. 00 ZTF 150 * 4. 50 14.00 6.00 1.50 1.25 3. 00 ZTF 250 * 5. 75 19.00 6.50 2.00 1.50 3. 00 ZTF 300 * 5. 75 19.00 6.50 2.00 1.50 3. 00 ZTF 500 * 5. 75 19.00 6.50 2.00 1.50 3. 00 ZTF 650 * 5. 75 26.75 6.50 2.00 1.50 3. 00 ZTF 1000 * 9.00 27.50 7.00 2.50 1.50 3.00 ZTF 1250 * 9.00 32.50 7.00 2.50 1.50 3.00 ZTF 1600 * 9.00 38.50 7.00 2.50 1.50 3.00

*ADD ELEMENTGRADE(H,G)

510588

MODEL

ZTF 1800 * 19. 00 38.31 7.44 4.19 27.06 ZTF 2400 * 19. 00 38.31 7.44 4.19 27.06 ZTF 3000 * 22. 00 42.31 9.00 4.19 28.88 ZTF 3600 * 27. 50 42.31 9.00 4.19 28.88 ZTF 4200 * 27. 50 42.31 9.00 4.19 28.88 ZTF 6000 * 27. 50 42.31 9.00 4.19 28.88

*ADD ELEMENTGRADE(H,G)

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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DIMENSIONS(INCH)FILTER

ABCDE

17.0 REPLACEMENT PARTS DIAGRAM

510518

90-600 ZPA

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

680619 705190 705190 630721 630721 630569 630569 632790 632790 AD0510 A D0510 AD0510 AD0510 630622 630803 705604 705604 680029 680572 680572 680572 630730 630730

680454 705190 705190 630725 630725 630575 630575 632790 632790 AD0510 A D0510 AD0510 AD0510 630622 630803 705604 705180 680029 680572 680572 680572 630730 630730

680454 705190 705190 630725 630725 630575 630575 632791 632791 AD0510 A D0510 AD0510 AD0510 630622 630803 705180 705180 680029 680572 680572 680572 630730 630730

680454 705188 705188 630725 630725 630575 630575 632791 632791 AD0515 A D0515 AD0515 AD0515 630622 630803 705180 705180 680429 680572 680572 680572 630730 630730

680454 705188 705188 633667 633667 630575 630575 632791 632791 AD0515 A D0515 AD0515 AD0515 630622 630803 705180 704972 680429 680572 680572 680572 630730 630730

680454 705188 705188 633667 633667 630575 630575 632792 632792 AD0515 A D0515 AD0515 AD0515 630622 630803 704972 704972 680429 680572 680572 680572 630730 630730

680454 705188 705188 633667 633667 630575 630575 632792 632792 AD0515 A D0515 AD0515 AD0515 630622 630803 725195 725195 680429 680572 680572 680572 630730 630730

120

160

200

250

300

400

500

MODEL EXHͲ1F0Ͳ1F0Ͳ2FVͲ1A FVͲ2A FVͲ1B FVͲ2B FVͲ1C FVͲ2C FVͲ1D FVͲ2D FVͲ1P FVͲ2P FVͲ5FVͲ5A FXͲ1FXͲ2HCVͲ3PIͲ1PIͲ2PIͲ3PSVͲ1PSVͲ2

600

17.0 REPLACEMENT PARTS DIAGRAM

510588

800-2700 ZPA

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

MODEL EXHͲ1F0Ͳ 3F0Ͳ4FVͲ1A FVͲ2A FVͲ1B FVͲ2B FVͲ1C FVͲ2C FV Ͳ1D FVͲ2D FVͲ1P FVͲ2P FVͲ5FVͲ5A FXͲ1FXͲ2HCVͲ3PIͲ1PIͲ2PIͲ3PSVͲ1PSVͲ2

680711 705192 705192 631478 631478 630572 630572 632794 632794 A D0515 AD 0515 683983 683983 630622 630803 725139 725139 680712 631324 631324 631324 680896 680896

800

1000

680711 705192 705192 631478 631478 630572 630572 632794 632794 A D0515 AD 0515 683983 683983 630622 630803 725139 725139 680712 631324 631324 631324 680896 680896

680455 705192 705192 630406 630406 633701 633701 632794 632794 683983 683983 683983 683983 630725 630803 725140 725140 680712 631324 631324 631324 680896 680896

1200

1500

680455 705192 705192 630406 630406 633701 633701 632794 632794 683983 683983 683983 683983 630725 630803 725269 725269 680712 631324 631324 631324 AD1415 AD1415

1800

680455 705192 705192 630406 630406 633701 633701 632794 632794 683983 683983 683983 683983 630725 630803 725269 725269 680712 631324 631324 631324 AD1415 AD1415

2100

680455 705193 705193 630406 630406 633701 633701 633364 633364 633943 633943 633943 633943 633667 630803 725269 725269 680466 631324 631324 631324 AD1415 AD1415

2700

17.0 REPLACEMENT PARTS DIAGRAM

510519

3300-5000 ZPA

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

www.zeks.com

680455 705193 705193 632170 632170 632172 632172 633364 633364 A D0515 A D0515 633943 633943 630622 633667 630803 725151 725151 680466 631324 631324 631324 AD1415 AD 1415

680455 705420 705193 632170 632170 632172 632172 633365 633365 A D0520 A D0520 634098 634098 630721 631478 630803 725270 725270 699817 631324 631324 631324 AD1415 AD 1415

4000

5000

3300

MODEL EXHͲ1F0Ͳ3F0Ͳ4FVͲ1A FVͲ2A FV Ͳ1B FVͲ2B FVͲ1C FVͲ2C FVͲ1D FVͲ2D FVͲ1P FVͲ2P FVͲ5FVͲ6FVͲ5A FXͲ1FXͲ2HCVͲ3PIͲ1PIͲ2PIͲ3PSVͲ1PSVͲ2

18.0 REPLACEMENT PARTS LIST

633856633856633856

632823 632823 632823

510518A-12

ZEKS Eclipse ZPA 90-5000 Desiccant Dryers

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

Specifications and Main Features

Frequently Asked Questions

User Manual