ECLlPSpM DESICCANT DRYERS ZHA HEATED PURGE MODELS

TABLE OF CONTENTS

1. INTRODUCTION 2. ABBREVIATED WARRANTY 3. NOMENCLATURE 4 RECE IVING AND INSPECTION 5. SAFETY AND OPERATION PRECAUTIONS 6. PRINCIPLES OF OPERATION 7. ALARMSAND INDICATORS 8. TECHNICIAN MODE 9. INSTALLATION/INITIAL START-UP

10. MAINTENANCE AND SYSTEM CHECK 11 . TRQUBlESHOOTING

ATIACHMENTS

A. B. C D. E.

GENERAL ARRANGEMENT DRAWING WIRING OIAGRAM P & 1 0 DIAGRAM ENGINEERING SPECIFICATIONS PARTS LIST

ZEKS Compressed A ir Solutions 1302 Goshen Parkway

West Chester, Pennsylvania 19380

PAGE

1 1 2 3 4 5

12 15 24 29 33

Class ~ Sub class SA LocatIOn A ~.9 Documontat:oo " Cert ;f,w l") rl

610-692-9 100 800-888-2323 FAX 610-692-9192 VW"'NZEKS.COM

1 INTRODUCTION

2.

ZEKS Ecl ipselM Hea! Reac!ivated Desiccant Dryers are designed to adsorb moisture from compressed air. The dryers are cOrl$tructed with two towers, each containing desiccanl beads, that alternate between on-line (drying) and offl ine (regenerating) modes, yielding a continuous stream of dry a ir atthe dryer's outlel.

During normal operation, wet air passes through the on line tower and waler vapor from the air is adsorbed (collected) on the desiccant beads. Whi le air is being adsorbed in the on-line tower, the moisture on the desiccanl in the offline lower is removed by a process called des-orption (regeneration) ln standard heat reactivated operation, afler an initial rapid depres-surizalion , a port ion of dried air from the on-line tower passes through a heater and over the desiccant bed and carries the moisture off the bed and out the dryer's exhausl. With the dryer's Bi-Mode feature, the dryers may also be operated in a Heatless mode, which uses more purge air but does not require use of the heater.

The continuous, alternating pro cess of adsorption and desorption is controlled using a Programmable Logic Controller that switches the towers in a specifie timed sequence. Very dry compressed air dew points are achieved through the continuous switching and operation of Ihis dryer. ZEKS offers heat react ivated dryers to provide either -40' F or - 1 OO"F pressure dew point ou! lel air.

ABBREVIATED WARRANTY

ZEKS Eclipse heat reactivated desiccan! dryer products are warran!ed la be free from defects in material and workmanship for a period of 12 months from the original date of shipment from Ihe factory. To allow the warranly la be in effect for 12 months from the date of equipment slart-up, the Warranty Registration Card must be compleled and returned 10 ZEKS. Alternately, the Warranty Registration Card may be completed on-line al W\VW.zeks.com. The lotal warranly period cannot exceed 18 months from the original date of shipment from the faclory.

Equipment musl be ins!alfed and operaled in accordance wilh ZEKS' recommendations. ZEKS liability is limited to repair of, refund of purchase priee paid for, or replacement in kind al ZEKS' sole option, during the warranty time period stated above. IN NO EVENT SHALL ZEKS BE LlABLE OR RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAM-AGES, Even if the possibility of such incidental or consequential damages has been made known 10 ZEKS Compressed Air Solutions ln addition, the usual maintenance and replace-ment type producls are nol covered by this warranty

The warranties expressed above are in lieu of and exclusive of ail other warranlies. There are no other warrant ies, expressed or implied, except as stated herein. There are no implied warranties of merchantability or fitness for a particular purpose, which are specifically dis-claimed .

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3. HEAT REACTIVATEp DRYER NQMENCLATURE

NOMINAL FlQW SCFM* TYPE { DESIGN SERIES

150 200 250 300 400 500 600 800 1000 1200 1500 1800 2100 3000 4000 5000 6000 8000

ZHA= HEAT REACTIVATED

He: NEMA 4, 150 psig Ee: NEMA 4,300 psig F= NEMA 4XF, 150 psig Je: NEMA4XF, 300 psig S= NEMA4XS, 150 psig U= NEMA 4XS, 300 psig

1 0= STANDARD P'" NON STANDARD PlC R '" REMOTE START STOP E '" NON-FUSED

DISCONNECT F'" FUSED DfSCONNECT

ElECTRICAL pOWER

4 = 460-3-60 (-40 F pdp) D = 460-3-60 (-100 F pdp) 5'" 230-3-60 (-40 F pdp) E '" 230-3-60 (-100 F pdp) 6'" 575-3-60 (-40 F pdp) F '" 575-3-60 (-100 F pdp)

1 0- STANDARD B = HIGH HUMIDITY M '" MOISTURE lOAD

CONTROL P '" POWER SAVER T = HIGH OUTLET TEMP

0= STANDARD 3'" TOWER INSULATION

OPTIONS

9 '" SS CONTROL AIR U NES G '" INlET 1 OUTlET TEMP

2

AND PRESS GAUGES S '" STEAM HEAT

REACTIVATION

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4. RECEIVING AND INSPECTIQN

4.1 INSPECTION Upon receiving your ZEKS air dryer, please inspect the unit closely. Visually check the dryer to make certain that ail air lines and electrical connections are securely fastened and were not damaged in transit If rough handling has been detected, please note il on your delivery receipt, especial ly if the dryer will not be immediately uncrated. Obtaining the delivery person's signed agreement to any noted damage wil l facilitate any insurance claim.

4.2 UNPACKING AND HANDLING Refer ta the General Arrangement drawing for the appropriate means for lifting or moving the dryer. For Ihose dryers thal indicale lifting via the structural skid, forks should exlend ali lhe way Ihrough the skid to reduce unnecessary forces to the dryer during moving. VVhen lifting the dryer, ensure that no stress is applied to the piping or valving. Refer 10 Section 7.2 for locating and mounling of dryer.

NOTtCE Under no circumslances should any person atlempt to lift heavy objects wilhoul prop-er lifting equipment (ie. , crane, hoist, slings or fork truck.) Lift ing any unit without proper lifting equipment can cause serious in jury.

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5. SAFETY AND QPERATION PRECAUTIONS

Because an air dryer is pressurized and contains mechanical parts, the same precautions should be observed as with any piece of machinery of th is type where carelessness in operation or maintenance is hazardous 10 personnel. In addition to the many obvious safety rules that should be fol lowed with this type of machinery, the safety precautions as listed below must be observed:

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

OSHA Heading Description

2. Read ail instructions completely before operating unit.

3. Pull ma in electrical disconnect switch and discon-nect any separate controllines, if used, before attempting to wol1l or perform maintenance on the unit.

'_''' "~ ,o_", r.n. ","ou._ w""'"' , .. ","'" prob ..,.,. 01 d ... ., '" " ",,,lnft.

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6. pRI NClplES OF OPERATION

6.1 INTRODUCTION As deSCfibed in Section 1, waler vapor IS removed from compressed air by diverting air now allernalely between two towers fille(! wilh aclivaled alumina desiccanl. While one tower processes Ihe compressed air slream adsorbing waler vapor, the opposite tower regenerates by desorbing the water vapor and venting it 10 atmosphere.

ZEKS Heat Reactivated Dryers are eq uipped with ZEKS' Bi-Mode feature. The OPC , .. Controller provides the ability 10 select between heated or heatiess regeneration. Both heated and heatless regenerat ion methods are described in the following sect ions. Reler to Section 8.2 for details on switching dryer operation between Heated Purge and Heatless Pressure Swing operation.

NOTICE The OPC TM Controlrer must be ln the OFF position prior to changing the mode (heated purge 1 heatless) 01 the dryer. Aller the change Is made and the OPC '" is subsequently tumed ON, the dryer will be in the new mode of operation.

6.2 DRYING CYCLE Salurated compressed air enlers the dryer and is diverted to the appropriate lowar by the Inlet Flow Valves. (Refer to the Process and Instrumentation Diagram.) The Right Tower Flow Valve is actuated to a closed position 10 prevenl air now Irom entering Ihe regenera!-ing lower. Simultaneously, lhe left Tower Flow Valve is aeluale

6.3.1 Setting the Regeneration Air Flow Proper sett ing of the purge flow is necessary ta achieve proper dryer performance in the heatless and exlernally healed modes. Setting the purge f10w tao high will waste compressed air and if set 100 low, the dryer wil l nol achieve dew point per-formance. The purge adjustment manifold consists of the purge adjustment valve, purge pressure gauge, and the purge orifice. The purge pressure gauge is located between the purge adjustment valve and purge orifice. Manually adjust the purge ad just me ni valve until the reading on purge pressure gauge matches the purge pressure sett ing listed on the specification sheet in the front of this manual as weil as the tag attached to the gauge. Note that there are two purge gauge values cor-responding with each mode of operation.

6.3.2 Heated Purge Regeneration ln the heal reactivaled mode, the process described in section 6.3.2 is repealed using 7.5% of dry compressed air expanded 10 atmospheric pressure. However, after air expansion through the Purge Orifice, the purge air is passed through the purge heater. This expanded, heated purge air is then passed through the regener-aling tower and exhausted out to atmosphere. Afler a three minute delay, the heat-ing process occurs for 2 hours and 57 minutes. During the heating process the electrie heater is cycled on and off by ZEKS' AceuTemp Solid state relay. This advaneed control ler precisely monitors purge air tempe rature and adjusts the heater temperatu re accard ingly. This results in a regeneration air temperature that remains w ithin 3 oF from the heater setpoint for the entire regeneration cycle, elimi-nating temperature swings assoeiated with contactor-based heating system. Upon complet ion of the three-hour heating period, the e lectric heater turns off. The dry regeneration air continues to flow for 57 minutes in order ta cool down the desie-cant bed.

6.3.3 Heatless Pressure Swing Regeneration ln the heatless mode, following depressurization , regeneration uses approximale-Iy 15% of the dry compressed air expanded 10 atmospheric pressure ta complete the desorption process. As shown on the P & ID, the compressed air exits the dry-ing tower and a portion of the air f1 0ws through the purge adjustment valve and the Purge Orifice. Once the air has passed through the Purge Orifice, il expands la atmospheric pressure and continues the regeneration process. Desorption occurs as the desiecant releases waler vapor into the regeneration air and is exhausled Ihrough the Outlet Purge Valves.

6.4 TOWER REPRESSURIZATION Upon completion of tower regeneration, and prior to changing the Inlet Flow Valve position to switch towers, the regenerated tower must be repressurized. Repressurizat ion is accomplished by closing the appropriate purge valve. Closing the Purge Valve allows the regeneration air to pressurize the lower.

NOTICE Failure 10 repressurize prior ta IOlVer switchover will result in shocking the desiccant material and cause premature desiccant dusting.

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6.4.1 Heated Purge Repressurization Three minutes prior to tower switchover, repressurizat ion is accomplished by clos-ing the appropr iate Purge Va lve. When the Purge Valve closes, the regeneration air begins to pressurize the tower. If the dryer is supplied with the optional repres-surizalion piping , the Repressurization Valve opens, allowing some additional air Irom the outiet of the dryer 10 assis! the purge air and to ensure adequate pressur-ization. Ouring norma l tower regeneration, the Repressurization Va lve is held closed so that the only source of air for regeneration passes through the purge adjustmen! assembly

6 .4.2 Heatless Pressure Swing Repressurizal ion 45 seconds prior to tower switch-over, repressurization is accomplished by closing the appropriate Purge Valve. When the Purge Valve closes, the regeneration air begins to pressurize the tower. If the dryer is supplied with the optional repres-surization piping , the Repressurizat ion Valve opens, allowing some addit ional air from the outlet of the dryer ta assis! the purge air and 10 ensure adequate pressur-izalion. During normal lower regeneralion, the Repressurizat ion Valve is held closed so that the only source of air for regeneration passes through the purge adjustment assembly.

6.5 VALVES Flow and Purge Valves are wo-way valves that are switched using air-operated double--acting ac!ua!ors. Each valve is actuated by a four-way solenoid valve as shawn on the P & ID.

NOTtCE Actualed valves require 75 psi min. pressure for proper operation.

The Inlet Flow Valves are connected as normally open valves. \Nhen the dryer is de-ener-gized, the solenoid valves for the Inle! Flow Valves supply control air ta the 'open" port on the appropriate valve actuator.

Purge Valves are connected as normally closed valves. \Nhen the dryer is de-energized, the solenoid valves for the Purge Valves supply control air 10 the "closed" port on the appropriate valve actuator.

Oulle! Check Valves, as weil as Purge Check Valves are single-direction check valves that w ill allow flow in the direction shawn on the P & ID, but not allow flow in the opposite direction.

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6.6 CONTROLS

6.6.1 OPCT'" User Interface The OPCw display provides the user with the operating parameters and lheir cor-responding values. \f\Ihen power is suppl ied to the dryer, the DPC w wi ll illuminate and default to the 'Standby" mode, displaying the "Press ON" prompt.

The fo llowing illustration summarizes the keypad funclions.

Fll)Ilre 1 OPC'" Control er

BUITQNS

0' tn itiates PLC program. Begin. system monitoring and valve Gwitching lunctions.

0" Stop. PLC program Stops vaille switching fu nctions. Initiates Shutdcwn Sequence. Opens Inlet Flow Vatveo Closes Purge Vailles.

SELECT DISPlAY Aliows the user 10 = 11 Ihrough the ~.ailable di.pla)'s. The last display seleded wil l rema;n displayed a. the de/au lt display.

" Anows user to incasc sm pooint values Set point val_ ues cycle th rough a fixed range. AI. n a~ow. "!lt",ing negatllle numbcr.; in Technido n.

9 or 'blank" hcrlton AlklI", uscr 10 step b~C~W3rd$ 10 the F't"ev,ous le.e l of the menu.

8

RESET Pressing on"" deaf'IT Permils the adjustment 01 p"famcters in TECHNICtAN

ENTER Used 10 acepl changed pa",meters ~ nd set pooint val .......

TEST Not used in Oesicmnt Dry"" app l;cnlion.

; Re.tricted l evel ~=.s br factory use onty.

6.6.2 DynOptic Panel User Interface The OynOptic T" Panel provides clear indication of dryer status via bright LED ind icators. The following il lustrat ion summarizes the panel 's features:

DryerON (G ;,,",),~

Let! Tower

"

Left Tower (Ye''''' Figure 2 - DynOplic"" P~oel

Tower

Heate, Operation

',~:,::,;;w" Drying ( Il

NOTE: ZEKS AccuTemp solid state temperature controller modulates the heater repeat-edly during the heating cycle. Pulsating of the heater LED will occur as a result and should be considered normal dryer operation .

6.6.3 DPCT,", Display Parameters The DPCT,", Controller is capable of displaying a number of system parameters in the default CUSTOMER MODE. The following summarizes the parameters that can be accessed by depressing the SELECT DISPLAY butlon from the DPC""' Controller. (Note that sorne displays are optiona! and may not appear on ail models):

Tower Status {LT DRY 1 RT REGEN or LT REGEN 1 RT DRY}: Provides visual confirmation of tower dl)'ing and regenerating status.

Step Timer {ie STEP 4 TIME 120}: Information screen displaying the current step in the program and the time remaining for the displayed step.

Dew Point Temperature (OPTIONAL) - {DEW POINTTEMP: XX}: When equipped with the optional Dew Point Display feature, provides accurate display of dl)'er oullet pressure dew point

Heater status (HEATED PURGE MODE ONL Y) - {ON f OFF}: Indicates thatthe heater is being given a signal to heallhe purge air

Heater Temperature (HEATED PURGE MODE ONLY) - {HEATER TEMP: XX} Indicates the current temperalure of the healer.

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Purge Oullet Temperature (OPTIONAL) - {PURGE OUT TEMP}: When equipped with the optional MLC, indicates the temperature of the purge air.

Alanns {ALARM LIST - PRESS ENTER}: Depressing at th is prompt per-mits viewing of current a larm status and alarm history, which includes the time and date of the alarm occurrence.

Operating & Purge Times - {OPERATING TIMES - PRESS ENTER}: Dep ressing al this prompt provides access to the operating and purge hours of opera-tion.

Operating Mode {OPERATING MODE: HEATLESS f HEATED PURGE}: ZHA dl)'-ers are capable of operating in Heated Purge and Heatless Pmssure Swing modes. This display indicates mode of operation for dryer.

Once the last screen is displayed, depressing the SELECT DISPLAY butlon will return the display 10 the lop of the lis!'

6.7 TIMING SEQUENCE Ali t iming functions are performed by ZEKS' DPCTIA Contro))er, an advanced micro PLC designed exclusively for ZEKS Eclipse'" dryers. The DPC"" Controller is completely pro-grammed at the factol)' and does not require any further adjuslmenl. The standard timing cycle switches the Inlet Flow Valve, which alternates the drying tower. At the same time as the Inlet Flow Valve opens, the appropriate tower Purge Valve opens to begin the purge flow generation. Once the pu rge regeneration flow portion of the dl)'er cycle is complete, tower repressurization begins as previously described.

6.7.1 Heatless Pressure Swing rimer Cycle ln the heatless operating mode, the DPCT'" controls a ten-minute cycle. The tower switch-over occurs every five minutes. Ten seconds after tower switch-over occurs, the regenerating tower depressurizes and tower regeneration occurs for four min-utes and 15 seconds. At that time, tower repressurization begins.

6.7.2 Heated Purge Tlmer Cycle ln the externally healed operating mode, the DPe T'" controls an eight-hour cycle. The tower switch-over occurs evel)' four hours. Ten seconds after switch-over occurs, the regenerating tower depressurizes for 50 seconds. After depressuriza-tion, heated regeneration begins and extends for 2 hours and 58 minutes. The heating supply is turned off and the purge air fiaI'.' continues for the next 58 min-utes. The purge air supply during th is lime is used ta cool down the hot desiccant After the cool down stage, a repressurization slage repressurizes the offline tower for 3 minutes

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6.8 RESTART MODES The DPC TM Control ler includes a Shutdown Sequence that is acl ivated when the dryer OFF butlon is depressed. This feature positions the valves to their failsafe position and resets the program and is the recommended method of shutling down the dryer. When the dryer is subsequently energized, the dryer is ready to run at the start of the program. Should, however, power be eut to the dryer before the Shutdown Sequence has been init i-ated, as would be the case from a power failu re, the dryer can be configured to restart in one of Iwo restart modes. Note that access to the settings to change the restart mode for the dryer are located in the TECHNICIAN MODE. Refer to Section 8.8 for a description of the restart-modes found in the TECHNICIAN MODE. Note that when the dryer is shut down using the OFF butlon, the dryer will require user intervention ta restart the dryer.

6.8.1 Manual Mode (ZERO) ZEKS dryers are shipped from the factory in the Manual Mode. Afler power is re-supplied ta the dryer, the user will be presented with the ' PRESS ON' display. The valve switching and timing operations will only start once the ON bulton is depressed. In this configuration, la restart the dryer, the user must manually depress the ON button on the DPC's control panel.

6.8.2 Auto Reslart Mode (LAST) ln this mode, the dryer w ili re--start automatically once power is applied ta the dryer. In TECHNICIAN MODE, th is operating mode is aclivated when the ' RESTART" prompt is set to "LAST". The OPcn .. will pick up where il left off in the program once power is applied.

6.9 OPERATING TIMES ln the CUSTOMER MODE, the DPCru Controller provides access ta the following operat-ing hours of the dryer:

"O"P5

7.0 ALARMS AND INOICATORS

7.1 MOISTURE INOICATOR (Standard) The moisture indicator senses a sample of the control air whlch is taken from the dryer oulle!. The indicator provides a gross indication of dew point deterioralion at the oulle! of the dryer. Under normal operating conditions, the indicator is blue. In the event of a dryer malfunction or prolonged dryer shut down, it wililum gray in the presence of moisture.

7.2 HEATER HIGH TEMPERATURE ALARM WlTH INTERLOCK (Standard) The Heater High Temperature Alarrn monitors the internai temperatu re of the heater hous-ing. Should a component fa ilure occur or system conditions result in the heater tempera-ture rising aboya the alarm set point, the dryer wi ll alarm. Ouring the alarrn condition, the healer is prevented from operating. the OPC'M halls the program at the point where the alarrn occurred and d isplays lhe condition in the OPC'" LCD display. The dryer will be unable 10 be resel untillhe temperature of the heater has fallen below the alarrn poin!. To reinstate the dryer, depress the RESET button on the OPC'" Controller ANO manually resel the Heater High Temperature Safety in the electrical enclosure. Note that the alarm condition will return should proper correct ive action not be taken.

7.3 HEATER FAILURE ALARM (Standard) This feature produces an alarrn should the heater failto generate heat atlhe beginning of the heating cycle. Ouring the initial ten minutes of the heating cycle, the OPC '" Controller monilors the heater temperature. Should the heater temperature fail 10 rise to 150 OF within the ten minule period, the Heater Failure Alarm will he trlggered. During this alarm

cond~ion, power to the heater is removed and the program is halted. Oepresslng the RESET butlon on the OPC '" COfitroller wi ll reinstate the program and provided the heater problem has been remedied, continue with normal operation.

7.4 FAILURE TO SHIFT ALARM (Standard) ZEKS Failure To ShiflAlarm monitors the dryer sequencing functions to insure proper dryer operation by sensing the pressure in each lower via tower pressure switches. Should one of the following conditions occur, the OPC'" Cootroller will communicate the alarm condition. There are several types of switching failure modes that can be detecled by the Failure To Shift Alarrn feature. They are as follows:

7.4.1 Failure 10 Repressurize At the end of the repressurization stage of the dryer operation, both lowers should be at line pressure. Should the pressure switches indicale that both towers are not at line pressure, the Failure to ShiftAlarm will activate and the OPC'" will stop the program at ifs current position in the program. The user must depress the RESET button at which time the OPC~" Control!er will resume operation from the last step in the program.

7.4.2 Failure 10 Oepressurize At the end of the depressurization stage of the dryer operation, the regenerating tower should be al atmospheric pressure. Should the pressure switches indcate thal this is not the case, the Failure to Shifl A1arm will activate and the OPC'''' will stop the program at ifs current position in the program. The user musl depress the RESET button at which time the OPC TM Conlroller wi ll resume operation trom the last step in the program.

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7.5 HIGH HUMIOITY ALARM (Optional) The High Humid ity A larm communicates an alarm condition in the event that outlet dew point deterioration occurs. One of tv.Ia maisture sensars are used ta sample the outlet air moisture content. VVhen a dl)'er is provided withaut Moisture Load Control' Oew Point Display option , a humidistat w ith a re lative humidity sensor is preset 10 communicate a High HumidityAlarm condition when the dew point rises abave _1 0F (for -40 oF dl)'ers). Refer ta Section 8.10 for details on enabling' disabling the High Humid ity alarm on dl)'ers equipped wilh this feature.

When a dl)'er is pravided with Moisture Load Control' Dew Point Display option, a dew point sensar is used ta delect this alarm condition The dew point sensor transmits the outlet pressure dew point ta the OPCT" Cantral ler. The OPC T" Controller compares the dew point ta the custamer specified set point. Shauld the dew point be greater than the set point, a High Humidity Alarm will be initiated. Refer ta Section 8.10 for details on set-ting the High Humidity Selpoint for dl)'ers equipped w ith the Moisture Load Control' Oew Point Display feature.

7.6 HIGH OUTLET TEMPERATURE (Optianal) This option provides continuaus monitoring of the the dryer discharge air temperature via a thermostat tha! senses the outlet air temperature during dryer operation. Shauld a high oullet temperature condition exist, the ala rm is displayed on the DPC"" Cantroller ta aler! maintenance personnel of a malfunction. This alarm does not in!errupt the dryer p ro-gram. Oepressing the RESET button will clear the alarm provided the alarm condition as been addressed. Note Ihat the alarm will clear automatically once the high temperature condition is corrected.

7.7 DEW POINT TRANSMITTER FAULT (Optional w! MLC) When operating the dryer with the Moisture Load Control (MLC) activated , should the OPC TM Cantral ler deteel a tault with the Oew Point Transmitter, the Contraller will display the message, "ALARM - MLC OFF' . When Ihis alarm indication appears, the MLC feature is automalical ly disabled. Once the source of the fault is detected and remedied, the user MUST REACTIVATE the MLC feature in TECHNIC IAN MODE. Note that provided the High Dew PointAlarm feature has been activated in TECHNICIAN MODE, depressing the RESET button without remedying the prablem will display the message "OP SENSOR FAUL T' after a brief delay. OtherNise, the dryer will continue to operale in the standard timed drying cycle.

Note that with the MLC fealure off and the High Dew Point Alarm activated in TECHN I-ClAN MODE, should the Controller delect a fault \Vith the Dew Point Transmitter, the DPCTM Controller will display the message, "OP SENSOR FAULT". As with the other alarms, pressing RESET without addressing the source of the fau lt wil l result in an new alarm after a brief delay

7.8 ALARM LIST The DPCTM Controller stores the 20 most recent alarm cond itions. These alarms are stored with the type of alarm as weil as the dale and time the alarm occurred . This list can greatly faci litate troubleshooting the dryer and provide an indication of dryer operation during unattended service. The following describe the method to access and review the alarms slored in the DPCTM Controller:

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(SELECT] 1

ALARM LIST 1

Oepresslhe SELECT DISPLAY buttoo....ml thotAl..ARM ~, PRESS ENTER UST display appeat'S.

El 1 BEGIN ALARMS 1 Depress.,g the ENTER buItQn en1eN; the MARM LIST ...... nu. ( SELECT]

1

ALARM OFF 1

Depressing th e SELECT OIS PLAY buHO

8.0 TECHN ICIAN MOpE The DPC provides a protected TECH NICIAN MODE to manipulate several parameters not accessible by the casual operator. Below is a list of parameters that can be accessed and manipulated by the technic ian in the TECHNICIAN MODE:

NOTE: Setpoints indicated are adjustable ONLY when dryer is equipped w ith the Moisture Load Control' Dew Point Display option. Setpoints are non-adjustable on dry-ers w ithout this option

8.1 ENTERING TECHNICIAN MODE

TECHNICIAN MODE should only be entered by qualified service personnel Altering the sel points in TECHNICIAN MODE will have a significanl effect on the operation of the dryer. Incorrect set points may damage dryer and cause potenlial serious in jury.

To enter the TECHNICIAN MODE, perform Ihe following keystrokes:

00 BEIjIN TECHNICIAN i'~ODE :;;;.~~ OPMuDE

HEATLESS

8.2 OPERATING MODE (BI-MODE)

Pre;~in g th" "2" and "3' butt""s simultaneously enters the TECHNICIAN MODE.

Deprcsslflg SELECT DISPlAY scro lls throu gh the a.a il ~ble p~rameter~ .

As described in Section 6, Eclipse ZHA Heat Reaclivated Dryers come standard with the Bi-Mode feature, permining the dryer to operate in a heated purge mode as weil as a heatless pressure swing mode. To change the operation mode of the dryer, perform the following keystrokes'

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SET OPMODE HEATED PURGE

SET OPMODE HEATLESS

Dep

8.4 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE ONLY) The DPCfl,IConlroller permils the user 10 adjusllhe lemperalure of the heater, thereby allering lhe regeneralion temperature in the heated purge mode.

The user is advised to only aller the regeneralion lemperature after being inslrucled 10 do 50 by ZEKS factory personnel. Improper or inappropriate manlpulalion of Ihe heater temperature can result in degraded dryer performance, equipment damage and serious in jury. Notify ZEKS Compressed Air Solutions prior 10 altering the heater temperature.

The following il lustrates the method of adjusting the setpoint for the heater temper-alure:

1

SET HTR TEMP . 375 0 F (190 0 C)

Depres$ the SELECT OISPLAY buItoo unti Ille HEATER TEMPERATURE SET POINT..:reen ~

8.4 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE ONLY) The DPCTMConlroller permits the user to adjust the lemperature of the healer, thereby allering the regeneration temperature in the heated purge mode_

The user is advised 10 only alter the regeneration tempe rature afler being instructed to do so by ZEKS factory personnel. Improper or inappropriate manipu lation of the heater lemperature can result in degraded dryer performance, equipment damage and serious in jury. Notify ZEKS Compressed Air Solutions prior to allering the heater temperature_

The fol lowing illustrates the method of adjusting the setpoint for the healer temper-ature:

~LEY DISPU.Y

G o o o ( '"'" 1

375',T/T~ I~0 c;. HTR TEl'lP SET

-375" F (1 '30 " C) HTR TEMP SET

3 oF

NOTICE On dryers equipped with the optional Moisture Load Control feature, the PurgeMizer MUST be set to 100% in order for the Moisture Load Control to operate properly.

8.6 MOISTURE LOAD CONTROL 1 DEW PO INT DISPLAY (OPTIONAL) The Moisture Load Control { Dew Point Display option includes a dew point sensor that transmits the outlet pressure dew point to the DPCTM Controller. The DPC'" Controller displays the out let pressure dew point in real-lime. This option package also includes Moisture Load Control, an energy savings feature that matches moisture load ing and regeneration energy usage. Drying equipment is typically operated below full flow rating and/or below maximum water loading capacity of the desiant bed . The Moisture Load Control feature utilizes the data communicated from the dew point sensor and exlends the normaltimed switching sequence in proportion to the moisture loading on the dryer.

When the Moisture Load Contro l feature is turned off, ai l switching sequences occur as described in Section 6.7. When the Moisture Load Control feature is activated, the drying sequence is governed by the outlet pressure dew point as measured by the dew point sensor. When the sampled outlet dew point registers below the customer set point (_43F default for _40F dryers; _1 02F on _100F dryers), an immediate change in dryer opera-tion w ill not be noticeable. The dryer will continue its normal regeneration process through tower re-pressurization. Once the tower is re-pressurized, both lowers wi ll be al line pres-sure but air will only f10w through the tower indicated by the DynOptic'" Panel Tower switch over sequence is delayed until the dew point elevales above the Moisture Load Control setpoint, at which point tower switch over will our.

NOTICE

New desiccant has a moisture holding capacity higher than the dryer's design regen-eration capacity. The desiccant ages in a three- to six- month lime period at which point it stabil izes to an "aged" state. During this aging process at initial start-up or after desiccant replacement, the Moisture Load Control feature should be deactivated.

8.6.1 Enabling 1 Disabling Moisture Load Control

o

The following illustrates the method of accessing and adjusting the Moisture Load Control feature:

MOI :::TURE LOAD CONTROL: OFF

CONTROL: ON

18

Depress the SELECT DtSPU\Y bunon until l ile MOtS TURE LOAD CONTROL screen is displayed

Depre .. th e

8.6,2 Set Point AdJustment On dryers equipped with the optional Digital Dew Point Display, the Moisture Load Control setpoint can be adjusted to match the dryers requirements la the desired pressure dew point. Note thal on dryers equipped with Moislure load Control but not the Digital Oew Point Display, manipulaUng Ihese val-ues will have no effect on Moislure Load Control operation.

The following illustrales Ihe method of adjusting the setpoint for the Moisture Load Control fealure:

1 MLC SET POINT 1

. -43"F (-41"0 . r.;;l 1 MLC SET PO 1 NT 1 L.::..J . -43' F (-41' C) .

O. l::::;;"';;:L;;C=S;;;T:::;;P;;:O;;IN;;T;=1 ~ OF (-41"C) , O 1 f>lLC SET POINT 1 - 4 OF (-410 . O MLC""", ~T -41 FL. (:4~~IC> ( _] l_'1~L=-C~S_E_T-,--,P..::O_I N",T----,

. _ 41F (-40"C)

Depron tne SELECT QtSPlAY bu\t0)/'l u~lillhe MLC S ET POINT ~ III di$played,

Pre01;Oig the SET burton ~ lhII VIIlue Dl the MLC SETPOINT to be thlllIQOd

To ente< Il negaIive ""mber, dep-en the . ,. button. 0Iherwise, proed 10 the ne.t Slep.

U", lhe nOOlI>llrs 0)/'1 the k8)'~d to ente< the desire

8.7 POWER SAVER (OPTIONAL, HEATED PURGE MODE) On dryers equipped with Power Saver, the temperature of the purge exhaust is monilored and displayed on the DPCTM Controller. After a lower switch-over, and allhe beginning of tower regeneration, the purge exhaust temperature wi ll be re latively low (normally 90 10 110"F). The purge exhaust temperature will increase as desiccant regeneralion progress-es. As nearly ail of the previously adsorbed moisture is driven off of the desiccanl, the exhaust lemperature will begin 10 rise . The timing for the temperature change will vary depending on moisture loading on the lowers . When the purge exhaust lemperature reaches 195"F, which ind icales that the desiccant heating is complete, Ihe OPCTM Controller wil l remove power to the heater. Once the heater is tumed off, Ihe tower cool down process begins and continues for 57 minutes. Purge air will continue 10 exhaust and the exhaust air tempe rature w ill cont inue to rise (25QoF is not uncommon) as it removes the heat from the regeneraled desiccant material. As the cool down progresses, the exhaust temperature wil l beg in to decrease. After cooling. Ihe Purge Valves close and the optional Repressurization Valve (if equipped) opens. The off-line tower remains pres-surized unti l the tower switchover sequence is initiated . Activation of the Power Saver feature S via the OPC T'" Controller.

The following illustrates the method of accessing and activaling Ihe Power Saver feature:

PuWER :jAVER: OFF

0 1 ~-----' PuWER ::;;AVER : ON 8.8 RESTART MODE

Depress the SELECT DISPLAY blJtton until the POWER SAVER sereen Is displayed.

Dep",s.lhe +/. bull"" umil the desircd set point il; dis-play"",. Pressing SELECT DISPLAY saves the CUITent seleclioo.

ZEKS' Eclipse TM dryers can be configured to restart in one of Iwo operating modes. As described in Section 6.8, the dryer rnay be configured for Manual operation (fac-tory defaull) or Auto Restart, which permits the dryer to operate automatically once power is re-applied 10 the dryer afler a power fai lure. The following illustrates the method of accessing and adjusting the differenl start modes for the dryer:

REST ART : ZERO

De~r~" Ih~ SELECT DISPLAY butto~ ""Iii the START MODE screen is displayM

O. l __ R_'E"C",",--'R,--'T_' __ . L A':;T Tc char>ge the star! mode l,om its clment selection ta the allemate setting. depress th

8.9 EXTENDED HEATING (OPTION Al) On dryers equipped with both the Moisture load Control option as weil as Power Saver, the dryer may be operaled in an extended healing mode. In Ihis mode, the heating cycle is extended while the Moisture load Control function prolongs the drying cycle. This fea-lure is particularly useful when operating the dryer with new desiccant. As described earli-er in this manual, new desiccant has the abi!ity ta adsorb more moisture than the dryer can desorb in a fixed regeneration cycle. With the Extended Heating operation, the Moisture load Control feature can be used immediately without the need to age the desic-cant. This feature is provided only when the dryer is equipped with both the Moisture load Control and Power Saver options. To enable the Extended Heating mode, perform the following keystrokes:

EXTENDEO HEATING OFF

o LI_EA_'T_E_N_D_E o:::D N~H_E_AT_I N_G-l 8.10 HIGH HUMIOITY ALARM (OPTIONAl)

6.10.1 Description and Activalion

Oe~* \!MI SELECT OISPLAY bull"" un~11/MI EXTEIIO-EO HEATING 8Cl"Mn is cIit.pI.rTe1tC teledion.

As described in Section 7.5, the High Humidity Alarm can be configured in two ways. Without the Moisture load Control f Dew Point Display option, the High Humidity Alarm is triggered bya humklistat. lNhen the dryer is equipped with the optional Moisture load Control f Dew Point Display fea-ture, the dew point sensor transmits the dew point to the DPC TU. Should the outlet pressure dew point exceed the customer specified set point, High Humidity A1arm will activale.

The foliowillQ illustrates the method of activatillQ the High Humidity Alarm feature:

HIROMID ALARM OFF

o LI_H_I_H_O_M-=~cc~~,-A_L_A_R_M---,

21

Oep re$. lhe SELECT DISPLAY button uni, the HIGH HUMIOITY sa..., i$ d"rsplflyed.

Depre the . /_ button unli the desir&d sel point i. dis-play&d. Pressi "ll SELECT OISPLAY oavel lhe ",,"ent selection.

8.10.2 Setpoint Adjustment On dryers equipped with the optional Moisture Load Control 1 Dew Point Display, the High Humidity Alarm setpoint can be adjusted as folfows. Note that on dryers equipped with the High Humidity Alarm but not the Digital Dew Point Display, manipulating these values will have no effect on the High Humidity Alarm operation.

The following illustrates the method of adjusting the setpolnt for the High Humidity Alarm feature:

1 HIHUMID SETPOINT 1

. _20 4 F (_28 C) .

r.;;l l_H=I H::O::M-,I_D---,S-,E::TP,-O-,I"N_T---,I t....::..J . 20F (-28C) .

O 1 HIHUMID SETPOINT : L ____ 0_F __ '_-2_8_0_C_)--" o H UM ID :.:.ETP -2 OF (_28C) O 1 HIHUMID SETPOINT . -21F (-2S0C)

'---- - -----'

[ ~._~ J IL_H_IH::U,-M...:I_D--,-S..:T:.:P,-O-,I-=N_T--, ","'~ . - 21F (_29C)

NOTICE

Depress!he SELECT DlSPlJ\Y botlon untiIlM HIGH HUMIDrTY SET POINT Weetl il dlsplayed.

Pressing !he SET buIton p8m'111 the v_ of !he HIGH HUMIDrTY ALARM SETPOINT 10 be changed

To enter a negative number, tlef>ren the .. ,. bu!ton OIherwise , pr-oOO to the ne.t .Iep.

Use 111" numbers on the keypad 10 &nier the desireUse !he nurrbers on !he keypad 10 enle< the d~ pressure dew pQnI \enIpefahn lof the HIGI-l HUMIDITY

""'"'-

The High Humidity Alarm sel point should not be grealer Ihan the Moisture Load Control set point. Failure 10 do so will resutt in an alarm indication. ZEKS recom-mends settlng the High Humidity Alarm at leasl 1 O~F wetter than the Morsture Load Control setpoints.

22

8.11 PROGRAM JOG Ali Eclipse heated purge and blower purge dryers come equipped with a Program Jog fea-ture tha! is accessible via the OPC T'" Controller. This feature allows the dryer cycle to be accelera!ed for troubleshooting and routine inspection purposes. By accessing the Program Jog routine in the OPC ..... , the cus!omer can advance the program to the nex! program step. Note that the program advance feature will no! advance through ail steps of the program

When the Program Jog is initiated in the middJe of the heating cycle, advancing the program without aUowing nOtmal tower cool down will result in an oullet air tempera-ture that may exceed 300F. As such , proper precautions must be taken to protect downstream equipment from high temperature exposure.

NOTICE

Ouring the Program Jog routine, the display may show intermediate steps in the pro-gram that are not active in the current program set up. This should be considered normal operation.

The OPC"" Controller will only permit the jog function during speciftc stages of the pro-gram. Should the program be at a stage where the program can not advance, the follow-ing will be displayed:

JOG, WAtT STEP 4 TIME 0

DItp

9. INSTALLATION AND START-UP

9.1 APPLICATION AND CHECK ANALYSIS ZEKS ECLIPSE Regenerat ive air dryers are shipped complete with desiccant up ta and including model 2000ZHA. On larger units. the desiccant is packaged separately for ease in handling. Refer to Section 10.6 for desiccant fill procedures.

To achieve the best dryer performance, carefully check that the design and installation requirements outlined below are satisfied

ZEKS dryers are avai lable w ith an operating range from 75 - 150 PSIG. Air available for your usage w ill vary with operating pressure. The maximum design pressure of the stan-dard Eclipse Dryers is 150 PSIG For units that require higher operating pressures, con-suit your ZEKS representalive.

Dryers are sized according ta flow and pressure drop, not pipe size. The difference between the inlet and the outlet flow is the amount of purge air required This air is exhausted ta atmosphere and is not available for use downstream. Make certain air sup-ply ta dryer meets air demand plus purge air requirements.

NOTfCE The standard dryer is not rated for any gas other than air.

NOTICE

ZEKS recommends that the mufflers be cleaned afler initial start-up ta remove any des-iccant dust generated during shipment. After running dryer for initial 30 minute period, de-energize / depressurize dryer and remove mufliers. Disassemble and clean the removable insert inside the muffler core. Reinstall mufflers prior ta operating dryer.

9.2 LOCATING AND MOUNTING The dryer must never be installed where air and/or ambient lemperature exceeds 120"F or drops below +35F. Locate dryer to avoid extremes of heat and cold Irom ambi-ent or other cond itions. If the dryer is exposed 10 ambient conditions below 32F, protec-tion must be provided againsl condensation and freez ing as described in SecUon 6.15. VVhere applicable, dryer tower1> may be insulated ta reduce heat loses. Avoid locating dryer outside or where it is exposed ta the el ements.

The dryer, or any air system componenl , must be located to avoid exposure ta pulsation in the compressed air as well as possible surges due to fluctuating demand. In addition, care must be used to minimize exposure to v ibration Iransmitted through mounting pads or piping.

Provide adequate space around the dryer for normal maintenance requirements and serv-ice.

24

If the dryer is shipped with the desiccant packaged separately, install the desiccant after locating and mounting. Desiccant has been provided separately la minimize handling difficulty and placing unnecessary stress on the dryer assembly.

Boit the dryer 10 the foundation using the boit holes provided in the base frame. Anchor bolts should project a minimum of 3.5 inches above the foundation and allow prop-er nut and washer assembly.

9.3 PIPING Pipe the compressed air lines ta the inlet and oullet connections. Locate the prefilters as close as possible ta the dryer. Ensure the positioning allows for ease of servicing

Note that the wet air inlet is located al the dryer's upper manifold and the dry oullet air is Iocated at dryer's lower manifold. In situations where air supply is required 24- hours a day (it is undesirable ta interrupt the airflow) , a three-valve bypass system is recommend-ed ta bypass the dryer. Ta keep pressure drop al a minimum, use the fewest elbows nec-essary

Once a il piping has been connected ail joints, including those on the dryer, should be soap bubble tested at line pressure ta ensure no joints have been damaged in transit and site placement.

9.4 FILTRATION Il is important that a prefilter and an afterfi ller be provided in your dryer installation.

NOTICE

Ai l dryers must have proper fittration. Liquid water and oil must be removed before Ihe air enlers the dryer. Ensure separalors , prefilters and drains are in good working order. Fai lure la do sa will void warranty.

It is recommended Ihat a mechanical separalor be inslalled immediately preceding the prefllter ta remove the bulk liquid and enlrained wate r,

Coalescing prefilters, located before the dryer, proteet desiceant beds from contamination by ail , enlrained waler, pipe scale, etc , thereby, extending dryer desiceant life. Locate prefi llers as close la dryer as possible

Afterfi lters. located after the dryer, help eliminate the possibility of desiccant dusting carrying over inlo the air system.

High temperalure fillers must be used 10 prevent rupture possibil ity in the event dryer failure should occur, Consult your ZEKS represenlalive for appropriate filler selection.

25

9.5 ELECTRICAl CONNECTION Refer to wiring diagram for ail electrical connect ions. Electrical connection must be hard piped w ith an external fused disconnect switch w ith proper overload protection.

Size field connection knock-out fo r the conduit fitting required by the NEC.

Service wires must be sized according to the minimum circuit ampacity shown on the dryer seriai nameplate and the requirements of the NEC.

The power connections are marked L 1, L2 and L3.

NOTICE Dryer must be grounded w ith the full sized g round w ire connected to an earth ground.

9.6 START-UP

NOTICE Initial dryer start-up must be in the Heated Purge Mode

With dryer de-energized , slowly pressurize the dryer. When the dryer reaches full oper-at ing pressure, check the system for air leaks. Soap test ail joints and fitting. To main-tain desired dew point, any leaks detected must be repaired, especially those on the oullet side of Ihe dryer.

Turn on dryer d isconnect switch to apply power to the dryer.

PRESS ON Once pOwer i$ applied to the dryer " 00 " fter" brief in itiat i.zatiorl sequ",",,,,,. the PRESS ON prompt wig "" dis-ptayed.

Verify ail actuated valves are in their failsafe position.

Using a voltmeter, check the power connections for the correct voltage shown on the dryer seriai nameplate

Close and secure ail electrical panel covers.

Ensure that the purge adjustment valve is in the open position.

El 1 LT DRY RT REliEN ! Depress the ON button 10 initiale lhe dryer P"'9r1!1m The DPC 'M Coolroller wi~ display lhe fi rsl CUSTOMER MODE screen

The sequence will initiale proper Inle! and Purge Valve positioning and tawer depressur-ization.

26

. If the dryer h"s been in storage or off for an extended period of time, the Blue Moislure Indicalor may be gray, Ihe High Humidity Alarm (if equipped) may he acti-vated and the Dew Point Display (if eQuipped) may indicale a high dew point Depending upon the duration of idle lime, il may take anywhere from one to twelve hours for the alarm 10 deactivale, the BMlio relum to its normal blue state and dew point to drop .

. For dryers equipped with Molsture load Control, refer to Section 8.6 regarding Ihe use of this oplion on new equlpment.

NOTICE -100 F dryers require flow through Ihe dryer 10 lower the pressure dew poinl to design levels. Failure to permit air flow through the dryer (dead-heading) will result in elevaled outJet dew points. Once air is permittecl to flow through the dryer, the pressure dew poinl will gradually reduce to design levels.

9.7 SHUT DOWN PROCEDURES

The following procedures musl be followed 10 properly shut down the Heat React iv" ted Dryer to avoid damage to the unit and preserve dryer performance. The dryer requires compressed air 10 "cluate the valves. Removing the compressed air supply prior 10 shul-ting down the dryer will resul! in improper valve positioning . In addition, the dryer musl complete a specifie Shutdown Sequence prior 10 being turned off. Should power be removed from the dryer or air pressure removed from Ihe dryer prior 10 the completion of the Shuldown Sequence, damage 10 the dryer may cccur. laslly, the inlet valves are con-figured 10 open on a loss of power and the purge valves configured to close (fail safe). Should a valve open 10 a depressurized lower, as would be the case if the dryer were slopped in mid-cycle, a rapid pressurization will occur.

NOTICE The force of repeated rapid pressurizations wlll damage the dryer.

NOTICE On dryers eQuipped wlth Moisl\Jre load Control (MlC), merely leaving II"Ie unit in MlC without " compressed air supply is nol advlsed, as it is likely that the system pressure will decay over lime. Should Ihis occur, Ihe unit will go into a FTS alarm as weil as risk misalignment of valves should swilchover occur prior 10 reinstating the " ir compressor.

27

CAUTION

Oryer shouklnot be shut down during the heating cycle. Ooing 50 may cause the Heater High Temperature alarm to activate, which will require the user to manually reset the Heater High Temperature safety in the control enclosure. If the dryer must be shut down during the heating cycle, advance the program via the Program Jog function (see Section 8. 11) to the end of the heating cycle prior to init iating the Shutdown Sequence.

For ail Heat Reaclivated Oryers that will be routinely shut down and restarted, ZEKS ree-ommends that an isolation valve be installed atlhe dryer oullel. Upon restarting the dryef, it is likely tha! the pressure downstream of the dryer will have decayed. V\lhen starting the dryer withoutthe valve (or w i!h the valve in the fully open position), the high velocities of the air through the towers could damage the desiccan!, as weil as provide unprocessed a ir down stream.

NOTICE Prier 10 removing power or compresseShut Down Procedure:

Mainla in a compressed air source to the dryer and a suppty of power to the OPC .... Controller.

SHUTDOWN SEQUENCE

Depress the OFF bunon 10 niUale 'M SHUTOOWN SEQUENCE.

Permit the dryer to complete the full SHUTDOWN SEQUENCE (30 seconds)

PRESS ON

Oe-enorglze the dryer

Once the PRESS ON PrompI I displayed. the dtyer hM ~ted the SHUTOOWN SEaUENCE. Power end air "'~y be sa!ely remoYed ' rom ' '''' clrrer,

Shut down air compressor or bypass dryer

Close Isolat ion Valves (if equlpped)

Note: On the subsequent Start-up, the outlet isolation valve should be in the closed position. Slowly open the valve to build pressure downstrearn.

28

10. MAINTENANCE AND SySTEM CHECK

10.1 SCHEOUlED MAINTENANCE Daily Maintenance Functions: o Check and record inlet pressure, temperature and flow. Verify that it is with in

specifications. o Check lower pressure gauge readings within operating tolerance. o Check tower pressure gauges for proper dryer cycling. o Check tha! prefiller condensale drains are functiooing property o Verity that pressure in purging lower is 5 PSIG or less. o Verity that prefilter and afterfilter d ifferen!ial pressure is wilhin operating limits.

Monthly Maintenance Functioos: o Check your opera!ing conditions: inlet flow, inle! pressure, and inle! !emperarure. o Check prefilter(s) and afterfilter(s) differentiaJ pressure and drans. o Check dryer cycle and sequence of operations (i.e. drying,depressurizing, regen-

era!ing).

Quarterly Maintenance Functions: o Replace prefillar(s) and afterfilter(s) cartridges . Check pilai air filler element and replace as needed.

Semi-Annuel Maintenance Functions: o Check oullet dew point. o Check amp draw on heater.

Annual Mainteoance Functions: o Check desiccant and replace if necessary. o Inspect and clean solenoid valves and check valves. Replace worn or damaged

seats and parts as required. o Testlights and switches, replace as necessary. o Test electrical components, replace as necessary . Check and repair any air leaks, Ioose bolts, flanges and fittings.

Every Two Years : o Change check valves o Change control solenoid valves o Check and change lemperalure probes

Every Five Years: o Replace desiccant.

NOTtCE Refer to Section 9.7 fot the proper way 10 shut down Ihe Heat Reactivated Oryer.

29

10.2 PREFllTERS andAFTERFILTERS Prefilter cartridges must be changed as often as require

10.6 DESICCANT CHANGEOUT PROCEDURE

To avoid in jury, depressurize dryer before perlorming any service.

CAUTION

Be su re to wear respiratory protection during the draining and filling process to mini-mize inhalation of desiccant, as desiccant will produce dus! during this procedure.

Eclipse dryers are furnished wi!h fill and drain ports on each desiccant tower. Remove the caps on both ports.

Ta assis! in getling the desiccant to flow from the tower, insert a small rod in to the drain port as necessary. This may be required as the desiccant is packed into the tow-ers which may interfere with the desiccant flow from the towers.

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

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

With the fill port plug removed, fi ll the dryer tower wi\h the appropriate grade and size desiccant. The level and grade of the desiccant should be consistent with the Desiccant Fill Chart.

CAUTION

Desiccant quantity, positioning and grades must match the corresponding values in the Desiccant Fill Chari. Failure to do sa may result in poor dryer perlormance.

Once the towers have been fi lled, replace the fill pori plug on each tower.

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

31

1>,ll", ~,-,." 'Mo" Gl,OO"

lWI""iZ'" -,- .:. . 00."- ,....,- , .. ". ,.=. .. -~"""'" ,- M.r..- J7."- l'ooz"v_ , S~_ ~ 01:.00-~,- ,,- ~-","- .., . .,- ~""". , .,,- f' .",,. 'J."--'''-'Il''' ,,- fl_"- ... ..,- ..:wlOZ...." .. u.., , . ", . ., 00" ,"""',,,-/," N',' " """. "W >oocz ..... II .. , .- . 00- Of co' --

Ho' " . ..,- ..... ~. -V' ~, ~,

,~- -.!II)' .. - N_"'" .. ....,.. ~, ~, ."

pESICCANT Eill CHART

32

11 . TROUBLESHOOIING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Elevated dew point Insumclent purge rate I l Check purge now settings.

Check purge piping for obstruction.

Clean purge piping and muffler.

Inlet air/gas pressure below Check pressure source. design condition.

Flow rate higher than design Check now rate and cause for condition. increased demand.

Inlet temperature above design Check aftercooler, clean and service condition. as necessary.

Entrained water entering desic- Check airlmoisture separalor and pre-cant bed. filler. Replace dryer desiccant If nec.

essary.

Desiccanl contaminaled by oil. Install suitable prefi lter. Replace dryer desiccant.

Excessive pressure Excessive flow rate. Check flow raie and cause for drop in dryer incressed air demand.

Inlel pressure below design Check pressure source. condition.

Excessive back pres- Air is leaking across valve. Check in lel va lve. Verify inle! valve 18 sure in regenerating closeExcessively high Improper calibration Check gauge agains! lower gauges pressure al the when in switching sequence. purge guage (Heat Replace gauge as require33

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Failure la Shift No inpul power Check power input. (Switching Failure)

Defective solenoid valve Check solenoid valve.

No pilot air 1 Law pilot air pres- Check pilot air line. Check that con-sure lrol air line filler is clean. Check regu-

lalor setpoint.

Defecl ive pressure switch Check switch. Open pressure: > 65 psig; close pressure: < 40 psig

Failure to Shift Faulty purge valve Check purge valve and its solenoid (Dryer fails 10 valve. pressurize.)

Check that repressurizat ion circuit is sending control signa!.

Fai lure 10 Shift Purge valve does not open. Check solenoid valve. Repair and (Oryer fai ls to Purge valve stuck in closed replace if necessary. depressurize.) posrtion.

Heater High Temp. Contactor stuck closed. Replace contactor. Alann (Healer runs continuously) Defective thermocouple Replace thermocouple.

Defective tempe rature control Replace tempe rature control.

Heat High Temp. Valve switching fai lure Contact ZEKS Distributor 1 Factory Alarm (Loss of fl ow across heater)

NOTICE

The Heater High Temperature A larm halts the OPC T" program. Prior ta reinstating dryer, noie Ihe position of ail valves. This is critical in determining the possible cause of Ihe alarm condit ion .

NOTICE

To rese! the Heater High Temperature Alarm, resellhe opeT'" Conlroller using the RESET button and manually reset the Heater High Temperature safety in the con-trol enclosure.

34

35

ZEKS ENGINEERING SPECIFICATIONS

MODEl NUMBER'

DATE OF MANUAL

GENERAl ARRANGEMENT WIRING DIAGRAM; PROCESS & INSTRUMENTATION DIAGRAM:

" CAPACITY G 100 psig 1 100 'F inlet cor>dilioos OPERATING PRESSURE INLET TEMPERATURE ourLET OEWPOINT

600ZHA6HTOOO M!t2,2008

~~~~ SCFM AIR P$IG ~ 0 l00PSIG Oryer cap.",ily redicated_ The ... ~ ..... U be conWered appropria!e lot the relerenced drye< ana m.v d.n ... rmm the $t8nda'd inIofmabon found in the Techniall M-..r.

ZEKS COUfflEss.(n . .. Rll.1I'1(IH$

SPARE PARTS LIST 600ZHA6HTOOO

""

NO TE : The Spares Parts List above has been generaled for the dryer indlCClled. This parts Iost was made .. 1 the Wnll 01 manufllClullI and st\31 be oonsidered apPfopriat8 for the rererenced dryer and may dlffe, from \he standard information round in the TechnCal Manua!.