Comfort Systems USA (Arkansas), Inc. P.O. Box 16620

Little Rock, AR 72231 Phone 501-834-3320

Fax 501-834-5416

4806 Rixey Road No. Little Rock, AR 72117

Date: 10/28/2019 Return Request: 11/4/2019Project: Lockheed Martin ATACMS PrSM Building Supplier: Arkansas Industrial Machinery, Inc. Manufacturer: VariousSubmittal: Compressed Air Equipment Submittal Number: 23 00 00-03 Spec Section: N/A Drawing # and Installation: Plumbing Drawings (Found on Plan Page P-105)

ARCHITECT ENGINEER Cromwell Architects Engineers Cromwell Architects Engineers 1300 E. 6th Street 1300 E. 6th Street Little Rock, AR 72202 Little Rock, AR 72202 501-372-2900 501-372-2900

GENERAL CONTRACTOR MECHANICAL SUBCONTRACTOR Baldwin & Shell Construction Comfort Systems USA (Arkansas), Inc. 1000 W. Capitol Ave. 4806 Rixey Road Little Rock, AR 72201 North Little Rock, AR 72117 501-374-8677 501-834-3320

CSUSA PROJECT NO. 19-212

tad@comfortar.com

*Lead times for this item will be 8-10 weeks; +/- weeks due to the Holidays, factories shut down processfrom the end of November through the beginning of the new year.

OIL-INJECTED ROTARY SCREW COMPRESSORS GA 15-26 / GA 11+-26+ / GA VSD+ 15-37 (11-37 kW/20-50 hp)

MEETING YOUR EVERY NEED FOR COMPRESSED AIRAtlas Copco's GA oil-injected screw compressors

provide you with industry-leading performance

and reliability and allow you to benefit from a low

cost of ownership. Atlas Copco offers a trinity

line-up of compressors that matches your precise

requirements. The GA 15-26 stands for a high

quality, reliable air compressor with the lowest initial

investment. The GA 11+-30 delivers top performance

in the fixed speed compressor market. Our premium

product, the GA 15-37 VSD+, is a unique state-of-the-

art air compressor with unparalleled performance

and energy savings.

GA 15-26 COMPACT ECONOMICAL COMPRESSORS• Premium GA quality and optimal serviceability

at the lowest initial investment.

• Good-quality, dry air thanks to the integrated dryer.

• Total control and assured efficiency with the

Elektronikon® controller.

GA 11+-30 STATE-OF-THE-ART PERFORMERS• Exceptional Free Air Delivery.

• Best-in-class power consumption and noise emission.

• Thanks to the integrated dryer, high quality dry air

is guaranteed.

• Easy monitoring and maintenance thanks to the Elektronikon®

graphic controller with high-definition color display.

GA 15-37 VSD+ ULTIMATE ENERGY SAVERS• On average 50% energy savings compared to traditional

fixed speed compressors via advanced Variable Speed

Drive+ technology.

• Flexible pressure selection: 4-13 bar.

• Excellent-quality, dry air at the lowest energy cost thanks to

the new, integrated dryer range.

• Easy monitoring and maintenance thanks to the Elektronikon®

graphic controller with high-definition color display.

• Innovative vertical design minimizes the required floor space

while improving serviceability.

4

1

GA 15-26: COMPACT ECONOMICAL COMPRESSORS Set to tackle your daily challenges, Atlas Copco’s high-performance tank-mounted GA compressors beat

any workshop solution. Ready to supply high-quality air, they keep your air network clean and your

production up and running.

Robust element & motor• The GA 15-26’s compression element, the most used

in its size, is combined with an IE3/NEMA Class 1

efficiency motor.

• A 2-3% higher efficiency with the gear-driven

drive train compared to belt-driven systems.

• Gear-driven drive train for best-in-class

reliability and limited maintenance.

1

Advanced monitoring• State-of-the-art monitoring using a simple Ethernet connection,

thanks to the Elektronikon® with a built-in server.

• Service and warning indications, error detection and

compressor shut-down.

• Optional Elektronikon® graphic controller for further enhanced

remote monitoring features and service time indications.

2

5

2

3

Easy installation• A true plug-and-play solution, ideal machine for installation

companies and OEMs.

• Optional integrated dryer, air filters and factory-mounted

500L receiver.

• Easy transportation by forklift.

• Remarkably compact footprint.

5

High tech oil vessel • Protection from oil contamination: extremely low oil carry-

over thanks to the vertical design of the oil vessel.

• Extremely low losses of compressed air during load/unload

cycle thanks to minimized oil vessel size.

3

Integrated quality air solutions • The integrated dryer avoids condensation and corrosion

in the network. Optional filters for air quality up to

ISO Class 1 level (<0.01 ppm).

• Standard included water-separator.

• Additional energy savings with the dryer’s no-loss

electronic drain.

4

1

3

2

GA 11+-30: INDUSTRY-LEADING PERFORMERS Re-engineered to break records, the industrial GA 11+-30 compressors have the best air delivery capacity in

the industry. These all-in-one solutions provide high-quality air at the lowest possible operating costs and offer

extended monitoring possibilities.

Reliable motor & drive train• The gearbox’s maintenance-free transmission

maximizes durability.

• The motor and drive train are greased for life

to avoid improper re-lubrication.

• Free Air Delivery is increased by 6-17% and power

consumption is reduced by 3-12% thanks to

packaging and new compressor element.

1

Electrical cubicle• Reduced cubicle temperature doubles the lifetime of the electrical components.

• Avoid damage with the electrical cubicle’s standard phase sequence relay.

2

1

4

Quality air solutions• Integrated dryer range with counterflow heat exchanger,

integrated water separator and optional Dryer Saver Cycle.

• The integrated dryer can be outfitted with optional UD+ filter,

resulting in oil carry-over as low as 0.01 ppm.

• Water separation of nearly 100% in all conditions with the

standard electronic no-loss drain and integrated water

separator in the aftercooler.

4

Advanced control• High-tech Elektronikon® graphic controller with

warning indications, compressor shut-down and

maintenance scheduling.

• Optional centralized control over up to 6 compressors

via Elektronikon®.

3

Energy-saving features• Optional energy recovery system.

• Optional fan Saver Cycle, reducing energy consumption.

5

7

4

1

38

2

GA 15-37 VSD+: ULTIMATE ENERGY SAVERS With its innovative vertical design, Atlas Copco's GA 15-37 VSD+ brings a game-changing revolution in

the compressor industry. It offers Variable Speed Drive as standard, a compact motor and small footprint

thanks to its in-house design and iPM (permanent magnet) technology. The GA VSD+ reduces energy

consumption by on average 50%, with uptimes assured even in the harshest conditions.

Interior Permanent Magnet (IPM) motor• Very high efficiency: exceeds IE3.

• Compact, customized design for optimal cooling by oil.

• Designed in-house in Belgium.

• IP66 vs. IP55.

• No cooling air flow required.

• Oil-lubricated motor bearing: no (re)grease(ing), increased uptime.

1

Element• Made by Atlas Copco.

• Robust and silent.

2

Direct drive • Vertical design, fewer parts.

• Oil-cooled, pressure-tight.

• No gears or belts, no shaft seal.

• Compact: footprint down 60%.

3

Innovative fan • Based on the newest technologies.

• In compliance with ERP2015 efficiency.

• Low noise levels.

4

64

5

9

Robust oil filter/separator• Integrated bypass valve with the oil filter.

• Easy maintenance.

5

Electronic no-loss water drain• Included as standard.

• Efficient removal of condensate without loss of compressed air.

• Manual integrated bypass for effective condensate removal in

case of power failure.

6

Elektronikon® controller• Integrated smart algorithms reduce system pressure

and energy consumption.

• Warning indications, maintenance scheduling and online

status visualization.

• Graphic display of key parameters (day, week, month) and

32 language settings.

7

Sentinel inlet valve• No inlet arrestor.

• No blow off losses.

• Maintenance free.

8

VSD+ cubicle• VSD+ superior to idling machines.

• Electrical components remain cool, enhancing lifetime of components.

• Dedicated drive for iPM technology motors.

• 5% DC choke as standard.

• Heat dissipation of inverter in separate compartment.

9

VSD+ FOR 50% AVERAGE ENERGY SAVINGS* Atlas Copco’s GA Variable Speed Drive+ (VSD+) technology closely matches the air demand by automatically

adjusting the motor speed. Combined with the innovative design of the iPM (Permanent Magnet) motor,

this results in average energy savings of 50% and an average cut of 37% in the lifecycle cost of a compressor.

VSD+ works with permanent, in-house designed permanent magnet motors.

Why Atlas Copco Variable Speed Drive+ technology?• On average 50% energy savings with an extensive flow range (20-100%).

• Integrated Elektronikon® Graphic controller controls the motor speed and high efficiency frequency inverter.

• No wasted idling times or blow-off losses during operation.

• Compressor can start/stop under full system pressure without the need to unload with special VSD+ motor.

• Eliminates peak current penalty during start-up.

• Minimizes system leakage due to a lower system pressure.

• EMC Compliance to directives (2004/108/EG).

Energy Investment Maintenance

GA Fixed Speed GA VSD+

In almost every production environment, air demand fluctuates depending on different factors such

as the time of the day, week or even month. Extensive measurements and studies of compressed air

demand profiles show that many compressors have substantial variations in air demand.

* Compared to fixed speed compressors, based on measurement performed by an independent energy audit agency.

SAVINGS50%

Energy consumptionFixed speed load/unload

Air demand

Air demand

Time

Energy consumption

GA VSD+ energy consumption

Air demand

Time

Energy consumption

Air demand

A STEP AHEAD IN MONITORING AND CONTROLSThe next-generation Elektronikon® operating system offers a great variety of control and monitoring features

that allow you to increase your compressor’s efficiency and reliability. To maximize energy efficiency,

the Elektronikon® controls the main drive motor and regulates system pressure within a predefined and

narrow pressure band.

• Improved ease of use: intuitive navigation system with clear

pictograms and extra 4th LED indicator for service.

• Visualization through web browser using a simple

Ethernet connection.

• Easy to upgrade.

• Increased reliability: more durable keyboard.

Key features:• Automatic restart after voltage failure.

• Delayed Second Stop function.

• Option to upgrade to the advanced Elektronikon®

graphic controller.

• Improved user-friendliness: 3.5-inch high-definition color

display with clear pictograms and extra 4th LED indicator

for service.

• Internet-based compressor visualization using a simple

Ethernet connection.

• Increased reliability: new, user-friendly, multilingual user

interface and durable keyboard.

Key features:• Automatic restart after voltage failure.

• Dual pressure set point.

• More flexibility: four different week-schedules that can be

programmed for a period of 10 consecutive weeks.

• On-screen Delayed Second Stop function and

VSD savings indication.

• Graphical indication Serviceplan.

• Remote control and connectivity functions.

• Software upgrade available to control up to 6 compressors

by installing the optional integrated compressor controller.

GA 15-26: Elektronikon® controller GA 11+-30 & GA 15-37 VSD+: Advanced Elektronikon® graphic controller

Optional integrated compressor controllerInstall, with a simple license, the optional integrated compressor controller and get

simple, central control to reduce system pressure and energy consumption in

installations of up to 4 (ES4i) or 6 (ES6i) VSD compressors.

Dual pressure set point & delayed second stopMost production processes create fluctuating levels of demand which,

in turn, can create energy waste in low use periods. Using either the

standard or graphic Elektronikon® controller, you can manually or

automatically create two different system pressure bands to optimize energy use

and reduce costs at low use times. In addition, the sophisticated Delayed Second Stop

(DSS) runs the drive motor only when needed. As the desired system pressure is maintained

while the drive motor’s run time is minimized, energy consumption is kept at a minimum.

Recover and save energyAs much as 90% of the electrical energy used by a compressed air solution is converted into heat. Using Atlas Copco’s integrated

energy recovery systems, it is feasible to recover up to ≈ 75% of that power input as hot air or hot water without any adverse influence

on the compressor’s performance. Through efficient usage of the recovered energy, you bring about important energy cost savings and

obtain a high return on investment.

Time Time

Power Power

Applications• Auxiliary or main heating of warehouses,

workshops…

• Industrial process heating

• Water heating for laundries, industrial

cleaning and sanitary facilities

• Canteens and large kitchens

• Food industry

• Chemical and pharmaceutical industries

• Drying processes

Without DSS With DSS

Saved energy

LoadedLoaded

Unloaded

Unloaded Stopped

EXCELLENCE IN QUALITY AIRUntreated compressed air contains moisture, aerosols and dirt particles that can damage your air system

and contaminate your end product. The resulting maintenance costs can far exceed air treatment costs.

GA compressors provide the clean, dry air that improves your system’s reliability, avoiding costly downtime

and production delays, and safeguarding the quality of your products.

Main benefits of the new, integrated dryer solutions• Thanks to the Saver Cycle, based on an extra ambient

sensor, the dryer will shut down when a normal dew point

is reached, meaning that 2/3 of the dryer’s power can be

recuperated (standard on GA VSD+, optional for GA+).

• Available in several variants, allowing you to gain

high-quality air in all ambient conditions.

• The heat exchanger with integrated water separator

minimizes the energy required to reach a certain air quality.

• Pressure dew point at 3°C on GA+ and GA VSD+ (100%

relative humidity at 20°C, 5°C on GA).

• The dryer’s global warming potential has been reduced by

44%. This not only results from the refrigerant type R134a’s

environmentally-friendly characteristics, but also from the

smaller volume that is needed (valid for both GA+

and GA VSD+).

• Can be outfitted with optional UD+ filter,

allowing you to obtain the exact air quality you need for

your specific application (DD and PD for GA 15-26; UD+ for

GA 11+-30 and GA 15-37 VSD+).

ISO QUALITY CLASS* DIRT PARTICLE SIZEWATER PRESSURE DEW POINT GA **

WATER PRESSURE DEW POINT GA+ **

OIL CONCENTRATION

Pack unit 3.-.4 3 microns - - 3 ppm

Full Feature unit 3.4.4 3 microns +5°C, 41°F +3ºC, 37°F 3 ppm

Full Feature unit with Class 2 integrated filter 2.4.2 1 micron +5°C, 41°F +3ºC, 37°F 0.1 ppm

Full Feature unit with Class 1 integrated filter 1.4.1 0.01 microns +3°C, 37°F +3ºC, 37°F 0.01 ppm

* The table values are maximum limits according to the respective ISO quality class.** Water pressure dew point based on 100% RH at 20°C/68°F.

Integrated purityMany Atlas Copco compressors (Full Feature option) come with an integrated dryer that efficiently removes moisture, aerosols and

dirt particles to protect your investment. This quality air expands the life of equipment, increasing efficiency and ensuring quality

in your final product.

GA 15-26 GA 11+-30 GA 15-37 VSD+

Integrated filter Class 1 • • •Integrated filter Class 2 • • •Dryer bypass • • •Integrated oil/water separator OSD - • •Electronic Water Drains (EWD) on coolers •Air receiver drain EWD • - -Oil retaining frame - • •Motor space heater • - -Motor space heater + thermistors - • •Phase sequence relay •Tropical thermostat • • -Freeze protection • • •Heavy duty air inlet filter - • •Fan Saver Cycle - •Compressor inlet pre-filter - • •Rain protection - • •Main power isolater switch • • •Lifting device - • •Nema 4 & Nema 4X cubicle (under release) - • •Relays for ES100 sequence selector - • -Central control license 4 (ES4i) or 6 (ES6i) machines (on graphic) • • •Elektronikon® graphic controller* •Food-grade oil • • •Roto-Xtend duty oil • • •Energy recovery - • •Modulating control - • -High ambient temperature versions (55°C for pack, 50°C for FF) - • -Compressor duct power fan (under release) - - -Dryer Save Cycle - • •

TAILORED TO YOUR NEEDSSome applications may need or may benefit from additional options and more

refined control and air treatment systems. To meet these needs, Atlas Copco has

developed options and easily integrated compatible equipment providing the

lowest cost compressed air.

* Optional for GA 30. - : Not available : Standard • : Optional

TECHNICAL SPECIFICATIONS GA 15-26

GA 15-26 (FULL FEATURE)

GA 15-26 (STANDARD)

H1: 1832 mm, 72”H2 : 1220 mm, 48”L1: 1280 mm, 50”L2: 1904 mm, 75”W: 833 mm, 33”

H1: 1827 mm, 72"H2: 1220 mm, 48”L1: 1775 mm, 70”L2: 1904 mm 75"W: 833 mm, 33”

COMPRESSOR TYPE

Max. working pressureCapacity FAD* Installed motor power

Noise level**

Weight (kg)

WorkPlace WorkPlace Full FeatureWorkPlace

WorkPlace Full Featurebar(e) psig bar(e) psig l/s m³/h cfm kW hp dB(A)

50 Hz VERSION

GA 15 7.5 7.5 109 7.3 105 45.7 164.2 96.9 15 20 65 375 529

8 8.5 116 8.3 120 43.6 157 92.4 15 20 65 375 529

10 10 145 9.8 141 37.85 136.2 80.2 15 20 65 375 529

13 13 189 12.8 185 32.4 116.6 68.7 15 20 65 375 529

GA 18 7.5 7.5 109 7.3 105 56.5 203.4 119.8 18.5 25 67 464 559

8 8.5 116 8.3 120 52.5 189 111.3 18.5 25 67 464 559

10 10 145 9.8 141 47 169.2 99.6 18.5 25 67 464 559

13 13 189 12.8 185 39.5 142.2 83.7 18.5 25 67 464 559

GA 22 7.5 7.5 109 7.3 105 64.6 232.6 137 22 30 68 480 575

8 8.5 116 8.3 120 62.4 224.6 132.3 22 30 68 480 575

10 10 145 9.8 141 54.2 195.1 114.9 22 30 68 480 575

13 13 189 12.8 185 47.6 171.4 101 22 30 68 480 575

GA 26 7.5 7.5 109 7.3 105 72.8 262.1 154.3 26 35 69 490 585

8 8.5 116 8.3 120 70.5 253.8 149.5 26 35 69 490 585

10 10 145 9.8 141 66.1 238 140.1 26 35 69 490 585

13 13 189 12.8 185 56.2 202.3 119.1 26 35 69 490 585

60 Hz VERSION

GA 15 100 7.4 107 7.2 104 45.4 163.4 96.2 15 20 65 375 529

125 9.1 132 8.9 128 41.5 149.4 88 15 20 65 375 529

150 10.8 157 10.3 149 38.2 138.5 81 15 20 65 375 529

175 12.5 181 12.3 178 30.9 111.2 65.5 15 20 65 375 529

GA 18 100 7.4 107 7.2 104 56.5 203.4 119.8 18.5 25 67 464 559

125 9.1 132 8.9 128 51.8 186.5 109.8 18.5 25 67 464 559

150 10.8 157 10.3 149 45.6 164.2 96.7 18.5 25 67 464 559

175 12.5 181 12.3 178 41 147.6 86.9 18.5 25 67 464 559

GA 22 100 7.4 107 7.2 104 66 237.6 139.9 22 30 68 480 575

125 9.1 132 8.9 128 59.2 213.1 125.5 22 30 68 480 575

150 10.8 157 10.3 149 53.7 193.3 113.8 22 30 68 480 575

175 12.5 181 12.3 178 47.8 172.1 101.3 22 30 68 480 575

GA 26 100 7.4 107 7.2 104 74.3 267.5 157.5 26 35 69 490 585

125 9.1 132 8.9 128 69.2 249.1 146.7 26 35 69 490 585

150 10.8 157 10.3 149 62.5 225 132.5 26 35 69 490 585

175 12.5 181 12.3 178 57.6 207.4 122.1 26 35 69 490 585

Intake air

Compressed air without free water

Air/oil mixture

Dry compressed air

Oil

Water

Wet compressed air

Refrigerant gas/liquid mixture

Condensate

High pressure, hot refrigerant gas

Dry air

Low pressure, cool refrigerant gas

Gaseous coolant

High pressure refrigerant liquid

Liquid coolant

Low pressure refrigerant liquid

L2

W

H1 H2

L1

1

2

4

5

6

78

9

1011

15*

12

13

14

16

3

17

Intake air

Air/oil mixture

Oil

Wet compressed air

Condensate

Dry compressed air

TECHNICAL SPECIFICATIONS GA 15-37 VSD+

* Unit performance measured according ISO 1217 ed. 4 2009, annex E, latest edition. ** Mean noise level measured at a distance of 1 m according to ISO 2151: 2004 using ISO 9614/2 (sound intensity method); tolerance 3 dB(A).

Reference conditions: - Absolute inlet pressure 1 bar (14.5 psi). - Intake air temperature 20°C, 68°F.

FAD is measured at the following effective working pressures: - 5.5 bar(e)- 7 bar(e)- 9.5 bar(e)- 12.5 bar(e)Maximum working pressure: - 13 bar(e) (188 psig)

COMPRESSOR TYPE

Maximum working pressureCapacity FAD* min-max Installed motor power Noise level**

Weight (kg)

WorkPlaceWorkPlace

WorkPlace Full Featurebar(e) psig l/s m³/h cfm kW hp dB(A)

GA 15 VSD+ 5.5 80 7.2-42.3 25.9-152.3 15.2-89.6 15 20 64 199 288

7 102 7.1-41.8 25.6-150.5 15.0-88.6 15 20 64 199 288

9.5 138 6.8-35.5 24.5-127.8 14.4-75.2 15 20 64 199 288

12.5 181 7.3-27.9 26.3-100.4 15.5-59.1 15 20 64 199 288

GA 18 VSD+ 4 58 15.1-63.9 54.4-230 32-135.4 18 25 67 367 480

7 102 14.9-62.5 53.6-225 31.6-132.4 18 25 67 367 480

9.5 138 17.1-53.6 61.6-193 36.2-113.6 18 25 67 367 480

12.5 181 16.4-43.5 59-156.6 34.7-92.2 18 25 67 367 480

GA 22 VSD+ 4 58 15.3-76.9 55.1-276.8 32.4-162.9 22 30 67 363 485

7 102 15-75.1 54-270.4 31.8-159.1 22 30 67 363 485

9.5 138 17.3-65.2 62.3-234.7 36.7-138.2 22 30 67 363 485

12.5 181 17.1-54.1 61.6-194.8 36.2-114.6 22 30 67 363 485

GA 26 VSD+ 4 58 14.9-86.3 53.6-310.7 31.6-182.9 26 35 67 373 490

7 102 14.5-85.5 52.2-307.8 30.7-181.2 26 35 67 373 490

9.5 138 17-78.4 61.2-282.2 36-166.1 26 35 67 373 490

12.5 181 16.4-64.5 59-232.2 34.7-136.7 26 35 67 373 490

GA 30 VSD+ 4 58 15.1-98 54.4-352.8 32-207.7 30 40 67 376 500

7 102 15-97.4 54-350.6 31.8-206.4 30 40 67 376 500

9.5 138 17.1-85.6 61.6-308.2 36.2-181.4 30 40 67 376 500

12.5 181 16.7-72 60.1-259.2 35.4-152.6 30 40 67 376 500

GA 37 VSD+ 4 58 15.3-116.5 55.1-419.4 32.4-246.8 37 50 67 376 500

7 102 14.8-115 53.3-414 31.4-243.7 37 50 67 376 500

9.5 138 17.1-102.3 61.6-368.3 36.2-216.8 37 50 67 376 500

12.5 181 16.4-86.7 59-312.1 34.7-183.7 37 50 67 376 500

Inlet filter

Sentinel valve

Screw element

Interior permanent magnet motor (iPM)

Air/oil vessel

Thermostatic bypass valve

Oil filter

Safety valve

Oil separator

Minimum pressure valve

Solenoid valve

After-cooler

Fan

Oil-cooler

Electronic drain (* mounted on after-cooler on models without dryer)

Dryer (Full Feature option)

Condensation prevention cycle

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

GA 18-37 VSD+ (STANDARD/

FULL FEATURE)

GA 15 VSD+ (STANDARD/

FULL FEATURE)

H: 1420 mm, 56”L: 630 mm, 25”W: 610/985 mm, 24/39”

H: 1590 mm, 63”L: 780 mm, 31”W: 811/1273 mm, 32/50”

L

W

H

816

17

22

18

19

20

9

8

21

10

3

5

6

7 9

1112

14

1315

1

2

TECHNICAL SPECIFICATIONS GA 11+-30 (50 HZ VERSION)

COMPRESSOR TYPE

Max. working pressureCapacity FAD* Installed motor power

Noise level**

Weight (kg)

WorkPlace WorkPlace Full FeatureWorkPlace

WorkPlace Full Featurebar(e) psig bar(e) psig l/s m³/h cfm kW hp dB(A)

GA 11+ 7.5 7.5 109 7.3 105 35,8 128,9 75,9 11 15 63 410 455

8.5 8.5 116 8.3 120 33,8 121,7 71,7 11 15 63 410 455

10 10 145 9.8 141 30,3 109,1 64,2 11 15 63 410 455

13 13 189 12.8 185 25,2 90,7 53,4 11 15 63 410 455

GA 15+ 7.5 7.5 109 7.3 105 46,9 168,8 99,4 15 20 64 420 470

8.5 8.5 116 8.3 120 43,8 157,7 92,9 15 20 64 420 470

10 10 145 9.8 141 39,8 143,3 84,4 15 20 64 420 470

13 13 189 12.8 185 32,8 118,1 69,5 15 20 64 420 470

GA 18+ 7.5 7.5 109 7.3 105 58,1 209,2 123,2 18.5 25 65 440 500

8.5 8.5 116 8.3 120 54,3 195,5 115,1 18.5 25 65 440 500

10 10 145 9.8 141 48,7 175,3 103,2 18.5 25 65 440 500

13 13 189 12.8 185 41,1 148,0 87,1 18.5 25 65 440 500

GA 22+ 7.5 7.5 109 7.3 105 68,2 245,5 144,6 22 30 66 455 515

8.5 8.5 116 8.3 120 64,5 232,2 136,7 22 30 66 455 515

10 10 145 9.8 141 58,1 209,2 123,2 22 30 66 455 515

13 13 189 12.8 185 50,7 182,5 107,5 22 30 66 455 515

GA 26+ 7.5 7.5 109 7.3 105 79,8 287,3 169,2 26 35 67 525 595

8.5 8.5 116 8.3 120 76,2 274,3 161,5 26 35 67 525 595

10 10 145 9.8 141 69,3 249,5 146,9 26 35 67 525 595

13 13 189 12.8 185 60,1 216,4 127,4 26 35 67 525 595

GA 30 7.5 7.5 109 7.3 105 90,0 324,0 190,8 30 40 68 540 610

8.5 8.5 116 8.3 120 86,4 311,0 183,2 30 40 68 540 610

10 10 145 9.8 141 79,8 287,3 169,2 30 40 68 540 610

13 13 189 12.8 185 68,7 247,3 145,6 30 40 68 540 610

Standard Full Feature version (FF)

Air flow

Air intake filter

Air intake valve

Compression element

Non return valve

Air/oil separator vessel

Minimum pressure valve

After-cooler

Air-air heat exchanger

Water separator with drain

DD/PD filters (optional)

Oil flow

Oil

Oil-cooler

Hermostatic bypass valve

Oil filter

Oil stop valve

Refrigerant flow

Refrigerant compressor

Condenser

Liquid refrigerant dryer/filter

Thermostatic expansion valve

Evaporator

Hot gas bypass valve

Accumulator

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

TECHNICAL SPECIFICATIONS GA 11+-30 (60 HZ VERSION)

COMPRESSOR TYPE

Max. working pressureCapacity FAD* Installed motor power

Noise level**

Weight (kg)

WorkPlace WorkPlace Full FeatureWorkPlace

WorkPlace Full Featurebar(e) psig bar(e) psig l/s m³/h cfm kW hp dB(A)

GA 11+ 100 7.4 107 7.2 104 37,0 133,2 78,4 11 15 63 410 455

125 9.1 132 8.9 128 32,0 115,2 67,8 11 15 63 410 455

10.8 157 10.3 149 29,3 105,5 62,1 11 15 63 410 455

175 12.5 181 12.3 178 25,3 91,1 53,6 11 15 63 410 455

GA 15+ 100 7.4 107 7.2 104 48,3 173,9 102,4 15 20 64 420 470

125 9.1 132 8.9 128 42,9 154,4 90,9 15 20 64 420 470

150 10.8 157 10.3 149 39,4 141,8 83,5 15 20 64 420 470

175 12.5 181 12.3 178 33,9 122,0 71,9 15 20 64 420 470

GA 18+ 100 7.4 107 7.2 104 59,6 214,6 126,4 18.5 25 66 440 500

125 9.1 132 8.9 128 53,3 191,9 113,0 18.5 25 66 440 500

150 10.8 157 10.3 149 47,8 172,1 101,3 18.5 25 66 440 500

175 12.5 181 12.3 178 42,5 153,0 90,1 18.5 25 66 440 500

GA 22+ 100 7.4 107 7.2 104 70,3 253,1 149,0 22 30 67 455 515

125 9.1 132 8.9 128 62,9 226,4 133,3 22 30 67 455 515

150 10.8 157 10.3 149 56,9 204,8 120,6 22 30 67 455 515

175 12.5 181 12.3 178 52,3 188,3 110,9 22 30 67 455 515

GA 26+ 100 7.4 107 7.2 104 81,2 292,3 172,1 26 35 67 525 595

125 9.1 132 8.9 128 74,1 266,8 157,1 26 35 67 525 595

150 10.8 157 10.3 149 67,4 242,6 142,9 26 35 67 525 595

175 12.5 181 12.3 178 60,7 218,5 128,7 26 35 67 525 595

GA 30 100 7.4 107 7.2 104 90,1 324,4 191,0 30 40 68 540 610

125 9.1 132 8.9 128 84,1 302,8 178,3 30 40 68 540 610

150 10.8 157 10.3 149 77,1 277,6 163,5 30 40 68 540 610

175 12.5 181 12.3 178 70,1 252,4 148,6 30 40 68 540 610

* Unit performance measured according to ISO 1217, Annex C, latest edition.** Mean noise level measured according to ISO 2151/Pneuro/Cagi PN8NTC2 test code; tolerance 2 dB(A).

Reference conditions: • Absolute inlet pressure 1 bar (14.5 psi)• Intake air temperature 20°C, 68°F

FAD is measured at the following working pressures:• 7.5 bar versions at 7 bar • 8 bar versions at 8 bar• 10 bar versions at 9.5 bar • 13 bar versions at 12.5 bar

Pressure dew point of integrated refrigerant dryer of GA 11+ - GA 15+ - GA 18+ - GA 22+ - GA 26+ - GA 30 at reference conditions 2°C to 3°C, 36°F to 37°F.

GA 26+ - GA 30

GA 11+ - GA 22+H: 1475 mm, 58”L: 1255 mm, 49”W: 692 mm, 27”

H: 1475 mm, 58”L: 1255 mm, 49”W: 865 mm, 34”

LW

H

COMMITTED TO SUSTAINABLE PRODUCTIVITYWe stand by our responsibilities towards our customers, towards the environment and the

people around us. We make performance stand the test of time. This is what we call –

Sustainable Productivity.

www.atlascopco.com

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INNOVATIVE COMPRESSED AIR SOLUTIONS

DESICCANT AIR DRYERS

90-8000 scfm

ZPA Heatless Regeneration

ZHA Heated Regeneration

ZBA Heated Blower Regeneration

www.zeks.com

2100ZHA

A MODEL FOR EVERY NEED

ZEKS Eclipse desiccant dryers have been engineered fromthe ground up to include the most desirable operating andservice benefits. Each component has been selected to provide long-term durability as well as energy efficiency. Inaddition, Eclipse’s low profile design permits easy viewingof critical dryer indicators while allowing for easy access to all serviceable parts.

Three models are available to enable air treatment selectionto suit the requirements of each installation:

ZPA Heatless RegenerationZHA Heated RegenerationZBA Heated Blower Regeneration

Your authorized ZEKS Distributor will help you select thebest dryer model to meet the application requirements andprovide the most favorable energy use profile.

• Heated & Heatless Regeneration Models–Designs for all drying requirements

• Options for Energy Savings-Minimize operating cost

• Low Profile Design-Reduces shipping costs and simplifies installation

• High Performance Valves-Reliable operation plus reduced maintenance

• Convenient Service Access-Minimizes maintenance time requirement

• Remote Communication Ready-Multiple communication options

• Comprehensive Warranty Coverage-Standard dryer warranty PLUS five years on flow valves and heater

RELIABLE PERFORMANCEINNOVATIVE DESIGNBefore compressed air is used in production, finishing orsensitive research or manufacturing processes, it must betreated to remove moisture and contaminants. Withoutproper treatment, air can damage tools and equipment,reduce productivity and adversely affect the quality of finishing processes and precision operations.

While the use of oil free compressors can reduce theamount of contaminants in a compressed air system, thecompression process itself causes concentrations of waterand airborne particulate to increase to harmful levels.ZEKS EclipseTM desiccant dryers effectively dry compressedair to extremely low moisture levels for use where the presence of even minimal amounts of moisture can not betolerated. In addition, with ZEKS Eclipse desiccant dryers,installations where compressed air piping is exposed toextremely low ambient temperatures won’t encounter thedetrimental effects of moisture that freezes inside compressed air lines.

www.zeks.com

DESICCANT AIR DRYERS

WARRANTY COVERAGE

1Moist compressed airenters dryer

4ZEKS particulate afterfilter protects

pneumatic tools and equipment

7Purge air flows counter-

current to regenerate thedesiccant media in the

offline (regenerating) tower, assisted by the

heat-of-adsorption

6A portion of dry purge air is directed to

the offline tower for

regeneration

8Moisture is exhausted to

atmosphere through muffler 2ZEKS coalescing prefilter

protects dryer

3Inlet flow valves automaticallydirect moist compressed air throughonline (drying) tower. As air passes overthe desiccant, the moisture is adsorbedby the desiccant. Heat is generated bythis removal of the moisture from the air(Heat-of-Adsorption)

5Dry air exits dryer for use

1Moist compressed air enters dryer

4ZEKS particulate afterfilter protects

pneumatic tools and equipment

7Purge air flows counter-current to regenerate the desiccant media in the offline (regenerating) tower

8Moisture is exhausted to atmosphere through muffler

2ZEKS coalescing prefilter

protects dryer

3Inlet flow valves automatically

direct moist compressed air throughonline (drying) tower. As air passes over thedesiccant, moisture is adsorbed by the media

5Dry air exits dryer for use

ECLIPSE TM DRYER OPERATION

ZPAmodels use a portion of dry,unheated compressed air to regeneratethe offline tower.

ZHAmodels use a smallamount of dry, heated compressedair to regenerate the offline tower.

ZBAmodels use air from a dedicatedblower that passes through a heater toregenerate the offline tower.

6A portion of dry purge air is directedthrough heater then into the offlinetower for regenerationH

EAT

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1Moist compressed air enters dryer

4ZEKS particulate afterfilter protects

pneumatic tools and equipment

7Purge air flows counter-current to regenerate the desiccant media in the offline (regenerating) tower

8Moisture is exhausted to atmosphere through muffler

2ZEKS coalescing prefilter

protects dryer

3Inlet flow valves automatically

direct moist compressed airthrough online (drying) tower.

As air passes over the desiccant, moisture is

adsorbed by the media5Dry air exits dryer for use

6Purge air is generated by blower anddirected through heater then into theoffline tower for regenerationH

EAT

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ZPAHeatless RegenerationZEKS’ ZPA desiccant dryers are available in flow rangesfrom 90 SCFM to 5000 SCFM. ZPA dryers require the use of no more than 15% of the compressed air volume forregeneration of the desiccant beds. Standard ZPA dryersdeliver -40°F pressure dew point air. For critical applications,ZPA dryers can be equipped to deliver -80°F and -100°Fpressure dew point air. With the optional DPC™ Controller,dew points ranging from -40°F to +38°F may be selectedusing the SelectDry™ feature for increased energy savings.In addition, the DPC Controller’s PurgeMizer™ feature permitsthe user to reduce the amount of purge air for applicationswhere the dryer is operated below full flow conditions. All ZPA dryers are supplied as 115V-1Ph-60Hz.

STANDARD FEATURES:

Dependable Diaphragm Switching and Purge Valves:Non-lubricated valves engineered fortrouble-free operation. Design allowsfor higher flows with lower associatedpressure drop than alternate valves.Internal valve components are easilyaccessed for routine maintenance without disconnecting valves frompipework. ZEKS dryers are designedso that the switching valves fail “open”and the purge valves fail “closed”,insuring continuous air delivery even in the event of power loss.

Reliable Solid State Timer: Used onZEKS heatless dryers for over tenyears, this design and technologydelivers precise control over all switchingand purge valve functions.

Dryer Status Indication Lights:Standard NEMA 1 dryers feature lights to indicate Left and Right Tower operation and Power On.

Purge Pressure Gauge: Visual indication of purge reactivation flow rate.

High Strength Desiccant: Minimizes dusting, increasesafterfilter element life and is unaffected by liquid waterexposure.

Blue Moisture Indicator: Continuously monitors outletairstream for excessive moisture. Indicator turns from blueto gray in the presence of an elevated air moisture content.

Control Air Filtration: ZEKS ZTF™ particulate filter protectsdryer operating controls.

ASME Coded Pressure Vessels: Carbon steel towers constructed for 150 psig MAWP operation meet ASMESection VIII, Div. 1 requirements. Towers are sized to provide low air flow velocity and high contact time.

Tower Pressure Gauges: Indicate pressure within eachtower.

Pressure Relief Valves: Standard fire-rated relief valves per API RP-520. Optional flow-rated valves available.

Sound Attenuating Purge Mufflers: Large mufflers minimize noise and include built-in relief valves to enhance safety.

Accessible Fill and Drain Ports: Port locations on eachvessel enable easy service access for scheduled change of desiccant media.

Removable Stainless Steel Diffuser Screens: Evenly distribute air through desiccant beds.

1200ZPA in NEMA 4 configuration with Purge SaverTM, Failure-to-Shift Alarm and

High Humidity Alarm options

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WARRANTY COVERAGEON FLOW VALVES

Contact your ZEKS distributor for details

OPTIONAL FEATURES:

NEMA 4/DPC™ Package: This premium electrical packageprovides increased protection of electrical components aswell as enhanced digital dryer controls and displays andincludes the following features:

– NEMA 4 Electrical Enclosure: Type 4 enclosure protects against splashing, falling, and hose-directed water as well as severe external condensation.

– UL/ULC Panel: Electrical panel constructed in accordance with UL/ULC 508A.

– DPC Controller: PLC Controller with integrated keypad interface provides instant access to dryer performance controls. The DPC controller is specifically program-med to execute all valve switching functions as well as monitor dryer operation. This fully-featured controller includes the following:

• Backlit LCD Display: Permits viewing of critical dryer parameters in all lighting conditions.

• Human-Machine Interface (HMI): Integrated keypad provides user with access to all internal functions and selectable displays.

• MODBUS Compatible: A port permits connection of the controller to MODBUS-capable networks.

• Remote Alarm Contact

• Failure Code Storage

– DynOptic™Panel: Schematic depiction of dryer provides visual indication of current operating status including:

• Dryer On• Dryer Alarm• Left/Right Tower Drying• Left/Right Tower Regeneration

– Enhanced Dryer Operation Functions: ZPA dryers with the NEMA 4/DPC Package provide the following operating functions:

• SelectDry™– Permits user to select between -40°F, -4°F or +38°F pressure dew point air. Selecting a higher dew point means lower energy costs for applications that do not require consistent -40°F pressure dew point air.

• PurgeMizer™- PurgeMizer allows the user to reduce the amount of purge air used for regeneration. Settings ranging from 30% to 100% of purge flow in 10% increments may be selected. Ideally suited to low flow applications.

• PurgeSync™- PurgeSync permits operation of the ZPA dryer to “mirror” that of the main air compressor. When the air compressor either unloads or is turned off, PurgeSync automatically completes the current drying cycle and closes the purge valves until the compressor indicates the need for more air. For applications with downstream (dry) storage, ZEKS recommends the Downstream Purge Option, sold separately, to maximize PurgeSync effectiveness.

EclipseTM dryers have been engineeredto provide a high ratio of premium desiccant per SCFM of compressed air for high operating efficiency.

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Dew Point Display: Highly accurate monitoring of dryerdew point performance with an Aluminum Oxide-type moisture sensor. Pressure dew point reading is displayedon DPC controller screen. Should a high dew point condi-tion occur, a visual alarm will be activated. Requires DPCController.

Failure-to-Shift Alarm: Automatically monitors tower pressure for proper sequencing and operation of valves.Should a valve be out of position, a visual alarm will beactivated.

High Humidity Alarm: Accurately monitors humidity levelsof the compressed air. Should a malfunction occur and ahigh humidity condition exist, a visual alarm will be activated.

Moisture Load Control: Reduces purge air consumption bymonitoring moisture loading in both towers. During low airdemand periods or low water loading (i.e. dry ambient con-ditions) the purge valves remain closed while flow controlvalves cycle as normal. By keeping purge valves closed, asignificant reduction in purge air consumption can occur,with subsequent savings in operating costs. When the moisture loading increases, the purge valves will open and begin reactivation of both towers sequentially.

Downstream Purge: Enables dryer to use dry purge airfrom downstream storage, as well as from the drying tower.Use of downstream purge in conjunction with properly sizedstorage can reduce compressor starts when air demand is low.

-80°F and -100°F Dew Points: Specially designed dryersprovide extremely low dew point air for critical applications.

250 psig and 300 psig MAWP: High pressure dryer designfor applications above 150 psig.

Filter Packages: High quality, factory installed coalescing prefilter and particulate afterfilter packages are available in a wide variety of configurations. Filter packages, featuring ZEKS ZTF filters, are available with filter and dryer bypasses for ease of service.

ZHAHeated RegenerationZBAHeated Blower RegenerationZHA heated desiccant dryers include an external heater toheat dry purge air for regeneration. This allows the dryersto use 7% purge air – significantly less than is required forheatless pressure swing type dryers. Available in sizesranging from 150 – 8000 SCFM, ZHA dryers deliver -40°Fpressure dew point air for critical drying applications. ZHA dryers are designed for a Maximum Allowable Working Pressure (MAWP) of 150 psig and are provided in 460V-3Ph-60Hz electrical configuration.

ZBA heated blower desiccant dryers are provided with adedicated blower to provide purge air for regeneration.With this design, the dryer does not rely on the dry com-pressed air for regeneration. Instead, the blower directsambient air through an external heater, thereby regeneratingthe offline tower. Using no compressed air for purge meansmore air available for critical compressed air applications.150 – 8000 SCFM models are available with each delivering -40°F pressure dew point air. A MAWP of 150 psig and460V-3Ph-60Hz electrics are standard.

STANDARD FEATURES:

High Performance Switching & Purge Valves:Dryers are equipped with reliable Jamesburyhigh performance ball and butterfly valves.These non-lubricated valves are designedspecifically for high temperature applicationsand feature stainless steel internals and filledPTFE seats. Valves include double-actingpneumatic actuators.

NEMA 4 Electrical Enclosure: Provides protection of electrical components against falling or hose-directed water and severe external condensation. Enclosure is suitable for indoor and outdoor use.

DPC™ Controller and DynOptic™ Panel:PLC Controller with integrated keypadinterface along with a schematic repre-sentation of the dryer provide instantaccess to dryer performance controlsand visual depiction of current operatingstatus. The controller is specifically programmed to execute all valve switching functions as well as monitor dryer operation. This fully-featured panel includes the following:

– Backlit LCD Display: Permits viewing of critical dryer parameters in all lighting conditions.

– Human-Machine Interface (HMI): Integrated keypad provides user with access to all internal functions and selectable displays.

– DynOpticTM Panel: Schematic depiction of dryer provides visual indication of current operating status.

– MODBUS Compatible: DPC Controller permits connectionto MODBUS-capable networks.

– Remote Alarm Contact– Failure Code Storage– Displays:

• Dryer On/Off Control• Dryer Alarm Annunciation/Cancellation• Heater Operation & Temperature Control• High Heater Temperature Alarm Indication• Heater Failure Alarm Indication• Blower Operation Control (ZBA Only)• Left/Right Tower Drying Indication• Left/Right Tower Regeneration Indication• Failure-to-Shift Alarm Indication• Regeneration Sequence Status

Failure-to-Shift Alarm: Automatically monitors tower pressure for proper sequencing and operation of valves and provides visual indication of alarm condition.

Bi-Mode Operation: ZEKS’ Bi-Mode provides systemredundancy should a heater (ZHA & ZBA) or blower (ZBAonly)- related failure occur, keeping potential downtime to a minimum. Should the heater and/or blower become inoperative, the Bi-Mode feature allows the dryer to beswitched to a heatless pressure swing operating mode.

150ZBA in standard configurationand 500ZHA with factory

installed filters

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www.zeks.com

OPTIONAL FEATURES:

High Humidity Alarm: Accurately monitors humidity levelsof the compressed air. Should a malfunction occur and ahigh humidity condition exist, a visual alarm is activated.

Moisture Load Control with Dew Point Display: Providesfully automated dryer operation based on continuous moni-toring of outlet air moisture content. Timing of the dryerregeneration sequence is adjusted to match the moistureloading on the dryer. Includes dew point display, highlyaccurate Aluminum Oxide dew point sensor and high dewpoint alarm.

Compressed Air Cooldown (ZBA Only): For blower purgedryer applications requiring tighter dew point control andlower air temperature at switchover. Control and pipingconfiguration uses unheated, dry compressed air for thefinal stage of regeneration, thereby cooling bed prior totower switchover.

Power Saver: Reduces energy consumption by matchingthe regeneration heating cycle to the actual moisture loadingof the regenerating bed. A sensor monitors the temperatureof the outlet purge air stream and stops the heater when full regeneration of the offline tower is detected. Especiallyeffective during times of low moisture loading.

Filter Packages: High quality, factory installed ZTF™coalescing prefilter and particulate afterfilter packages areavailable in a wide variety of configurations. Available withfilter and dryer bypasses for ease of service.

-100°F Dew Point (ZHA Only): Specially designed dryers provide extremely low dew point air for critical applications.

300 psig MAWP: High pressure dryer design for applicationsabove 150 psig.

AccuTemp™ Heater Control: Innovative Solid State Relayheater control. Unlike heater contactors that permit wideswings of heater temperature, ZEKS’ AccuTemp™ controllerprecisely monitors and controls heater temperature.

The result is longer valve life and extended heater life.

Incoloy Sheath External Heater: Heaters include Incoloysheath for increased element life. External mounting outsideof desiccant bed eliminates potential for desiccant scorchingwhile low watt density design provides long, reliable service life.

Heater High Temperature with Interlock Alarm: Providescontinuous monitoring of heater sheath temperature. If thesensor indicates a high temperature condition, the heater isde-energized and an alarm routine is initiated.

High Efficiency Blower (ZBA Only): Blowerprovides quiet, reliable operation. Intakefilter is positioned for convenient accessto facilitate filter element changeout.

Pressure & Temperature Gauges:Stainless steel temperature and pressuregauges, located on each tower, providevisual indication of pressure and temperature during the drying and regeneration processes.

High Strength Desiccant: Minimizes dusting, increasesafterfilter element life and is unaffected by liquid waterexposure.

Control Air Filtration: ZEKS ZTFTM particulate filter protectsdryer operating controls.

ASME Coded Pressure Vessels: Carbon steel towers constructed for 150 psig MAWP operation meet ASMESection VIII, Div. 1 requirements. Towers are sized to provide low air flow velocity and high contact time.

Pressure Relief Valves: Standard fire-rated relief valves per API RP-520. Optional flow-rated valves available.

Sound Attenuating Purge Mufflers: Large mufflers minimize noise and include built-in relief valves to enhance safety.

Accessible Fill and Drain Ports: Port locations on eachvessel enable easy service access for scheduled change of desiccant media.

Removable Stainless Steel Diffuser Screens: Evenly distribute air through desiccant beds.

RELIABILITY&

INNOVATION

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DESICCANT AIR DRYERS

395oF

390oF

385oF

380oF

375oF

370oF

365oF

360oF

355oFAccuTempTM Control Thermostat and Contactor

WARRANTY COVERAGEON FLOW VALVES

AND HEATERContact your ZEKS distributor for details

ZPAHeatlessRegeneration

ZHAHeatedRegeneration

ZBAHeated BlowerRegeneration

1302 Goshen ParkwayWest Chester, PA 19380

Phone: 610-692-9100 800-888-2323Fax: 610-692-9192www.zeks.com

Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication wasapproved for printing. The company reserves the right to change specifications, discontinue models, equipment or design withoutnotice and without incurring obligation. The information set out in this brochure is for preliminary information only and is not intendedto constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.

ZPA/ZHA/ZBA-1207-DBO

Performance data obtained and presented in accordance with CAGI Standard 200. Pressure dew point (PDP) at 100 psig, 100oF inlet air, 100oF ambient air.Pressure vessels are designed and constructed in accordance with ASME and CRN requirements.Maximum working pressure is 150 psig.Minimum working pressure is 75 psig.Desiccant is factory-installed on models 90-2700 ZPA and 150-2100 ZHA/ZBA.Desiccant ships loose on all other models.

FLOW CAPACITY AIR DIMENSIONS** SHIPPINGSCFM HEATER BLOWER CONNECTION INCHES WEIGHTMODEL -40oF* PDP -100oF* PDP KW HP IN/OUT WIDTH DEPTH HEIGHT LBS

90ZPA 90 72 – – 1.0”NPT 40.5 30.0 63.0 531120ZPA 120 96 – – 1.0”NPT 40.5 30.0 63.0 563160ZPA 160 128 – – 1.5”NPT 44.5 32.0 66.0 707200ZPA 200 160 – – 1.5”NPT 44.5 32.0 66.0 731250ZPA 250 200 – – 1.5”NPT 48.5 32.0 67.0 869300ZPA 300 240 – – 2.0” NPT 48.5 32.0 67.0 924400ZPA 400 320 – – 2.0” NPT 52.5 32.0 68.0 1115500ZPA 500 400 – – 2.0”NPT 56.5 34.0 82.0 1564600ZPA 600 480 – – 2.0”NPT 56.5 34.0 82.0 1664800ZPA 800 640 – – 3.0”NPT 64.0 42.0 88.0 20171000ZPA 1000 800 – – 3.0”NPT 64.0 42.0 88.0 22371200ZPA 1200 960 – – 3.0”NPT 64.0 42.0 88.0 24241500ZPA 1500 1200 – – 4.0”FLG 78.5 55.0 81.0 29741800ZPA 1800 1440 – – 4.0”FLG 84.0 61.0 94.0 39052100ZPA 2100 1680 – – 4.0”FLG 84.0 61.0 94.0 42792700ZPA 2700 2160 – – 4.0”FLG 84.0 61.0 94.0 49263300ZPA 3300 2640 – – 6.0”FLG 96.0 66.0 98.0 67374000ZPA 4000 3200 – – 6.0”FLG 96.0 66.0 98.0 72065000ZPA 5000 4000 – – 6.0”FLG 102.0 72.0 90.0 8932150ZHA 150 150 2.0 – 1.0” NPT 44.5 32.0 66.0 758200ZHA 200 200 3.0 – 1.5”NPT 48.5 32.0 67.0 913250ZHA 250 250 3.0 – 1.5”NPT 52.5 32.0 68.0 1119300ZHA 300 300 3.0 – 1.5” NPT 52.5 32.0 68.0 1191400ZHA 400 400 4.5 – 2.0” NPT 56.5 34.0 82.0 1539500ZHA 500 500 4.5 – 2.0”NPT 56.5 34.0 82.0 1707600ZHA 600 600 6.0 – 3.0”NPT 64.0 47.0 86.0 2369800ZHA 800 800 9.0 – 3.0”NPT 64.0 47.0 86.0 26811000ZHA 1000 1000 9.0 – 3.0”NPT 78.5 48.0 80.0 30431200ZHA 1200 1200 12.0 – 3.0”NPT 78.5 48.0 80.0 32851500ZHA 1500 1500 15.0 – 3.0”NPT 84.0 55.0 92.0 44801800ZHA 1800 1800 18.0 – 4.0”FLG 84.0 60.0 92.0 49562100ZHA 2100 2100 18.0 – 4.0”FLG 84.0 60.0 92.0 53503000ZHA 3000 3000 30.0 – 4.0”FLG 96.0 66.0 98.0 77504000ZHA 4000 4000 36.0 – 6.0”FLG 102.0 76.0 90.0 95785000ZHA 5000 5000 50.0 – 6.0”FLG CF CF CF CF6000ZHA 6000 6000 60.0 – 6.0”FLG CF CF CF CF8000ZHA 8000 8000 75.0 – 8.0”FLG CF CF CF CF150ZBA 150 – 3.0 1.0 1.0” NPT 44.5 32.0 66.0 874200ZBA 200 – 4.5 1.0 1.5”NPT 48.5 32.0 67.0 1136250ZBA 250 – 6.0 1.5 1.5”NPT 52.5 32.0 68.0 1379300ZBA 300 – 6.0 1.5 1.5” NPT 52.5 32.0 68.0 1477400ZBA 400 – 9.0 2.0 2.0” NPT 56.5 34.0 82.0 1897500ZBA 500 – 12.0 2.0 2.0”NPT 56.5 34.0 82.0 2111600ZBA 600 – 12.0 5.0 3.0”NPT 64.0 47.0 86.0 2804800ZBA 800 – 18.0 5.0 3.0”NPT 64.0 47.0 86.0 31981000ZBA 1000 – 24.0 7.5 3.0”NPT 78.5 48.0 80.0 37671200ZBA 1200 – 24.0 7.5 3.0”NPT 78.5 48.0 80.0 40911500ZBA 1500 – 30.0 15.0 3.0”NPT 84.0 55.0 92.0 55151800ZBA 1800 – 36.0 15.0 4.0”FLG 84.0 60.0 92.0 61132100ZBA 2100 – 45.0 15.0 4.0”FLG 84.0 60.0 92.0 69113000ZBA 3000 – 60.0 20.0 6.0”FLG 96.0 66.0 98.0 97304000ZBA 4000 – 80.0 25.0 6.0”FLG 102.0 76.0 90.0 121675000ZBA 5000 – 100.0 30.0 6.0”FLG CF CF CF CF6000ZBA 6000 – 125.0 30.0 6.0”FLG CF CF CF CF8000ZBA 8000 – 175.0 40.0 8.0”FLG CF CF CF CF

ECLIPSE TM SPECIFICATIONS

www.cagi.org

* ** Dimensions shown are for base models only. Optional equipment mayalter dryer dimensions. Dimensions and weights are approximate. All ZPA dryers are supplied as 115V-1Ph-60Hz.All ZHA and ZBA dryers are supplied as 460V-3Ph-60Hz.CF = Consult Factory

TM ZBA 150-8000 V0615

TECHNICAL MANUAL

COMPRESSED AIR SOLUTIONS

ZBA HEATED BLOWER PURGE150-8,000 SCFM

ZEKS Compressed Air Solutions

1302 Goshen ParkwayWest Chester, PA 19380

Phone: 610-692-9100800-888-2323

Fax: 610-692-9192

Web: www.zeks.com

NOTICE

Those operating the machine or performing maintenanceshould read and understand the decals positioned on themachine and the contents of this Technical Manual.Ensure that this Technical Manual is not removed permanently from the machine.

TABLE OF CONTENTSPAGE

1. INTRODUCTION 2

2. ABBREVIATED WARRANTY 2

3. HEATED BLOWER DRYER NOMENCLATURE 3

4. RECEIVING AND INSPECTION 4

5. SAFETY AND OPERATION PRECAUTIONS 5

6. PRINCIPLES OF OPERATION 8

7. ALARMS AND INDICATORS 17

8. TECHNICIAN MODE 21

9. INSTALLATION/INITIAL START-UP 30

10. MAINTENANCE AND SYSTEM CHECK 35

11. TROUBLESHOOTING 39

ATTACHMENTS

A. GENERAL ARRANGEMENT DRAWING

B. WIRING DIAGRAM

C. P & ID DIAGRAM

D. ENGINEERING SPECIFICATIONS

E. PARTS LIST

ZBA HEATED BLOWER PURGE150-8,000 SCFM

1. INTRODUCTION

ZEKS Eclipse™ Blower Purge Desiccant Dryers are designed to adsorb moisture from

compressed air. The dryers are constructed with two towers, each containing desiccant

beads, that alternate between on-line (drying) and offline (regenerating) modes, yielding

a continuous stream of dry air at the dryer’s outlet.

During normal operation, wet air passes through the on-line tower and water vapor from the

air is adsorbed (collected) on the desiccant beads. While air is being adsorbed in the on-line

tower, the moisture on the desiccant in the offline tower is removed by a process called

desorption (regeneration). In standard blower purge operation, after an initial rapid depres-

surization, air from a blower on the dryer skid passes through a heater and over the desiccant

bed and carries the moisture off the bed and out the dryer’s exhaust. With the dryer’s Bi-Mode

feature, the dryers may also be operated in a Heatless mode, which uses dry compressed

air as the purge air source but does not require use of the heater or blower.

The continuous, alternating process of adsorption and desorption is controlled using a

Programmable Logic Controller that switches the towers in a specific timed sequence. Very

dry compressed air dew points are achieved through the continuous switching and operation

of this dryer.

2. ABBREVIATED WARRANTY

ZEKS Eclipse™ blower purge 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 on-line at www.zeks.com.

The total warranty period cannot exceed 18 months from the original date of shipment from

the factory.

Equipment must be installed and operated in accordance with ZEKS’ recommendations.

ZEKS liability is limited to repair of, refund of purchase price paid for, or replacement in kind

at ZEKS’ sole option, during the warranty time period stated above. IN NO EVENT SHALL

ZEKS BE LIABLE OR RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,

even if the possibility of such incidental or consequential damages has been made known to

ZEKS Compressed Air Solutions. In addition, the usual maintenance and replacement type

products are not covered by this warranty.

The warranties expressed above are in lieu of and exclusive of all other warranties. There

are no other warranties, expressed or implied, except as stated herein. There are no implied

warranties of merchantability or fitness for a particular purpose, which are specifically

disclaimed.

2

3

3. HEAT REACTIVATED DRYER NOMENCLATURE

NOMINAL

FLOW

SCFM* TYPE / DESIGN SERIES ELECTRICAL POWER OPTIONS

150 ZBA = Blower Purge 4 = 460-3-60 ( -40°F pdp)

200 D = 460-3-60 (-100°F pdp)

250 5 = 230-3-60 ( -40°F pdp)

300 E = 230-3-60 (-100°F pdp)

400 6 = 575-3-60 ( -40°F pdp)

500 F = 575-3-60 (-100°F pdp)

600

800

1000

1200

1500

1800

2100

3000

4000

5000

6000

8000

H = NEMA 4, 150 psig

E = NEMA 4, 300 psig

F = NEMA 4XF, 150 psig

J = NEMA 4XF, 300 psig

S = NEMA 4XS, 150 psig

U = NEMA 4XS, 300 psig

0 = Standard

P = Non Standard PLC

R = Remote START/STOP

E = Non-Fused Disconnect

F = Fused Disconnect

0 = Standard

B = High Humidity

M = Moisture Load Control

P = Power Saver

T = High Outlet Temp.

0 = Standard

3 = Tower Insulation

9 = SS Control Air Lines

G = INLET/OUTLET Temp.

and Press. Gauges

S = Steam Heat Reactivation

4

4. RECEIVING AND INSPECTION

4.1 INSPECTION

Upon receiving your ZEKS air dryer, please inspect the unit closely. Visually check the

dryer to make certain that all air lines and electrical connections are securely fastened and

were not damaged in transit. If rough handling is detected, note it on your delivery receipt,

especially if the dryer will not be immediately uncrated. Obtaining the delivery person’s

signed agreement to any noted damage will facilitate filing of an insurance claim.

4.2 UNPACKING AND HANDLING

Refer to the General Arrangement drawing for the appropriate means for lifting or moving

the dryer. For those dryers that indicate lifting via the structural skid, forks should extend

all the way through the skid to reduce unnecessary forces to the dryer during moving.

When lifting the dryer, ensure that no stress is applied to the piping or valving. Refer to

SECTION 7.2 for locating and mounting of dryer.

Under no circumstances should any person attempt to lift heavy objects without proper

lifting equipment (ie.: crane, hoist, slings or fork truck). Lifting any unit without proper

lifting equipment can cause serious injury.

NOTICE

5

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 obser-

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

1. Only qualified personnel shall be permitted to

adjust, perform maintenance or repair this dryer.

2. Read all instructions completely before operating

unit.

3. Pull main electrical disconnect switch and discon-

nect any separate control lines, if used, before

attempting to work or perform maintenance on the

unit.

4. Do not attempt to remove any part while dryer is in

an operational mode.

5. Do not attempt to remove any parts without first

relieving the entire air system of pressure.

6. Do not operate the dryer at pressures in excess of

its rating.

7. Inspect unit daily to observe and correct any unsafe

operating conditions.

“Notice” is used to indicate a

statement of company policy as

the message relates directly or

indirectly to the safety of person-

nel or protection of property.

Notice should not be associated

directly with a hazard or haz-

ardous situation and must not be

used in place of “Danger,”

“Warning,” or “Caution.”

“Caution” is used to indicate a

hazardous situation which may

result in minor or moderate injury.

“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 person-

al injury risk is present.

OSHA Heading

Description

5. SAFETY AND OPERATION PRECAUTIONS

5.1 PRECAUTIONS AND MARKINGS

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:

NOTICE

CAUTION

NOTICE

WARNING

6

5.2 SAFETY CONSIDERATIONS FOR DRYER INSTALLATION

ZEKS ZBA series blower purge desiccant dryers are designed to regenerate the towers in

an up-flow configuration. The heated regeneration air is exhausted from the tower through

a dedicated full flow purge exhaust valve that is provided for each tower. The exhaust

valves are located on the upper manifold and are positioned to discharge the hot regener-

ation air stream vertically above the dryer.

During the regeneration cycle, the temperature of the air exiting the valve and the surface

temperature of the tower undergoing regeneration & the associated purge piping will

exceed 200°F. The regeneration cycle may last up to 3.75 hours during a normal cycle.

The following safety considerations must be taken into account by the customer during the

installation process:

Proper ventilation:

The unit shall be installed in an area with sufficient means to properly exhaust the heat

emitted during the regeneration process. This is required in order to prevent unnecessary

heat build-up during unit operation. The installer shall be responsible for ensuring the ven-

tilation system complies with building codes that are recognized both nationally and locally.

Heated surfaces during regeneration process:

Additional field installed provisions such as additional insulation may be field provided for

the vessels and purge piping to safeguard against hot surface contact during unit opera-

tion. Proper training must be provided to on-site personnel by the installer and equipment

owner.

Purge Exhaust Vent Lines (Optional):

The left and right tower full flow purge exhaust valves can be vented to an external loca-

tion. This can be accomplished via a field supplied and installed piping system. The exter-

nal piping system will aid in minimizing the heat load on the space during the regeneration

cycle. The following must be taken into consideration for this option:

• The exhaust valves for each tower can be piped into a common header or be piped

separately.

• All exhaust risers should have a drip leg to collect condensate. A ball valve must be

provided to allow the condensate to properly drain and not collect within the piping.

The ball valve should be rated for this temperature.

7

• The piping must be sized appropriately in order to prevent additional pressure drop to

the blower and the piping shall be properly rated for the temperature of the regenera-

tion exhaust airstream. The temperature of the air exiting the full flow purge valve will

exceed 350°F near the end of the regeneration step. Plastic piping cannot be used

for this application.

The blower is not designed to incur additional pressure drop due to external pip-

ing. The length of the external piping shall be kept to a minimum and it must be

sized such that the additional piping pressure drop will not exceed 0.1 PSI.

• Vertical pipe penetrations through a roof structure: Vertical pipes extending beyond

the roof shall be transitioned with an elbow and a section of horizontal piping (15 pipe

diameters) at a minimum to prevent water ingress back into the piping section. It is

recommended that the end section of the horizontal pipe be terminated with a 45

degree angle. An additional elbow can also be added to direct the outlet air down-

wards towards the roof.

• For pipe penetrations that extend horizontally beyond the building, the pipe should be

allowed to extend vertically above the roof line and vent onto the roof via a 90 degree

elbow. The exhaust piping shall never be piped to allow the exhaust air to be directed

to a ground location due to safety considerations.

Proper Personal Protective Equipment (PPE) should be worn in the vicinity of

compressed air equipment.

The equipment should only be installed and serviced by authorized personnel.

8

6. PRINCIPLES OF OPERATION

6.1 INTRODUCTION

As described in SECTION 1, water vapor is removed from compressed air by diverting

air flow alternately between two towers filled with activated alumina desiccant. While one

tower processes the compressed air stream adsorbing water vapor, the opposite tower

regenerates by desorbing the water vapor and venting it to atmosphere.

ZEKS Blower Purge Dryers are equipped with ZEKS’ Bi-Mode feature. The DPC™

Controller provides the ability to select between blower purge or heatless regeneration.

Both blower purge and heatless regeneration methods are described in the following

sections. Refer to SECTION 8.2 for details on switching the dryers operation between

Blower Purge and Heatless Pressure Swing operation.

6.2 DRYING CYCLE

Saturated compressed air enters the dryer and is diverted to the appropriate tower by the

Inlet Flow Valves (Refer to the Process and Instrumentation Diagram). The Right Tower

Flow Valve is actuated to a closed position to prevent air flow from entering the regenerat-

ing tower. Simultaneously, the Left Tower Flow Valve is actuated to an open position allow-

ing air flow to the drying tower. During this time, the Left Tower Purge Valve is actuated to

a closed position, preventing the compressed air from venting to atmosphere. As the com-

pressed air flows through the desiccant material in the left tower at pressure, removal of

water vapor from the air stream begins to occur through adsorption. In the adsorption

process, the desiccant material draws water vapor out of the compressed air and “holds”

it until the left tower drying cycle is complete. Compressed air flows out of the tower for

delivery to the process use. The Outlet Flow Check Valves provide air flow diversion to

the outlet air connection of the dryer.

6.3 REGENERATION CYCLE

Previously adsorbed moisture removed from the process stream gets stripped or desorbed

from the desiccant material in the regeneration process. The first stage of regeneration is

tower de-pressurization. After the Inlet Flow Valves are switched to divert air flow away

from the regenerating tower, the Depressurization Valve opens and the tower will be

depressurized. Through depressurization, a significant portion of the previously adsorbed

water vapor is stripped off of the desiccant material and exhausted to atmosphere.

The DPC™ Controller must be in the OFF position prior to changing the mode

(blower / heatless) of the dryer. After the change is made and the DPC™ is subse-

quently turned ON, the dryer will be in the new mode of operation.

NOTICE

Any time the dryer is switched between two operating modes, care must be taken

to ensure the purge adjustment valve is adjusted correctly. Refer to the specifica-

tion sheet in this manual for proper gauge setting.

CAUTION

9

6.3.1 Blower Purge Regeneration

In the blower mode, there is no dry compressed air used for regeneration. Ambient

air is drawn into the blower intake and then discharged through the purge heater

and through the regenerating tower. After tower depressurization, the heater and

blower operate for 3 hours, 44 minutes. The blower continues to operate for ten

minutes to cool the heater element.

6.3.2 Blower Purge Regeneration with Optional Compressed Air Cooldown

With the Compressed Air Cooldown feature, which uses a portion of dried com-

pressed air to cool the bed at the end of the regeneration cycle, the heater and

blower operate for 2 hours and 57 minutes. The blower continues to operate for

an additional ten minutes to cool the heater. The Repressurization Valve is then

opened, allowing dry compressed air to pass through the regenerating tower for

48 minutes.

6.3.3 Heatless Pressure Swing Regeneration

In the heatless mode, following depressurization, regeneration uses approximately

15% of the dry compressed air, expanded to atmospheric pressure to complete the

desorption process. As shown in the P & ID, the compressed air exits the drying

tower and a portion of the air flows through the Purge Adjustment Valve and the

Purge Orifice. Once the air has passed through the Purge Orifice, it expands to

atmospheric pressure and continues the regeneration process. Desorption occurs

as the desiccant releases water vapor into the regeneration air and is exhausted

through the Purge Valves. Note that in the Heatless Pressure Swing Mode, proper

setting of the purge flow is necessary to achieve optimum dryer performance.

Setting the purge flow too high will waste compressed air and if set too low, the

dryer will not achieve dew point performance. The purge adjustment manifold con-

sists of the purge adjustment valve, purge pressure gauge, and the purge orifice.

Manually adjust the purge adjustment valve until the reading on purge pressure

gauge matches the purge pressure setting listed on the specification sheet in the

front of this manual as well as the tag attached to the gauge.

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.

Failure to repressurize prior to tower switchover will result in shocking the desiccant

material and cause premature desiccant dusting.

NOTICE

When operating dryer in standard Blower Purge mode, dryer may exhibit high dis-

charge temperatures at tower switchover (300°F) and dew point spikes (+20°F).

This is considered normal operation for this equipment. Operator must insure that

equipment located downstream of dryer be capable of tolerating these conditions.

NOTICE

10

6.4.1 Blower Purge Repressurization

Three minutes prior to tower switch-over, the blower will be shut off and the Purge

Valves and Depressurization Valves will close. The Repressurization Valve will then

open, allowing air from the outlet of the dryer to pressurize the tower prior to switch-

over. During normal tower regeneration, the Repressurization Valve is closed, so that

the blower supplies the only source of regeneration air.

6.4.2 Blower Purge Repressurization with Optional Compressed Air Cooldown

Three minutes prior to tower switch-over, the Purge Valves and Depressurization

Valves will close. The Repressurization Valve will then open, allowing air from the

outlet of the dryer to pressurize the tower prior to switch-over.

6.4.3 Heatless Pressure Swing Repressurization

45 seconds prior to tower switch-over, repressurization is accomplished by closing

the appropriate Purge Valve and the Depressurization Valve. When the Purge Valve

closes, the regeneration air begins to pressurize the tower. In addition, the

Repressurization Valve opens, allowing additional air from the outlet of the dryer to

assist the purge air and to ensure adequate pressurization. During normal tower

regeneration, is held closed so that the only source of air for regeneration passes

through the purge adjustment assembly.

6.5 VALVES

Actuated valves are two-way valves that are switched using double acting actuators. Each

valve is actuated by a four-way Solenoid Valves as shown on the P & ID.

The Inlet Flow Valves are connected as normally open valves. When the dryer is de-ener-

gized, the solenoid valves for these valves supply air the “OPEN” port on the appropriate

valve actuator.

Purge Valves are connected as Normally Closed valves. When the dryer is de-energized,

the solenoid valves for these valves supply air the “CLOSED” port on the appropriate valve

actuator.

On 2,500 SCFM dryers and smaller, switching valves are provided as two-way normally

closed pilot air operated valves. Control air is supplied by solenoid valves in order to open

valves as required. On 3,000 SCFM and larger dryers, these valves are “Actuated Valves”

as described above and are operated by four-way Solenoid Valves.

Outlet Check Valves, as well as Purge Check Valves, are single direction check valves that

will allow flow in the direction shown on the P&ID but not allow flow in the opposite direc-

tion. Valve positions must be changed accordingly for the appropriate mode selected.

Actuated valves require 75 psi min. pressure for proper operation.

NOTICE

11

6.6 CONTROLS

6.6.1 DPC™ User Interface

The DPC™ display provides the user with the operating parameters and their cor-

responding values. When power is supplied to the dryer, the DPC™ will illuminate

and default to the “Standby” mode, displaying the “Press ON” prompt.

The following illustration summarizes the keypad functions.

PRESS ON

BUTTONS

• ON

Initiates PLC program. Begins system monitoring and

valve switching functions.

• OFF

Stops PLC program. Stops valve switching functions.

Initiates Shutdown Sequence. Opens Inlet Flow Valves.

Closes Purge Valves.

• SELECT DISPLAY

Allows the user to scroll through the available displays.

The last display selected will remain displayed as the

default display.

• + / -

Allows user to increase set point values. Set point

values cycle through a fixed range. Also allows

entering negative numbers in Technician.

• �Allows user to step backwards to the previous level of

the menu.

• RESET

Pressing once clears the local alarm indication and

de-energizes the remote alarm contact for many alarm

conditions. Should the alarm condition persist, the alarm

will return after the alarm inhibit time has expired.

• SET

Permits the adjustment of parameters in TECHNICIAN.

• ENTER

Used to accept changed parameters and set point

values.

• TEST

Not used in Desiccant Dryer applications

• i

Restricted Level access for factory use only.

�

Figure 1 - DPC™ Controller

12

6.6.3 DPC™ Display Parameters

The DPC™ 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 button from the DPC™ Controller

(Note that some displays are optional and may not appear on all models):

• Tower Status {LT DRY / RT REGEN or LT REGEN / RT DRY}: Provides visual

confirmation of tower drying 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 POINT TEMP: XX}: When equipped

with the optional Dew Point Display feature, provides accurate display of dryer

outlet pressure dew point.

• Heater Status (BLOWER PURGE MODE ONLY) - {On / Off}: Indicates that the

heater is being given a signal to heat the purge air.

• Blower Status (BLOWER PURGE MODE ONLY) - {On / Off}: Indicates that the

heater is being given a signal to heat the purge air.

6.6.2 DynOptic™ Panel User Interface

The DynOptic™Panel provides clear indication of dryer status via bright LED indicators.

The following illustration summarizes the panel’s features:

Dryer ON (Green)

Left Tower

Regeneration

(Yellow)

Left Tower Drying

(Yellow)

Dryer OFF / Alarm

(Red)

Right Tower

Regeneration

(Yellow)

Right Tower Drying

(Yellow)

Figure 2 - DynOptic™ Panel

Heater Operation

(Green)

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.

Blower Operation

(Green)

13

6.7 TIMING SEQUENCE

All timing functions are performed by ZEKS’ DPC™ Controller, an advanced micro PLC

designed exclusively for ZEKS Eclipse™ dryers. The DPC™ Controller is completely pro-

grammed at the factory and does not require any further adjustment. The standard timing

cycle switches the Inlet Flow Valves, 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 purge regeneration flow portion of the dryer cycle is

complete, tower repressurization begins as previously described.

6.7.1 Blower Purge Timer Cycle

In the blower purge operating mode, the DPC™ controls an eight-hour cycle. The

tower switch-over occurs every four hours. After switch-over occurs, the regenerating

tower depressurizes for 2 minutes. Once the tower is depressurized, the blower

and heater operated as described in SECTION 6.3 The optional Power Saver

feature may reduce the heating time.

6.7.2 Blower Purge Timer Cycle with Optional Compressed Air Cooldown

The Compressed Air Cooldown feature makes use of approximately 8% of the

dried compressed air for a portion of the drying cycle. Using dry purge air cools

the regenerating bed, which results in a lower compressed air temperatures at

switchover as well as reduced dew point spikes. In this mode, after switch-over

occurs, the regenerating tower depressurizes for 2 minutes. Once the tower is

depressurized, the blower and heater operated as described in SECTION 6.3.

The optional Power Saver feature may reduce the heating time.

6.7.3 Heatless Pressure Swing Timer Cycle

In the heatless operating mode, the DPC™ 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.

• Heater Temperature (BLOWER PURGE MODE ONLY) - {HEATER TEMP: XX}:

Indicates the heater temperature set point.

• Purge Outlet Temperature (OPTIONAL) - {PURGE OUT TEMP}: When equipped

with the optional MLC, indicates the temperature of the purge air.

• Alarms {ALARM LIST - PRESS ENTER}: Depressing <ENT> at this prompt per-

mits viewing of current alarm status and alarm history, which includes the time

and date of the alarm occurrence.

• Operating & Purge Times - {OPERATING TIMES - PRESS ENTER}: Depressing

<ENT> provides access to the operating and purge hours of operation.

• Operating Mode {OPERATING MODE: HEATLESS / BLOWER PURGE}: ZBA

dryers are capable of operating in Blower Purge and Heatless Pressure Swing

modes. This display indicates mode of operation for dryer.

Once the last screen is displayed, depressing the SELECT DISPLAY button will return the

display to the top of the list.

14

6.8 RESTART MODES

The DPC™ Controller includes a Shutdown Sequence that is activated when the dryer

OFF button is depressed. This feature positions the valves to their failsafe position and

resets the program and is the recommended method of shutting down the dryer. When the

dryer is subsequently energized, it is ready to run at the start of the program. However,

should power be cut to the dryer before the Shutdown Sequence has been initiated - as

would be the case from a power failure - the dryer will automatically re-start when power

is restored. The DPC™ will pick up where it left off in the program when power is applied.

6.9 OPERATING TIMES

In the CUSTOMER MODE, the DPC™ Controller provides access to the operating hours

of the dryer. The following describe the method to access and review the operating and

purge hours for the dryer:

Depress the SELECT DISPLAY button until the

OPERATING TIMES display appears.OPERATING TIMES

PRESS ENTERSELECTDISPLAY

Depressing the ENTER button enters the OPERATING

TIMES menu. BEGIN TIMES

Depressing the SELECT DISPLAY button displays the

cumulative operating hours of the dryer.OPERATING HOURS

000000065SELECTDISPLAY

PURGE HOURS000000009

SELECTDISPLAY

ENTER

Depressing the SELECT DISPLAY button displays the

cumulative hours the dryer has used purge air.

Depressing the ENTER button returns the display to the

top of the OPERATING TIMES menu.BEGIN TIMES

SELECTDISPLAY

Depressing the � button (located above the SET button)

returns the controller to the CUSTOMER MODE�OPERATING TIMES

PRESS ENTER

HEATER HOURS000000009

SELECTDISPLAY

Depressing the SELECT DISPLAY button displays the

cumulative hours the heater has been energized.

15

6.10 HIGH LIMIT TEMPERATURE CONTROLLER

(3000-8000ZBA; Effective Date: April 2015)

The Temperature Controller is located in the enclosure that is mounted underneath the

main control enclosure on the front of the dryer. The high limit temperature controller is an

FM-approved device that:

• Continuously monitors the sheath temperature of the heating element using a Type K

thermocouple input.

• Disables operation of the heater if the sheath temperature exceeds the high limit temper-

ature set-point and requires the user to manually reset the controller. The controller can

be reset by opening the heater enclosure and depressing the <RST Button. (See

Temperature Controller, below.)

Parameters that are preset at factory should only be changed by a factory-authorized

technician using High-Limit Controller Manual (provided as a separate document).

NOTICE

HIGH VOLTAGE - Dryer must be energized to reset Controller. Follow OSHA regulations

regarding safe working practices in a live, high voltage open enclosure. Only qualified

personnel should perform this task.

WARNING

16

The key Setup Parameters are listed in the table below.

TEMPERATURE CONTROLLER - for Sheath Temperature

PV/SV Display Mode

Press SET push button (pb) to scroll PV/SV info

PV = measured temperature (or process variable)

SV=limit set value 1000

PHLd=peak hold value

TIME=time when PV > SV

Parameter Setting Mode

Press SET pb for 2 sec to access this mode,

then press SET pb to scroll.

AL1=alarm1 setting 925

AL2=alarm2 setting 0

OH=limit action differential gap 2

dF=digital filter 1

Pb=PV bias 0

AHS=analog output scale high 2300

ALS=analog output scale low 32

LCK=set data lock [0000 (unlocked) /0111 (all locked)]

Initialization Mode

Press SET & RST pb simultaneously for 2 sec.

Change LCK setting to 1000 to modify settings

COD=0000

SL1=TC/RTD type [0=K; 1=J] 0

SL2=C/F[0/1] 1

SL3=Action @ Reset 0

SL4=alarm 1 type 11

SL5=alarm 2 type 0

SL6=limit action 10

SL7=special 1100

SL8=special 11

SL9=reset action selection [0=press for 1 sec.; 1= momentarily] 0

SL10=option selection 1

SL11=mfr own use 0

COD=0001

SLH=setting limiter Hi 2300

SLL=setting limiter Lo 32

AH1=differential gap alm1 2

AH2=differential gap alm2 0

17

7.0 ALARMS AND INDICATORS

7.1 MOISTURE INDICATOR (Standard)

The moisture indicator senses a sample of the control air which is taken from the dryer

outlet. The indicator provides a gross indication of dew point deterioration at the outlet of

the dryer. Under normal operating conditions, the indicator is blue. In the event of a dryer

malfunction or prolonged dryer shut down, it will turn gray in the presence of moisture.

7.2 HEATER HIGH TEMPERATURE ALARM WITH INTERLOCK (150-2100ZBA)

The Heater High Temperature Alarm monitors the internal temperature of the heater hous-

ing. Should a component failure occur or system conditions result in the heater tempera-

ture rising above the alarm set point, the dryer will alarm. During the alarm condition, the

heater is prevented from operating, the DPC™ halts the program at the point where the

alarm occurred and displays the condition in the DPC™ LCD display. The dryer will be

unable to be reset until the temperature of the heater has fallen below the alarm point.

To reinstate the dryer, depress the RESET button on the DPC™ Controller AND manually

reset the Heater High Temperature Safety in the electrical enclosure by depressing the

<RST Button . Note that the alarm condition will return should proper corrective action

not be taken.

7.2.1 HEATER HIGH TEMPERATURE ALARM WITH INTERLOCK

(3000-8000ZBA; Effective Date: April 2015)

The Heater High Temperature Alarm monitors the internal temperature of the heater

housing. Should a component failure occur or system conditions result in the heater

temperature rising above the alarm set point, the dryer will alarm. During the alarm

condition, the heater is prevented from operating, the DPC™ halts the program at

the point where the alarm occurred and displays the condition in the DPC™ LCD

display. The dryer will be unable to be reset until the temperature of the heater has

fallen below the alarm point. To reinstate the dryer, depress the RESET button on

the DPC™ Controller AND manually reset the Heater High Temperature Safety in

the electrical enclosure by depressing the <RST Button (See depiction below) . Note

that the alarm condition will return should proper corrective action not be taken.

18

7.3 HEATER FAILURE ALARM (Standard)

This feature produces an alarm should the heater fail to generate heat at the beginning of

the heating cycle. During the initial ten minutes of the heating cycle, the DPC™ Controller

monitors the heater temperature. Should the heater temperature fail to rise to 150°F within

the ten minute period, the Heater Failure Alarm will be triggered. During this alarm condi-

tion, power to the heater is removed and the program is halted. Depressing the RESET

button on the DPC™ Controller will reinstate the program and provided the heater prob-

lem has been remedied, continue with normal operation.

7.4 FAILURE TO SHIFT ALARM (Standard)

ZEKS Failure To Shift Alarm monitors the dryer sequencing functions to insure proper

dryer operation by sensing the pressure in each tower via tower pressure switches.

Should one of the following conditions occur, the DPC™ Controller will communicate the

alarm condition. There are several types of switching failure modes that can be detected

by the Failure To Shift Alarm feature. They are as follows:

7.4.1 Failure to Repressurize

At the end of the repressurization stage of the dryer operation, both towers should

be at line pressure. Should the pressure switches indicate that both towers are not

at line pressure, the Failure to Shift Alarm will activate and the DPC™ will stop the

program at it’s current position in the program. The user must depress the RESET

button at which time the DPC™ Controller will resume operation from the last step

in the program.

19

7.4.2 Failure to Depressurize

At the end of the depressurization stage of the dryer operation, the regenerating

tower should be at atmospheric pressure. Should the pressure switches indicate

that this is not the case, the Failure to Shift Alarm will activate and the DPC™ will

stop the program at it’s current position in the program. The user must depress the

RESET button at which time the DPC™ Controller will resume operation from the

last step in the program.

7.5 HIGH HUMIDITY ALARM (Optional)

The High Humidity Alarm communicates an alarm condition in the event that outlet dew

point deterioration occurs. One of two moisture sensors are used to sample the outlet air

moisture content. When a dryer is provided without Moisture Load Control / Dew Point

Display option, a humidistat with a relative humidity sensor is preset to communicate a

High Humidity Alarm condition when the dew point rises above -10°F (for -40°F dryers).

Refer to SECTION 8.11 for details on enabling / disabling the High Humidity alarm on

dryers equipped with this feature.

When a dryer is provided with Moisture Load Control / Dew Point Display option, a dew

point sensor is used to detect this alarm condition. The dew point sensor transmits the

outlet pressure dew point to the DPC™ Controller. The DPC™ Controller compares the

dew point to the customer specified set point. Should the dew point be greater than the

set point, a High Humidity Alarm will be initiated. Refer to SECTION 8.11 for details on

setting the High Humidity Setpoint for dryers equipped with the Moisture Load Control /

Dew Point Display feature.

7.6 HIGH OUTLET TEMPERATURE (Optional)

This option provides continuous monitoring of the the dryer discharge air temperature via

a thermostat that senses the outlet air temperature during dryer operation. Should a high

outlet temperature condition exist, the alarm is displayed on the DPC™ Controller to alert

maintenance personnel of a malfunction. This alarm does not interrupt the dryer program.

Depressing the RESET button will clear the alarm provided the alarm condition as been

addressed. Note that the alarm will clear automatically once the high temperature condi-

tion is corrected.

7.7 DEW POINT TRANSMITTER FAULT (Optional w/ MLC)

When operating the dryer with the Moisture Load Control (MLC) activated, should the

DPC™ Controller detect a fault with the Dew Point Transmitter, the Controller will display

the message, “ALARM - MLC OFF”. When this alarm indication appears, the MLC feature

is automatically disabled. Once the source of the fault is detected and remedied, the user

MUST REACTIVATE the MLC feature in TECHNICIAN MODE. Note that provided the

High Dew Point Alarm feature has been activated in TECHNICIAN MODE, depressing the

RESET button without remedying the problem will display the message “DP SENSOR

FAULT” after a brief delay. Otherwise, the dryer will continue to operate in the standard

timed drying cycle.

Note that with the MLC feature off and the High Dew Point Alarm activated in TECHNI-

CIAN MODE, should the Controller detect a fault with the Dew Point Transmitter, the

DPC™ Controller will display the message, “DP SENSOR FAULT”. As with the other

alarms, pressing RESET without addressing the source of the fault will result in an new

alarm after a brief delay.

20

Depress the SELECT DISPLAY button until the ALARM

LIST display appears.ALARM LISTPRESS ENTER

SELECTDISPLAY

Depressing the ENTER button enters the ALARM LIST

menu. BEGIN ALARMS

Depressing the SELECT DISPLAY button advances the

menu to the current alarm status. ALARM OFF SELECT

DISPLAY

Depressing the SELECT DISPLAY list displays the most

recent of the alarms stored by the DPC™. Refer to the

diagram at the end of this section for an explanation of

the ALARM LIST Display.

FAIL TO SHIFTTM 1635 DATE 1104

SELECTDISPLAY

Depressing the SELECT DISPLAY button will reveal the previous alarm condition(s), as

well as the remaining available alarm placeholders for alarms. To EXIT the ALARM LIST,

perform the following:

Depressing the � button (located above the SET button)

returns the controller to the top of the ALARM LIST.

BEGIN ALARMS �

Depressing the � button again returns the controller to

the CUSTOMER MODE.

ALARM LISTPRESS ENTER

�

ENTER

FAIL TO SHIFTTM 1635 DATE 1104

Alarm Condition

Date of Alarm

(Date-Month)

Example shows April 11

Time of Alarm

(Military Time)

Figure 3 - Alarm Screen Details

7.8 ALARM LIST

The DPC™ Controller stores the 20 most recent alarm conditions. These alarms are

stored with the type of alarm as well as the date and time the alarm occurred. This list

can greatly facilitate troubleshooting the dryer and provide an indication of dryer operation

during unattended service. The following describe the method to access and review the

alarms stored in the DPC™ Controller:

21

8.0 TECHNICIAN MODE

The DPC provides a protected TECHNICIAN 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 technician when in the TECHNICIAN MODE:

TECHNICIAN MODE should only be entered by qualified service personnel. Altering the

set points in TECHNICIAN MODE will have a significant effect on the operation of the

dryer. Incorrect set points may damage dryer and cause potential serious injury.

8.1 ENTERING TECHNICIAN MODE

To enter the TECHNICIAN MODE, perform the following keystrokes:

Pressing the “2” and “3” buttons simultaneously

enters the TECHNICIAN MODE.

BEGINTECHNICIAN MODE

SELECTDISPLAY

Depressing SELECT DISPLAY scrolls through the

available parameters. SET OPMODE

BLOWER PURGE

2 3

8.2 OPERATING MODE (BI-MODE)

As described in SECTION 6, Eclipse ZBA Blower Purge Dryers come standard with the

Bi-Mode feature, permitting the dryer to operate in a blower purge mode as well as a

heatless pressure swing mode. To change the operation mode of the dryer, perform

the following keystrokes:

WARNING

* NOTE: Setpoints indicated are adjustable ONLY when dryer is equipped with the

Moisture Load Control / Dew Point Display option. Setpoints are non-adjustable on

dryers without this option

PARAMETER DISPLAY SET POINT

BI-MODE Operation OPMODE HTLS, BLOWER

Compressed Air Cooldown COMP AIR COOLDOWN OFF, ON

SelectDry Setting (Heatless Mode Only) SELECTDRY -40, -4, +38

Heater Temperature Set Point SET HTR TEMP 300 - 425

Moisture Load Control (Optional) MOISTURE LOAD CONTROL OFF, ON

Moisture Load Control Set Point (Optional) MLC SETPOINT -76 - +68

Power Saver POWER SAVER OFF, ON

Restart Mode RESTART LAST, ZERO

Extended Heating EXTENDED HEATING OFF, ON

PurgeMizer Setting (Heatless Mode Only) PURGEMIZER 30% - 100%

High Humidity Alarm Activation (Optional) HIHUMID ALARM OFF, ON

High Humidity Set Point (Optional)* HIHUMID SETPOINT -76 - +68

22

Depress the +/- button until the desired operating mode is

displayed. Pressing SELECT DISPLAY saves the current

selection.

Depress the SELECT DISPLAY button until the SET

OPERATION MODE screen is displayed.SET OPMODE

BLOWER PURGESELECTDISPLAY

+-

SET OPMODEHEATLESS

Any time the dryer is switched between two operating modes, care must be taken

to ensure the purge adjustment valve is adjusted correctly. Refer to the specifica-

tion sheet in this manual for proper gauge setting.

CAUTION

8.3 SelectDry™ (-40°F DRYERS ONLY, HEATLESS MODE ONLY)

When the ZBA dryer is in the heatless operating mode, the SelectDry™ allows the

user to select between -40°F, -4°F and +38°F pressure dew points. Selecting a

higher (wetter) pressure dew point lengthens the drying cycle, making the regener-

ation process commence less frequently than at lower (dryer) dew points. This

results in energy savings by depressurizing the system less times per hour. The

chart below describes the available outlet pressure dew points that may be selected

along with their respective cycle times.

Depress the +/- button until the desired dew point is

displayed. Pressing SELECT DISPLAY saves the

current selection.

SELECTDISPLAY

+-

Depress the SELECT DISPLAY button until the

SELECTDRY screen is displayed.

The following illustrates the method of accessing and adjusting the SelectDry™

feature.

The DPC™ Controller must be in the OFF position prior to changing the mode

(blower / heatless) of the dryer. After the change is made and the DPC™ is subse-

quently turned ON, the dryer will be in the new mode of operation.

NOTICE

When switching the dryer operation from Heatless to Blower Purge mode, the

purge adjustment valve must be set to the closed position prior to operating dryer.

Failure to do so may cause damage to dryer.

CAUTION

SELECTDRY DEW PT-40°F (-40°C)

SELECTDRY DEW PT-4°F (-20°C)

ISO 8573.1 Pressure Cycle Regenerations

Class Dew Point Length Per Hour

2 -40oF -40oC 10 Min. 12

3 -4oF -20oC 16 Min. 7.5

4 +38oF +3oC 24 Min. 5

23

Depress the SELECT DISPLAY button until the HEATER

TEMPERATURE SET POINT screen is displayed.SELECTDISPLAY

The following illustrates the method of adjusting the setpoint for the heater

temperature:

Depressing ENTER saves the selected set point.

SETPressing the SET button permits the value of the

HEATER TEMPERATURE SETPOINT to be changed

ENTER

Use the numbers on the keypad to enter the desired

value for the HEATER TEMPERATURE setpoint. 3

8

8.5 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE ONLY)

The DPC™Controller permits the user to adjust the temperature of the heater,

thereby altering the regeneration temperature in the heated purge mode. Note

that the value must be between 300°F and 425°F.

The user is advised to only alter the regeneration temperature after being instructed to

do so by ZEKS factory personnel. Improper or inappropriate manipulation of the heater

temperature can result in degraded dryer performance, equipment damage and serious

injury. Notify ZEKS Compressed Air Solutions prior to altering the heater temperature.

Use the numbers on the keypad to enter the desired

value for the HEATER TEMPERATURE setpoint.

0Use the numbers on the keypad to enter the desired

value for the HEATER TEMPERATURE setpoint.

8.4 COMPRESSED AIR COOLDOWN (OPTIONAL)

The Compressed Air Cooldown option is available on ZBA dryers to cool the regen-

erating bed prior to switchover. For applications requiring tight dew point control,

using compressed air to cool the bed prior to switchover will provide a more consis-

tent dew point and lower outlet compressed air temperatures. To enable the

Compressed Air Cooldown mode, perform the following keystrokes:

Depress the +/- button until the desired set point is

displayed. Pressing SELECT DISPLAY saves the

current selection.

Depress the SELECT DISPLAY button until the

COMPRESSED AIR COOLDOWN screen is displayed.COMPRESSED AIRCOOLDOWN: OFF

SELECTDISPLAY

+-

COMPRESSED AIRCOOLDOWN: ON

WARNING

SET HTR TEMP375°F (190°C)

HTR TEMP SET375°F (190°C)

HTR TEMP SET3__°F (190°C)

HTR TEMP SET38_°F (190°C)

SET HTR TEMP380°F (193°C)

HTR TEMP SET380°F (190°C)

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 time period at which

point it stabilizes to an "aged" state. During this aging process at initial start-up or after

desiccant replacement, the Moisture Load Control feature should be deactivated.

8.7 MOISTURE LOAD CONTROL / DEW POINT DISPLAY (OPTIONAL)

The Moisture Load Control / Dew Point Display option includes a dew point sensor that

transmits the outlet pressure dew point to the DPC™ Controller. The DPC™ Controller

displays the outlet pressure dew point in real-time. This option package also includes

Moisture Load Control, an energy savings feature that matches moisture loading and

regeneration energy usage. The Moisture Load Control feature utilizes the data communi-

cated from the dew point sensor and extends the normal timed switching sequence in

proportion to the moisture loading on the dryer.

When the Moisture Load Control feature is turned off, all switching sequences occur as

described in SECTION 6.7. When the Moisture Load Control feature is activated, the dry-

ing 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 (-43°F

default for -40°F dryers), an immediate change in dryer operation will not be noticeable.

The dryer will continue its normal regeneration process through tower re-pressurization.

Once the tower is re-pressurized, both towers will be at line pressure but air will only flow

through the tower indicated by the DynOptic™ Panel. Tower switch over sequence is

delayed until the dew point elevates above the Moisture Load Control setpoint, at which

point tower switch over will occur.

24

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.

NOTICE

NOTICE

8.6 PurgeMizer™ (HEATLESS MODE ONLY)

In the heatless pressure swing mode, the PurgeMizer™ feature allows the user to

reduce the duration of the purge cycle to more closely match the inlet conditions to

the dryer. This feature is well suited for applications where the dryer is consistently

under-flowed, allowing only the required amount of purge air to be used. The

PurgeMizer feature allows the user to select the relative duration of the purge

cycle, from 30% - 100%, in 10% increments. The following illustrates the method

of accessing and adjusting the PurgeMizer™ feature:

Depress the +/- button until the desired percent purge is

displayed. Pressing SELECT DISPLAY saves the current

selection.

Depress the SELECT DISPLAY button until the PURGE

MIZER screen is displayed.PURGE MIZER

% PRG SELECT 100SELECTDISPLAY

+-

PURGE MIZER% PRG SELECT 70

25

Depress the +/- button until the desired set point is

displayed. Pressing SELECT DISPLAY saves the

current selection.

Depress the SELECT DISPLAY button until the

MOISTURE LOAD CONTROL screen is displayed.MOISTURE LOADCONTROL: OFF

SELECTDISPLAY

+-

8.7.1 Enabling / Disabling Moisture Load Control

The following illustrates the method of accessing and adjusting the Moisture

Load Control feature:

MOISTURE LOADCONTROL: ON

8.7.2 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 to

the desired pressure dew point. Note that on dryers equipped with Moisture

Load Control but not the Digital Dew Point Display, manipulating these

values will have no effect on Moisture Load Control operation.

To enter a negative number, depress the +/- button.

Otherwise, proceed to the next step.

Depress the SELECT DISPLAY button until the MLC SET

POINT screen is displayed.SELECTDISPLAY

+-

The following illustrates the method of adjusting the setpoint for the Moisture

Load Control feature:

Depressing ENTER saves the selected set point.

SETPressing the SET button permits the value of the MLC

SETPOINT to be changed

ENTER

Use the numbers on the keypad to enter the desired

pressure dew point temperature for the MLC setpoint.4

Use the numbers on the keypad to enter the desired

pressure dew point temperature for the MLC setpoint.1

The Moisture Load Control set point should not be lower (wetter) than the SelectDry

setting. Failure to do so will prevent the Moisture Load control feature from operating.

In addition, when operating in Moisture Load Control, the PurgeMizer™ should be set

to 100%.

NOTICE

MLC SET POINT-43°F (-41°C)

MLC SET POINT- °F (-41°C)

MLC SET POINT_-43°F (-41°C)

MLC SET POINT-4 °F (-41°C)

MLC SET POINT-41°F (-41°C)

MLC SET POINT-41°F (-40°C)

26

Depress the +/- button until the desired set point is dis-

played. Pressing SELECT DISPLAY saves the current

selection.

Depress the SELECT DISPLAY button until the POWER

SAVER screen is displayed.POWER SAVER:

OFFSELECTDISPLAY

+-

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

POWER SAVER:ON

8.9 EXTENDED HEATING (OPTIONAL, BLOWER PURGE MODE)

On dryers equipped with both the Moisture Load Control option as well as Power Saver,

the dryer may be operated in an extended heating mode. In this mode, the heating cycle

is extended while the Moisture Load Control function prolongs the drying cycle. This feature

is particularly useful when operating the dryer with new desiccant. As described earlier in

this manual, new desiccant has the ability to 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 desiccant. 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:

Depress the +/- button until the desired set point is

displayed. Pressing SELECT DISPLAY saves the

current selection.

Depress the SELECT DISPLAY button until the

EXTENDED HEATING screen is displayed.EXTENDED HEATING

OFFSELECTDISPLAY

+-

EXTENDED HEATINGON

8.8 POWER SAVER (OPTIONAL, BLOWER PURGE MODE)

On dryers equipped with Power Saver, the temperature of the purge exhaust is monitored

and displayed on the DPC™ Controller. After a tower switch-over, and at the beginning of

tower regeneration, the purge exhaust temperature will be relatively low (normally 90°F - 110°F).

The purge exhaust temperature will increase as desiccant regeneration progresses. As

nearly all of the previously adsorbed moisture is driven off of the desiccant, the exhaust

temperature will begin to rise. The timing for the temperature change will vary depending

on moisture loading on the towers. When the purge exhaust temperature reaches 195°F,

which indicates that the desiccant heating is complete, the DPC™ Controller will remove

power to the heater and subsequently the blower. On standard units, the towers will then

repressurize and remain repressurized until the tower switchover sequence is initiated. On

dryers with the optional Compressed Air Cooldown feature, the Compressed Air Cooldown

routine will commence. After cooling, the Purge Valves close and the Repressurization

Valve opens. The off-line tower remains pressurized until the tower switchover sequence

is initiated. Activation of the Power Saver feature is through the DPC™ Controller.

27

8.10 HIGH HUMIDITY ALARM (OPTIONAL)

8.10.1 Description and Activation

As described in SECTION 7.5, the High Humidity Alarm can be configured

in two ways. Without the Moisture Load Control / Dew Point Display option,

the High Humidity Alarm is triggered by a humidistat. When the dryer is

equipped with the optional Moisture Load Control / Dew Point Display fea-

ture, the dew point sensor transmits the dew point to the DPC™. Should

the outlet pressure dew point exceed the customer specified set point,

High Humidity Alarm will activate.

Depress the +/- button until the desired set point is

displayed. Pressing SELECT DISPLAY saves the

current selection.

Depress the SELECT DISPLAY button until the HIGH

HUMIDITY screen is displayed.HIHUMID ALARM:

OFFSELECTDISPLAY

+-

The following illustrates the method of activating the High Humidity Alarm

feature:

HIHUMID ALARM:ON

28

The High Humidity Alarm set point should not be drier than the Moisture Load Control

set point. Failure to do so will result in an alarm indication. ZEKS recommends setting

the High Humidity Alarm at least 10°F wetter than the Moisture Load Control setpoints.

NOTICE

8.10.2 Setpoint Adjustment

On dryers equipped with the optional Moisture Load Control / Dew Point

Display, the High Humidity Alarm setpoint can be adjusted as follows. 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.

To enter a negative number, depress the +/- button.

Otherwise, proceed to the next step.

Depress the SELECT DISPLAY button until the HIGH

HUMIDITY SET POINT screen is displayed.SELECTDISPLAY

+-

The following illustrates the method of adjusting the setpoint for the High

Humidity Alarm feature:

Depressing ENTER saves the selected set point.

SETPressing the SET button permits the value of the HIGH

HUMIDITY ALARM SETPOINT to be changed

ENTER

Use the numbers on the keypad to enter the desired

pressure dew point temperature for the MLC setpoint.2

Use the numbers on the keypad to enter the desired

pressure dew point temperature for the HIGH HUMIDITY

ALARM setpoint.

1

HIHUMID SETPOINT-20°F (-28°C)

HIHUMID SETPOINT- °F (-28°C)

HIHUMID SETPOINT_20°F (-28°C)

HIHUMID SETPOINT-2 °F (-28°C)

HIHUMID SETPOINT-21°F (-28°C)

HIHUMID SETPOINT-21°F (-29°C)

29

When the Program Jog is initiated in the middle of the heating cycle, advancing the

program without allowing normal tower cool down will result in an outlet air tempera-

ture that may exceed 300°F. As such, proper precautions must be taken to protect

downstream equipment from high temperature exposure.

During the Program Jog routine, the display may show intermediate steps in the

program that are not active in the current program set up. This should be considered

normal operation.

NOTICE

Depress the SELECT DISPLAY button until the JOG

MODE display appears. The WAIT prompt will appear

should the program not be able to advance at this stage.

SELECTDISPLAY

Depress the SELECT DISPLAY button until the JOG

MODE display appears. The PRESS ENTER prompt will

appear, along with the current step and remaining time,

should the program be able to advance at this stage.

JOG: ENT TO JOGSTEP 6 TIME10699

8.11 PROGRAM JOG

All Eclipse heated purge and blower purge dryers come equipped with a Program Jog

feature that is accessible via the DPC™ Controller. This feature allows the dryer cycle to

be accelerated for troubleshooting and routine inspection purposes. By accessing the

Program Jog routine in the DPC™, the customer can advance the program to the next

program step. Note that the program advance feature will not advance through all steps

of the program

To exit the TECHNICIAN MODE, press the “Select Display” key to the initial “SET

OPMODE” screen or “BEGIN TECHNICIAN MODE” screen and depress the � button

to return to the CUSTOMER MODE

NOTICE

Should the program be at a stage whereby the DPC™ permits the jog feature, the following

will be displayed:

Depressing the ENTER button advances the program to

the next step. The display will indicate the next step has

been initiated.

JOG MODESTEP 8 TIME00550

ENTER

The DPC™ Controller will only permit the jog function during specific stages of the program.

Should the program be at a stage where the program can not advance, the following will

be displayed:

The Program Jog advances steps #6, #8, #20 & #22, which are the longest program

steps. The balance of the steps are not advanced in Program Jog Mode.

NOTICE

WARNING

JOG: WAITSTEP 4 TIME 0

30

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

9. INSTALLATION AND START-UP

9.1 APPLICATION AND CHECK ANALYSIS ZEKS ECLIPSE Regenerative air dryers are shipped complete with desiccant up to and including model 2100ZBA. 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 installationrequirements outlined below are satisfied.

ZEKS dryers are available with an operating range from 75 -150 PSIG. Air available for your usage will vary with operating pressure. The maximum design pressure of thestandard Eclipse Dryers is 150 PSIG. For units that require higher operating pressures,consult your ZEKS representative.

Dryers are sized according to 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 to atmosphere and is not available for use downstream. Make certain air

supply to dryer meets air demand plus purge air requirements.

9.2 LOCATING AND MOUNTINGThe dryer must never be installed where process 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. If the dryer is exposed to ambient conditions below 50°F, dryer must be equipped with provisions for low ambient operation. Where applicable, dryer towers may be insulated to reduce heat loses. Avoid locating dryer outside or where it is exposed to the elements.

The dryer, or any air system component, must be located to avoid exposure to pulsation in the compressed air as well as possible surges due to fluctuating demand. In addition,care must be used to minimize exposure to vibration transmitted through mounting padsor piping.

Provide adequate space around the dryer for normal maintenance requirements and

service.

NOTICE

ZEKS recommends that the mufflers be cleaned after initial start-up to remove any

desiccant dust generated during shipment. After running dryer for initial 30 minute period,

de-energize / depressurize dryer and remove mufflers. Disassemble and clean the

removable insert inside the muffler core. Reinstall mufflers prior to operating dryer.

NOTICE

31

If the dryer is shipped with the desiccant packaged separately, install the desiccant

after locating and mounting. Desiccant has been provided separately to minimize

handling difficulty and placing unnecessary stress on the dryer assembly.

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 and allow

proper nut and washer assembly.

9.3 PIPING

Pipe the compressed air lines to the inlet and outlet connections. Locate the

prefilters as close as possible to the dryer. Ensure the positioning allows for ease

of servicing.

Note that the wet air inlet is located at the dryer’s upper manifold and the dry outlet air is

located at dryer’s lower manifold. In situations where air supply is required 24 hours a day

(it is undesirable to interrupt the airflow), a three-valve bypass system is recommended to

bypass the dryer. To keep pressure drop at a minimum, use the fewest elbows necessary.

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 site placement.

9.4 FILTRATION

It is important that a prefilter and an afterfilter be provided in your dryer installation.

It is recommended that a mechanical separator be installed immediately preceding

the prefilter to remove the bulk liquid and entrained water.

Coalescing prefilters, located before the dryer, protect desiccant beds from

contamination by oil, entrained water, pipe scale, etc., thereby, extending dryer

desiccant life. Locate prefilters as close to dryer as possible. FAILURE TO PROVIDE

AND MAINTAIN A HIGH EFFICIENCY COALESCING PREFILTER WILL VOID DRYER

WARRANTY.

Afterfilters, located after the dryer, help eliminate the possibility of desiccant dusting

carrying over into the air system.

All dryers must have proper filtration. Liquid water and oil must be removed before the

air enters the dryer. Ensure separators, prefilters and drains are in good working order.

Failure to do so will void warranty.

High temperature filters must be used to prevent rupture possibility in the event dryer

failure should occur. Consult your ZEKS representative for appropriate filter selection.

NOTICE

WARNING

32

9.5 ELECTRICAL CONNECTION

Refer to wiring diagram for all electrical connections. Electrical connection must be

hard piped with an external fused disconnect switch with proper overload protection.

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

Service wires must be sized according to the minimum circuit ampacity shown on

the dryer serial nameplate and the requirements of the NEC.

The power connections are marked L1, L2 and L3.

9.6 START-UP

• With dryer de-energized, slowly pressurize the dryer. When the dryer reaches full oper-

ating pressure, check the system for air leaks. Soap test all joints and fitting. To main-

tain desired dew point, any leaks detected must be repaired, especially those on the

outlet side of the dryer.

• Turn on dryer disconnect switch to apply power to the dryer.

• Verify all actuated valves are in their failsafe position.

• Using a voltmeter, check the power connections for the correct voltage shown

on the dryer serial nameplate

• Close and secure all electrical panel covers.

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

• The sequence will initiate proper Inlet and Purge Valve positioning and tower

depressurization.

Dryer must be grounded with the full sized ground wire connected to an earth ground.

Initial dryer start-up must be in the Blower Purge Mode

NOTICE

NOTICE

Once power is applied to the dryer and after a brief

initialization sequence, the PRESS ON prompt will

be displayed.

PRESS ON

Depress the ON button to initiate the dryer program.

The DPC™ Controller will display the first CUSTOMER

MODE screen

LT DRY RT REGENON

33

• If the dryer has been in storage or off for an extended period of time, the Blue Moisture

Indicator 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 to

deactivate, the BMI to return to its normal blue state and dew point to drop.

• For dryers equipped with Moisture Load Control, refer to SECTION 8.6 regarding the use

of this option on new equipment.

9.7 SHUT DOWN PROCEDURES

The following procedures must be followed to properly shut down the dryer to avoid damage

to the unit and preserve dryer performance. The dryer requires compressed air to actuate

the valves. Removing the compressed air supply prior to shutting down the dryer will

result in improper valve positioning. In addition, the dryer must complete a specific

Shutdown Sequence prior to being turned off. Should power be removed from the dryer

or air pressure removed from the dryer prior to the completion of the Shutdown Sequence,

damage to the dryer may occur. Lastly, the inlet valves are configured to open on a loss

of power and the purge valves configured to close (fail safe). Should a valve open to a

depressurized tower, as would be the case if the dryer were stopped in mid-cycle, a rapid

pressurization will occur.

The force of repeated rapid pressurizations will damage the dryer.

NOTICE

Dryer should not be shut down during the heating cycle. Doing so 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 8.12) to the end of the heating cycle prior to initiating the

Shutdown Sequence.

CAUTION

On dryers equipped with Moisture Load Control (MLC), merely leaving the unit in

MLC without a compressed air supply is not advised, as it is likely that the system

pressure will decay over time. Should this occur, the unit will go into a FTS alarm as

well as risk misalignment of valves should switchover occur prior to reinstating the

air compressor.

NOTICE

34

For all Blower Purge Dryers that will be routinely shut down and restarted, ZEKS recom-

mends that an isolation valve be installed at the dryer outlet. Upon restarting the dryer, it

is likely that the pressure downstream of the dryer will have decayed. When starting the

dryer without the valve (or with the valve in the fully open position), the high velocities of

the air through the towers could damage the desiccant, as well as provide unprocessed

air down stream.

Shut Down Procedure:

• Maintain a compressed air source to the dryer and a supply of power

to the DPC™ Controller.

• Permit the dryer to complete the full SHUTDOWN SEQUENCE (90 seconds)

• De-energize the dryer

• Shut down air compressor or bypass dryer

• Close Isolation Valves (if equipped)

NOTE: On the subsequent Start-up, the outlet isolation valve should be in the

closed position. Slowly open the valve to build pressure downstream.

Prior to removing power or compressed air from the dryer, depress the OFF but-

ton on the DPC™. This initiates the Shutdown Sequence, which closes the purge

valves, repressurizes the off-line tower and opens the flow valves. DO NOT

REMOVE POWER OR COMPRESSED AIR FROM THE DRYER DURING THE

SHUTDOWN SEQUENCE.

NOTICE

Depress the OFF button to initiate the SHUTDOWN

SEQUENCE.SHUTDOWNSEQUENCE

OFF

Once the PRESS ON Prompt is displayed, the dryer has

completed the SHUTDOWN SEQUENCE. Power and air

may be safely removed from the dryer.

PRESS ON

35

10. MAINTENANCE AND SYSTEM CHECK

10.1 SCHEDULED MAINTENANCE

Daily Maintenance Functions:

• Check and record inlet pressure, temperature and flow.

Verify that it is within specifications.

• Check tower pressure gauge readings within operating tolerance.

• Check tower pressure gauges for proper dryer cycling.

• Check that prefilter condensate drains are functioning properly

• Verify that pressure in purging tower is 5 PSIG or less.

• Verify that prefilter and afterfilter differential pressure is within operating limits.

A filter with 0 psig pressure may indicate a damaged element.

Monthly Maintenance Functions:

• Check your operating conditions: inlet flow, inlet pressure, and inlet temperature.

• Check prefilter(s) and afterfilter(s) differential pressure and drains.

• Check dryer cycle and sequence of operations (i.e. drying,depressurizing,

regenerating).

Quarterly Maintenance Functions:

• Replace prefilter(s) and afterfilter(s) cartridges.

• Check pilot air filter element and replace as needed.

Semi-Annual Maintenance Functions:

• Check outlet dew point.

• Check amp draw on heater.

• Replace blower intake filter

Annual Maintenance Functions:

• Check desiccant and replace if necessary.

• Inspect and clean solenoid valves and check valves. Replace worn

or damaged seats and parts as required.

• Test lights and switches, replace as necessary.

• Test electrical components, replace as necessary.

• Check and repair any air leaks, loose bolts, flanges and fittings.

Every Two Years:

• Change check valves

• Change control solenoid valves

• Check and change temperature probes

Every Five Years:

• Replace desiccant.

Refer to SECTION 9.7 for the proper way to shut down the Blower Purge Dryer.

NOTICE

36

10.3 MUFFLER CHANGE-OUT PROCEDURE

• Turn control power off per shutdown procedures described in SECTION 9.7.

• Once the dryer has been depressurized, replace the muffler.

• Follow normal start-up procedures as described in SECTION 9.

Should the drying system be overloaded and/or malfunctioning causing high

pressure drop, afterfilters will prematurely plug. This problem can be avoided by

frequent inspection and cleaning of cartridges.

To avoid injury, depressurize dryer before performing any service

NOTICE

10.4 SOLENOID VALVES

Periodically clean all solenoid valves. Cleaning can be accomplished by removing

the solenoid, removing the mufflers and removing the valve bodies from the mani-

fold. Check and replace O-rings as necessary. If the solenoid valves fail to operate,

check the following:

• Control Circuit - Verify that the solenoid is receiving electric current.

• Burned out solenoid coil.

• High/low voltage - Voltage should be +/- 10% of nameplate readings.

• Solenoid valve leaking - Disassemble, clean and repack or replace.

10.5 PILOT OPERATED ACTUATOR

Should the actuator fail to rotate, disconnect the pilot lines to check if the actuator

is receiving pilot pressure.

If the actuator is receiving pressure:

• Verify that control pressure is 75 psig min.

• Ensure the inlet valve is not plugged.

10.2 PREFILTERS and AFTERFILTERS

Prefilter cartridges must be changed as often as required to prevent contamination

of the regenerative dryer’s desiccant bed.

Prefilter drains must be checked daily. Failure to drain condensed liquid from the

sump of the filter housing will result in carry over and damage to the desiccant

material. Afterfilters are used to prevent desiccant dust particulate contamination

from migrating downstream into plant processes. Elements should be changed as

pressure drop increases to an undesirable level.

WARNING

37

10.6 DESICCANT CHANGEOUT PROCEDURE

• Eclipse™ dryers are furnished with fill and drain ports on each desiccant tower.

Remove the caps on both ports.

• To assist in getting 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

towers 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 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.

• With the fill port plug removed, fill the dryer tower with the appropriate grade and size

desiccant. The level and grade of the desiccant should be consistent with the Desiccant

Fill Chart.

• Once the towers have been filled, replace the fill port plug on each tower.

• Any connections disturbed in the desiccant changeout process should be leak tested

prior to re-commissioning the dryer.

To avoid injury, depressurize dryer before performing any service.

Be sure to wear respiratory protection during the draining and filling process to mini-

mize inhalation of desiccant, as desiccant will produce dust during this procedure.

CAUTION

Desiccant quantity, positioning and grades must match the corresponding values in

the Desiccant Fill Chart. Failure to do so may result in poor dryer performance.

CAUTION

WARNING

38

DESICCANT FILL CHART

39

Check purge flow settings.

Check purge piping for obstruction.

Clean purge piping and muffler.

Check pressure source.

Check flow rate and cause for

increased demand.

Check aftercooler, clean and service

as necessary.

Check air/moisture separator and

prefilter. Replace dryer desiccant if

necessary.

Install suitable prefilter. Replace dryer

desiccant.

Check flow rate and cause for

increased air demand.

Check pressure source.

Check inlet valve. Verify inlet valve

is closed to purging tower (0 PSIG

tower).

Check gauge against tower gauges

when in switching sequence.

Replace gauge as required.

Insufficient purge rate

Inlet air/gas pressure below

design condition.

Flow rate higher than design

condition.

Inlet temperature above design

condition.

Entrained water entering

desiccant bed.

Desiccant contaminated by oil.

Excessive flow rate.

Inlet pressure below design

condition.

Air is leaking across valve.

Improper calibration

Elevated dew point

Excessive pressure

drop in dryer

Excessive back pres-

sure in regenerating

tower (Above 5

PSIG).

Excessively high

pressure at the

purge gage (Blower

and Heatless Modes)

11. TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

40

Check power input.

Check solenoid valve.

Check pilot air line. Check that control

air line filter is clean. Check regulator

setpoint.

Check switch. Open pressure: >65

psig; close pressure: <40 psig

Check purge valve and its solenoid

valve.

Check that repressurization circuit is

sending control signal.

Check solenoid valve. Repair and

replace if necessary.

Replace contactor.

Replace thermocouple.

Replace temperature control.

Contact ZEKS Distributor/Factory

No input power

Defective solenoid valve

No pilot air / Low pilot air

pressure

Defective pressure switch

Faulty purge valve

Purge valve does not open.

Purge valve stuck in closed

position.

Contactor stuck closed.

Defective thermocouple

Defective temperature control

Valve switching failure

Failure to Shift

(Switching Failure)

Failure to Shift

(Dryer fails to

pressurize.)

Failure to Shift

(Dryer fails to

depressurize.)

Heater High Temp.

Alarm (Heater runs

continuously)

Heat High Temp.

Alarm (Loss of flow

across heater)

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

The Heater High Temperature Alarm halts the DPC™ program. Prior to reinstating

dryer, note the position of all valves. This is critical in determining the possible

cause of the alarm condition.

NOTICE

To reset the Heater High Temperature Alarm, reset the DPC™ Controller using the

RESET button and manually reset the Heater High Temperature safety in the con-

trol enclosure.

NOTICE

41

INNOVATIVE COMPRESSED AIR SOLUTIONS

ZEKS Compressed Air Solutions

Web: www.zeks.com

Oil carryover from oil-lubricated compressors is common in today’s compressed air systems. Lubricant aerosols combine with water vapor that is present in the compressed air. When cooled in downstream equipment such as aftercoolers, dryers, filters and separators, the aerosols and vapors condense to form a liquid mixture that needs to be removed from the compressed air stream. The presence of lubricants in the liquid condensate may render it unsafe for discharge into surface water, sanitary sewers and wastewater treatment plants. Using absorption technology, ZEKS OS Oil/Water Separators remove over 99% of oil content (mineral, synthetic, semi-synthetic, and polyglycol 1) and stable emulsions from the discharged condensate. Replaceable filter element bags trap lubricants within the OS Separator but allow water to pass through. The conditioned water meets stringent EPA guidelines and conforms to State and local codes. Testing shows lubricant carryover in the separated water to be 10ppm or lower. Disposal as stated by local and State guidelines is necessary for only the oil soaked elements. The multi-tower units have no moving parts and require no electrical hookup. Seamless molded-plastic construction will not crack or leak while removable lids provide easy access for periodic element replacement. Units can remain in service during the simple element replacement procedure. A port for collecting samples for visual inspection of outgoing wastewater is conveniently located. Four OS models are available. Model selection is based on total air compressor capacity and lubricant type. Multiple sources of condensate can be connected simultaneously. Refer to the Technical Specifications chart to choose the model that meets or exceeds the total compressor volume (scfm). Installation requires positioning of the unit for collection of condensate from all sources, and connection to inlet and outlet piping. Effective In All Compressed Air Systems • Separates mineral, synthetic and semi-synthetic lubricants, stable emulsions and polyglycol • Requires no electricity • Receives condensate discharged by intelligent drains, timed solenoid drains, manual drains or float style drains • Easy to install and maintain • Operates with all makes of compressors

1 Special Polyglycol elements required for Polyglycol Lubricated compressed air systems. Polyglycol units denoted with ‘PG’ suffix on model number.

OS Oil/Water Separators Separate Lubricant Carryover From Air Treatment Condensate

See reverse side for Technical Specifications.

OS2501/OS2501PG

To conform to available space, the 3-tower OS 2501 can be configured in-line or at a right angle.

OS300/OS300PG

OS751/OS751PG

OS1251/OS1251PG

Technical Specifications AIR COMPRESSOR CONNECTION SIZE REPLACEABLE ELEMENT ELEMENT ELEMENT MODEL CAPACITY APPLICATION (Qty) INLETS OUTLET ITEM NUMBER TYPE APPLICATION OS300 Up to 300 scfm Mineral, Synthetic, (2) 1/2” 1/2” 683535 Absorption (TWR 1) Mineral Oil, Synthetic Oil, 2-Tower Unit Semi-Synthetic Oils, Semi-Synthetic Oil 683536 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS300PG Up to 300 scfm Polyglycol (2) 1/2” 1/2” 683749 Absorption (TWR 1) Polyglycol 2-Tower Unit 683536 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS751 300 to 750 scfm Mineral, Synthetic, (2) 1/2” 1/2” 684130 Absorption (TWR 1) Mineral Oil, Synthetic Oil, 2-Tower Unit Semi-Synthetic Oils, Semi-Synthetic Oil 684132 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS751PG 300 to 750 scfm Polyglycol (2) 1/2” 1/2” 684131 Absorption (TWR 1) Polyglycol 2-Tower Unit 684132 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS1251 750 - 1250 scfm Mineral, Synthetic, (4) 1/2” 1/2” 683750 Absorption (TWR 1) Mineral Oil, Synthetic Oil, 2-Tower Unit Semi-Synthetic Oils Semi-Synthetic Oil 683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS1251PG 750 - 1250 scfm Polyglycol (4) 1/2” 1/2” 683751 Absorption (TWR 1) Polyglycol 2-Tower Unit 683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol OS2501 1250 - 2500 scfm Mineral, Synthetic, (4) 1/2” 1/2” 683750 Absorption (TWR 1) Mineral Oil, Synthetic Oil, 3-Tower Unit Semi-Synthetic Oils Semi-Synthetic Oil 683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil 683753 Carbon Finishing (TWR 3) Extends Absorption Time OS2501PG 1250 - 2500 scfm Polyglycol (4) 1/2” 1/2” 683751 Absorption (TWR 1) Polyglycol 3-Tower Unit 683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Synthetic Oil, Polyglycol 683753 Carbon Finishing (TWR 3) Extends Absorption Time OSEXT / OSEXTPG Mineral, Semi & Synthetic Oils (4) 1/2” 1/2” 683753 Carbon Finishing (TWR 3) Extends Absorption Time Stable Emulsions, Polyglycol

OS Oil/Water Separator Dimensions

Model W D H

OS300/OS300PG 28.0” 13.0” 28.2” OS751/OS751PG 31.1" 14.2" 39.4" OS1251/OS1251PG 41.8” 15.4” 45.3” OS2501/OS2501PG (inline) 68.9” 16.2” 45.3” (angled) 41.8” 43.0” 45.3” Overall dimensions indicated.

TOWER 1 Absorption

Test Valve

Depressurization Pad

TOWER 3 Carbon Finishing

EXT Extender (OS 2501 only) Can be added to 1251

TOWER 2 Carbon Finishing

Inlet Connections: OS 300 (2) OS 751 (2) OS 1251 (4) OS 2501 (4)

H

W D

Stable Emulsions

Stable Emulsions

Stable Emulsions

OS 1251 separation capacity can be expanded at any time through addition of an OS EXT carbon finishing tower. Technical specifications, as well as installation and maintenance procedures then match those for the OS 2501.

Stable Emulsions

Stable Emulsions

Stable Emulsions

© 2011 ZEKS Compressed Air Solutions OWS-0411

1302 Goshen Parkway West Chester, PA 19380 Phone: 610-692-9100 Fax: 610-692-9192 Web: www.zeks.com

Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication was approved for reproduction. The company reserves the right to change specifications, discontinue models, equipment or design without notice and without incurring obligation. The information set out in this brochure is for preliminary information only and is not intended to constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.

1

Installation & Maintenance Instructions

OSB Oil/Water Separators

GENERAL OPERATION The OSB Oil/Water Separator Series separates oil from condensate generated by compressed air systems. OSB Oil/Water Separators achieve separation of oil from condensate by directing the condensate through multiple separation stages. As condensate flows in to the OSB Oil/Water separator, oil is filtered out through multiple filtration elements. The first oil absorbing element has a clever saturation indicating feature, offering the user visual indication of operating status at a distance. The replaceable elements are designed to combine various types of absorption technologies resulting in less than 10 ppm oil residue values at the output stage. The final separation stage includes specially selected activated carbon that removes any contaminants that may remain following the two absorption stages.

2

SAFETY INSTRUCTIONS

SAFETY AND PROPER USAGE To ensure safe and long lasting operation of this product, the operator must comply strictly with the instructions enclosed herein. Non-compliance with instructions or improper handling of the product will void the product warranty! Usage of this product in conditions not specified in this Manual or that are contrary to the instructions provided is considered IMPROPER. The manufacturer will not be held liable for any damages resulting from improper use of the product.

SAFETY & WARNING INSTRUCTIONS

ATTENTION

• Observe valid and generally accepted safety rules when planning, installing and using this product.

• Take proper measures to prevent unintentional operation of the product or damage to it.

• Do not attempt to disassemble this product or lines in the system while they are under pressure.

• Always depressurise the compressed air system before working on the system.

It is important that personnel use safe working practices and observe all regulations and legal requirements for safety when operating this product. When handling, operating or carrying out maintenance on this product, personnel must employ safe engineering practices and observe all local health & safety requirements & regulations. International users refer to regulations that prevail within the country of installation. Most accidents that occur during operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. Often an accident can be avoided by recognising potentially dangerous situations. Improper operation or maintenance of this product could be dangerous and result in an accident causing injury or death. The manufacturer cannot anticipate every possible circumstance that may represent a potential hazard. The WARNINGS in this manual cover the most common potential hazards and are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by the manufacturer, he must ensure the product will not be damaged or made unsafe and that there is no risk to persons or property.

3

EXPLODED VIEW AND IDENTIFY ALL COMPONENTS DIAGRAM

Overflow Indicator Test Bottle Lid 2 Absorption Element 2 Carbon Element Outlet Port OSB Housing Test Drain Supporting Bracket Service Drains (2X)

Element Indicator

Lid 1

Inlet Ports (2X)

Absorption Element 1

Depressurising

Pad

Inner Depressurising

Pad

Name Plate

Screws (3x)

4

INSTALLATION INSTRUCTIONS

IMPORTANT NOTICE

Before installing this product, make sure it complies with the

order and that it suits the application!

1. Unpack the unit and inspect it for transport damage. Do not install if damage is detected.

2. Depressurise the compressed air system before installation or maintenance of the ZEKS OSB Oil/Water Separator

3. Locate the OSB Oil/Water Separator within the compressed air system near a suitable waste water drain. The unit is designed to fit easily against a wall. Condensate collection pipe

4. Remove the lids from Tower 1 and Tower 2.

5

INSTALLATION INSTRUCTIONS

5. Remove the plastic bag that is placed on top of Absorption Element 2 inside Tower 2.

6. Remove the white Absorption Element from Tower 1 and Tower 2.

7. Connect condensate piping to the OSB Oil/Water Separator inlet(s).

8. Connect the OSB Oil/Water Separator Outlet Port to a suitable waste water point. Make sure the condensate always flows in a downward direction.

9. Before filling the unit with water make sure the Test Drain and Service Drains are closed. �

10. Fill the unit by pouring water into Tower 1 until both towers contain water and water flows out of the Outlet Port. Tip: To prevent carbon dust from spreading, spray water over the black Carbon Element in Tower 2 before filling the unit.

6

INSTALLATION INSTRUCTIONS

11. Make sure the black element rests on the bottom of the tower by pushing it down.

Push the element down until all trapped air is forced out of the Carbon Element.

12. When both towers are filled with water and the black Carbon Element is resting on the bottom of Tower 2, both white Absorption Elements can be put into position: tall element in Tower 1, short element in Tower 2.

13. Replace each lid on Tower 1 and on Tower 2. The lid on Tower 2 will force Absorption Element 2 into the correct position.

Make sure both lids are positioned and secured properly.

14. The OSB Oil/Water Separator is now fully operational.

7

SERVICE INSTRUCTIONS

OSB Oil/Water Separators require period replacement of the two Absorption Elements and the Carbon Element. When the top of the White Visual Indicator that normally protrudes above Tower 1 retracts to lid level, replace Absorption Element 1, Absorption Element 2 and the Carbon Element. (Refer to the dedicated Maintenance Instructions supplied with the Service Kit.) See REPLACEMENT PARTS list for Item Numbers. If the Red Visual Indicator that is normally retracted within the Tower 2 lid rises to become visible, check for blockage of flow downstream of the OSB Oil/Water Separator.

MAINTENANCE CHART

Date Description Name

8

TECHNICAL SPECIFICATIONS

Max. Oil Absorption Elements (Approximate element absorption capacity)

OSB175 – 1.3 Gallons (US) OSB350 – 2.6 Gallons (US) OSB750 - 4 Gallons (US) OSB1250 - 7 Gallons (US)

Inlet Connections ½” (2x) Outlet Connections 1” Test Valve Yes Service Drain Yes (2x) Element Life Indicator Yes Overflow Indicator Yes Housing Material PE Total Recyclable Yes Housing Color Black Lid Color Gray Mineral Lubricants Yes Synthetic Lubricants Yes Stabile Condensate Emulsions Yes Polyglycol Yes (consult factory) Max. Air Compressor capacity (Based on a single 8-hour shift)

OSB175 – up to 175 SCFM OSB350 - 176 to 350 SCFM OSB750 - 351 to 750 SCFM OSB1250 - 751 to 1250 SCFM

REPLACEMENT PARTS Order Replacement Elements based on OSB Model Number. Replacement Element Kits include: Pre-Absorption Element #1, Pre-Absorption Element #2, Carbon Finishing Element. Pre-Absorption Pre-Absorption Carbon Finishing Replacement OSB Model Element #1 Element #2 Element Element Kit OSB175 684743 684751 684759 684763 OSB175PG 684744 684752 684759 684764 OSB350 684745 684753 684760 684765 OSB350PG 684746 684754 684760 684766 OSB750 684747 684755 684761 684767 OSB750PG 684748 684756 684761 684768 OSB1250 684749 684757 684762 684769 OSB1250PG 684750 684758 684762 684770

Phone: 610-692-9100 Fax: 610-692-9192 www.zeks.com

EZDB 2Motorized Ball Valve

The EZDB 2 is a motorized ball valve drain that is designed to discharge highly viscouscondensate in compressed air applications at pressure ratings up to 720 psi. It has beenengineered specifically for use in compressed air systems and is reliable and simple to installand set-up for effective timed discharge of condensate. Valve OPEN and CLOSED adjustmentsare made through a touchpad on the front of the valve body. There are seven EZDB 2 models withfeatures that make them the ideal timed electric drain valve for many compressed air applications.

EZDB 2 Features:

• Microprocessor controlled• External touchpad controls• Programmable 10-cycle control• Remote contact connection• Anti-blockage protection of gear mechanism• LED indicates valve ON (OPEN)• LCD displays program CYCLE NUMBER• Manual TEST button• 720 PSI maximum pressure• Stainless steel ball; Nickel-plated brass valve• Power failure protection – battery back-up (batteries not included)• Weatherproof

Air compressor, air dryer, filter, and receiver performanceIs dependent on reliable drain valve operation.

Count on the EZDB 2 Motorized Ball Valve to dependablydischarge condensate from your compressed air system!

See reverse side for Technical Specifications.

EZDB 2Motorized Ball Valve

Technical Specifications

• Microprocessor controlled• External push-button controls• Programmable 10-cycle control

Interval time OFF (CLOSED) – 4 min. – 24 hrs.Discharge/ball rotation time ON (OPEN) – 7 sec. – 14 min./53 sec.

• Remote contact connection• Anti-blockage protection of gear mechanism• FPM O-rings and PTFE seals• Voltage: 115 VAC and 230 VAC; 50/60 Hz• ½” NPT connection size with ½” internal orifice diameter• Ball rotation: 180º in 7.5 seconds• Manual TEST button• 720 PSI maximum pressure• Stainless steel ball; Nickel-plated brass valve• Power failure protection – battery back-up (4, AA, 1.5V batteries not included)• Weatherproof

Model Connection WorkingNumber Size Voltage Pressure Weight

EZDB 2 1/2” NPT 115/1/50-60 720 psi max. 3.5 lbs.EZDB 2-3/4 3/4” NPT 115/1/50-60 720 psi max. 4.0 lbs.EZDB 2-1 1” NPT 115/1/50-60 720 psi max. 4.0 lbs.EZDB 3 1/2” NPT 230/1/50-60 720 psi max. 3.5 lbs.EZDB 3-3/4 3/4” NPT 230/1/50-60 720 psi max. 4.0 lbs.EZDB 3-1 1” NPT 230/1/50-60 720 psi max. 4.0 lbs.EZDB 2HP 1/8” NPT 115/1/50-60 6000 psi max. 3.5 lbs.

INNOVATIVE COMPRESSED AIR SOLUTIONSwww.zeks .com

© 2004 ZEKS Compressed Air Solutions EZDB2-1204-WO

1302 Goshen ParkwayWest Chester, PA 19380Phone: 610-692-9100 Fax: 610-692-9192 Web: www.zeks.com

Specifications, illustrative materials and descriptions contained herein were as accurate as known at the time this publication was approved for reproducto change specifications, discontinue models, equipment or design without notice and without incurring obligation. The information set out in this brochuand is not intended to constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer.

6.14”5.25”

2.72” 1.42

2.9

3.77

”5.

59”

6.30

”

1”

tion. The company reserves the rightre is for preliminary information only

”

TOP VIEW

REV

TYPE

DRAWING NOCHECKEDDRAWN

E22

A10333

TITLE

DMM

SIZE: B SHEET 1 OF 1

KAT

9/14/2016 10/10/2016

STOCK

VERTICAL AIR RECEIVER

ASME

CUSTOMER

(BUILT IN ACCORDANCE WITH LATEST EDITION OF SECTION VIII DIV 1 ASME CODE)

THIS DRAWING & SPECIFICATIONS ARE PROPERTY OF SPVG AND MAY NOT BE

COPIED, REPRODUCED, OR USED IN WHOLE OR PART, AS A BASIS FOR DESIGN

MANUFACTURE OR SALE WITHOUT PRIOR PERMISSION FROM SPVG.

E22 ISSUED

REV DESCRIPTION BY DATE

DESIGN INFORMATION

SPECIFICATION VALUE

DIAMETER O.D./I.D.

60 O.D.

MAWP 150 PSI AT 400°F

MDMT -20°F AT 150 PSI

CAPACITY APPROX 2000 GALLONS

SHIPPING WEIGHT 3503 LBS

CRN L6794.56801234T9YN

NOZZLE CHART

NOZZLE ID NPT SIZE

N1

1/4

N2 1

N3

1 1/4

N4 3

N5 6

N6 MANWAY

34

8

72

110

148

182

N4

N1

N3

N3

N3

N6

N5

N2

N5

11/16 X 1 1/2 SLOTS 4-PLACES

EQUALLY SPACED

ON A 43 13/16 DIA BC

46

GENERAL ARRANGEMENT400 & 500 ZBA

FILTER PACKAGE ''A''

510167

06/23/06SAJ

1 OF 1NTS

12.19

40.50

33.00

2.00 (TYP)

2.00 (TYP)

(4) .56'' O MTG. HOLES

HEATER INSULATION

OPTIONAL TOWER INSULATION(SHOWN THIS VIEW ONLY)

DPC CONTROLLER & DYNOPTIC PANEL(SEE DETAIL)

1) DRYER ON/OFF CONTROL2) DRYER ALARM3) HEATER OPERATION & TEMP CONTROL4) HIGH HEATER TEMP ALARM5) HEATER FAILURE ALARM6) LEFT/RIGHT TOWER DRYING7) LEFT/RIGHT TOWER REGEN8) FAILURE TO SHIFT ALARM9) REGEN SEQUENCE STATUS10) BLOWER OPERATION CONTROL11) HIGH HUMIDITY ALARM (OPTIONAL)12) MOISTURE LOAD CONTROL WITH DEW POINT DISPLAY (OPTIONAL)

DPC LCD DISPLAY

DESICCANT FILL PORT

TOWER PRESSURE GAUGE

TOWER TEMPERATURE GAUGE

DESICCANT DRAIN PORT

56.50

82.50

PURGE PRESSURE GAUGE

PURGE ADJUSTMENT VALVE

ELECTRICAL ENCLOSURENEMA 4

40.50

11.50

73.38

40.00

PILOT AIR SHUT-OFF VALVE

RELIEF VALVE

DEPRESSURIZATIONMUFFLER

DEPRESSURIZATIONVALVE

INLET FLOW VALVE

HEATER

2'' FPT AIR OUTLETCONNECTION

OUTLET FLOW VALVES

INLET PURGE CHECK VALVESL

C OF INLETL

2'' FPT AIR INLETCONNECTION

C OF OUTLETL

C OF INLETL

*NOTES: 1) MAXIMUM WORKING PRESSURE - 150 P.S.I. 2) SAFETY RELIEF VALVE SETTING - 165 P.S.I 3)PILOT AIR LINES NOT SHOWN FOR CLARITY 4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE'S LATEST REVISION.

PILOT AIR FILTER

BLUE MOISTURE INDICATOR

ZTF TYPE ''G''AFTERFILTER

20.81

27.50 @ 500 ZHA26.25 @ 400ZHA

FACE OF INLET

26.25

SIZE SCALE DWG NO REVSIZE

UNLESS OTHERWISE SPECIFIEDDIMENSION ARE IN INCHES

TOLERANCES ARE:

APPROVED

CHECKED

DRAWN

DATEAPPROVALS

MATERIAL

FRACTIONS±

DECIMALS .XX ± .50.XXX ±

ANGLE±

REV ECO DATE APPROVED

BSHEET

NOTICE: THIS DRAWING EMBODIES ACONFIDENTIAL PROPRIETARY DESIGNOWNED BY ZEKS AND ALL PATENTRIGHTS AND DESIGN AND CAN NOT BEALTERED IN ANY WAY. MANUFACTUR-ING THE SAME ARE EXPRESSLY RE-SERVED TO ZEKS. THIS DRAWING ISSUBMITTED UNDER A CONFIDENTIALRELATIONSHIP FOR A SPECIFIED PUR-POSE AND THE RECIPIENT HEREOF BYACCEPTING THIS DRAWING ASSUMESCUSTODY THEREOF AND AGREES NOTTO DISCLOSE ANY INFORMATION RE-GARDING IT TO ANY UNAUTHORIZEDPERSON OR TO INCORPORATE THISPROPRIETARY DESIGN OR THE SUB-STANCE OF IT EITHER IN WHOLE OR INPART IN ANY EQUIPMENT, NOR USE ITFOR THE MANUFACTURE OF ANYPARTS.

DO NOT SCALE

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

A

B

C

D D

A

B

C

DESCRIPTION

BSHEET_DESIC 000201

TITLE

1302 Goshen ParkwayWest Chester, PA 19380

A

FACE OF OUTLET

ZTF TYPE ''H''PREFILTER

11.25

POWER ON LIGHT

ALARM LIGHT

PUSH BUTTONS

CONTROL SYSTEM DETAIL

1) ON2) OFF3) RESET4) TEST5) SET6) SELECT DISPLAY7) ENTER8) +/-

LEFT TOWER REGEN LIGHTBLOWER ON LIGHT

HEATER ON LIGHT

RIGHT TOWER REGEN LIGHT

RIGHT TOWER DRYING LIGHT

LEFT TOWER DRYING LIGHT

REACTIVATIONHEATER

BLOWER INTAKE FILTER

BLOWER PRESSURE GAUGE

REPRESSURIZATIONVALVE

29.00

C OF OUTLET

PURGE VALVE