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
*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
ER
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
ER
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