ZEKS Eclipse 1000ZPB, Technical Manual

Page 1: ...w zeks com Form ZEKS ZPB V0121 ZPB Heatless Purge Desiccant Compressed Air Dryers 90 5 000 scfm NOTICE Those operating the machine or performing maintenance should read and understand the decals posit...

Page 2: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com...

Page 3: ...NCLATURE 3 4 RECEIVING AND INSPECTION 3 5 SAFETY AND OPERATION PRECAUTIONS 4 6 PRINCIPLES OF OPERATION 5 7 ALARMS AND INDICATORS 15 8 INSTALLATION INITIAL START UP 18 9 SCHEDULED MAINTENANCE 22 10 TRO...

Page 4: ...s from the date of equipment start up the Warranty Registration Card must be completed and returned to ZEKS Alternately the Warranty Registration Card may be completed online at www zeks com The total...

Page 5: ...g fork tongs beneath these rails to avoid damaging piping at the rear of the dryer 4 0 RECEIVING AND INSPECTION NOTICE Nomenclature shown above represents standard price sheet options Other options ar...

Page 6: ...ons OSHA Heading Descriptions 5 0 SAFETY AND OPERATION PRECAUTIONS ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 4 NOTICE The user of any air dryer manufactured by ZEKS Compressed Air Solut...

Page 7: ...ed to atmosphere The second stage of regeneration uses a portion of the dry compressed air expanded to atmospheric pressure to complete the desorption process As depicted in the P ID the compressed ai...

Page 8: ...cycle is turned o 6 8 PURGESYNC FUNCTION with NEMA 4 Digital Controller option The PurgeSync function enables the dryer to reduce the timing of the purge cycle based on compressed air demand When this...

Page 9: ...this screen the user can navigate to start stop monitor or alter the dryer Operating Cycle and test dryer functions CONTROLLER BUTTONS AND KEYS i INFORMATION BUTTON Restricted Level access for factory...

Page 10: ...on Keys to highlight the value that needs to be changed 2 Press the button to change the value to the new setting ZPB Controller Display Display of dryer status program sequence information alarm stat...

Page 11: ...thin that Step Jog Step Use key to jog the primary steps in the operating sequence TECHNICIAN MODE SCREEN 2 12 Dryer must be turned OFF and system or Control Air Circuit must be pressurized before ini...

Page 12: ...rigger when measured value exceeds the high Dew Point setting HI DEWPT SETPOINT Value establishes the Alarm trigger point LO DEWPT ALM Choose ON or OFF In certain cases during low flow operation outle...

Page 13: ...s not rise above this set point during the pressurization cycle for the tower that is designated for drying TECHNICIAN MODE SCREEN 11 12 This screen permits the user to set the Date and Time format th...

Page 14: ...ce Reminder Interval for key components An alert will be displayed indicating that inspection replacement may be required when the time Interval is reached INLET FILTER Reminder Interval Weeks OUTLET...

Page 15: ...conds RETRIES Default 3 attempts DELAY Default 10 minutes COMMUNICATIONS SCREEN 2 4 BAUD RATE Press Enter key to highlight field Press to select from preset values DATA BITS Default 8 For information...

Page 16: ...Fail To Shift option OPERATING STATUS SCREEN 3 7 LT RT Left and Right Tower operating status DRYING or REGENERATING MLC SETPT Status of Moisture Load Control option ON or OFF Indication of Setpoint 40...

Page 17: ...the towers during the drying and regeneration steps to ensure correct tower pressure values are maintained during each step The tower designated for regeneration should be under 7 PSI during this step...

Page 18: ...n is true Activate while alarm condition is true Activated while alarm condition is true RECOMMENDED ACTION 1 Troubleshooting Sequence a Verify operation of purge valve Use test button on control air...

Page 19: ...appear in two weeks Maintenance Alert A pop up ALERT will be displayed to indicate that the Filter Regulator element should be replaced If the user selects NO the reminder will be acknowledged and wi...

Page 20: ...PREVENT FLOODING OF THE DESICCANT BED When all piping is connected all joints including those on the dryer should be soap bubble tested at line pressure to ensure no joints have been damaged in transi...

Page 21: ...rotective packaging must not be installed until the dryer has been in operation for 24 hours Color of the Blue Moisture Indicator BMI must appear blue before the Transmitter is installed The dryer War...

Page 22: ...ller to verify drain functionality after the dryer is placed into operation Drain maintenance or cleaning of system debris is not covered under the ZPB dryer warranty Improper drain maintenance will r...

Page 23: ...ressurized in order for the main flow valves on the dryer to revert to the default position The status line in the Home screen will display OFF The system will remain pressurized at all times The drye...

Page 24: ...t 7 days of operation SEMI ANNUAL MAINTENANCE FUNCTIONS Check outlet dew point MLC option only Check Control Air Filter NEMA 1 or Filter Regulator NEMA 4 element and clean or replace as required Repla...

Page 25: ...t side requires replacement 9 7 DESICCANT CHANGEOUT PROCEDURE When it becomes necessary to replace the desiccant in the towers or on units that are shipped without the desiccant installed observe the...

Page 26: ...20 38 134 100 34 160ZPB 22 00 29 75 192 150 50 200ZPB 14 00 21 50 236 177 59 250ZPB 23 00 28 00 290 215 75 300ZPB 12 00 21 25 344 258 86 400ZPB 11 00 22 25 470 352 118 500ZPB 27 00 32 00 638 478 160 6...

Page 27: ...outlet of the dryer is piped to a booster compressor verify that the flow of the booster compressor is below the rated capacity of the dryer Excessive flow will fluidize desiccant bed and result in du...

Page 28: ...0 Purge Air Flow SCFM Purge Meter Setting psig Dryer Model 160ZPB Purge Pressure Setting 50 psig 26 SCFM Purge Orifice 3 16 0 5 10 15 20 25 30 35 40 45 0 10 20 30 40 50 60 70 Purge Air Flow SCFM Purge...

Page 29: ...70 80 90 100 110 120 130 0 10 20 30 40 50 60 70 Purge Air Flow SCFM Purge Meter Setting psig Dryer Model 500ZPB Purge Pressure Setting 35 psig 81 SCFM Purge Orifice 3 8 0 10 20 30 40 50 60 70 80 90 10...

Page 30: ...0 180 210 240 270 300 330 360 0 10 20 30 40 50 60 70 Purge Air Flow SCFM Purge Meter Setting psig Purge Orifice 5 8 1800ZPA Setting 51 psig 292 SCFM 0 50 100 150 200 250 300 350 400 450 500 0 10 20 30...

Page 31: ...urge Meter Setting psig Purge Orifice 7 8 3300ZPA Setting 47 psig 535 SCFM 0 100 200 300 400 500 600 700 800 900 1000 0 10 20 30 40 50 60 70 Purge Air Flow SCFM Purge Meter Setting psig Purge Orifice...

Page 32: ...5479 5 7 2 1 7 94 7 57 88 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 3 57 19 7 459 43 1 89 5 79 1 9 9 7 19 7 459 43 1 19 7 5 0 24 39 3 41 8 8 39 11 5479 54 7 43 1 9 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5...

Page 33: ...7 94 7 57 88 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 3 57 19 7 459 43 1 19 7 5 0 89 5 79 1 9 9 7 19 7 459 43 1 24 39 3 41 8 8 39 11 5479 1 24 89 7 3 947 5 149 7 8 9 4 1 4 7 4 91 9 4 7 31 9 349 8 2...

Page 34: ...9 43 1 19 7 5 0 24 39 3 41 8 1 97 1 3 148 7 5 149 7 19 7 1 24 89 7 3 947 54 7 43 1 9 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5 149 7 8 9 4 1 5 5 4 7 4 91 9 4 7 31 9 59 7 4 91 9 433 9 43 59 7 31 9 433 9 43 G...

Page 35: ...1 3 472 9 43 1 24 89 7 3 947 5 5 4 7 4 91 9 4 7 31 9 59 7 4 91 9 433 9 43 89 5 79 1 9 9 7 19 7 459 43 1 59 7 31 9 433 9 43 General Arrangement Dryer Models 160ZPB 200ZPB NEMA 4 Drawing No 47597121 34...

Page 36: ...1 1 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 3 57 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 9 5 9 5 5 5 5 5 24 39 3 41 8 54 7 43 1 9 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5 149 7 19...

Page 37: ...459 43 1 19 7 5 0 3 57 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 5 149 7 19 7 7 1 947 5 149 7 8 9 4 1 9 5 9 5 5 5 5 5 24 39 3 41 8 1 24 89 7 3 947 7 31 9 433 9 43 59 5 59 5 5 5...

Page 38: ...31 8 39 11 5479 94 7 57 88 7 7 1 1 3 57 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 89 5 79 1 9 9 7 19 7 459 43 1 24 39 3 41 8 5 149 7 8 9 4 1 5 149 7 19 7 1 24 89 7 3 947 54 7 43...

Page 39: ...1 47 9 1 3 472 9 43 8 39 11 5479 94 7 57 88 7 7 1 1 3 57 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 89 5 79 1 9 9 7 19 7 459 43 1 24 39 3 41 8 1 24 89 7 3 947 4 7 4 91 9 9 5 4 7...

Page 40: ...7 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 54 7 43 1 9 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5 149 7 8 9 4 1 1 24 89 7 3 947 5 149 7 19 7 1 97 1 3 148 7 4 7 4 91 9 4 7 31 9 General...

Page 41: ...3 459 43 1 19 7 5 0 7 1 1 3 57 19 7 459 43 1 5 7 2 1 7 259 942 9 7 3 433 9 43 459 43 1 19 7 5 0 1 24 89 7 3 947 4 7 4 91 9 4 7 31 9 General Arrangement Dryer Models 500ZPB 600ZPB NEMA 4 Drawing No 475...

Page 42: ...14 359 7 4 91 9 433 9 43 359 7 31 9 433 9 43 89 5 79 1 9 9 7 19 7 459 43 1 19 7 5 0 1 9 3 8 55479 8 349 4 7 31 9 4 91 9 459 43 1 1 5 88 8 1 3 9 459 43 1 1 5 88 5 7 892 39 1 4 7 4 91 9 459 43 1 19 7 5...

Page 43: ...9 942 9 7 3 433 9 43 459 43 1 5 0 9 5 9 5 459 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 14 359 7 4 91 9 433 9 43 359 7 31 9 433 9 43 89 5 79 1 9 9 7 19 7 459 43 1 19 7 5 0 1 9 3 8 55479 8 349 4 7 31 9 4 9...

Page 44: ...2 1 7 459 43 1 94 7 38 1 9 43 9 8 431 5 7 892 39 1 5 7 14 7 1 3 7 4 91 9 433 9 43 1 9 3 8 55479 8 349 1 3 7 4 91 9 433 9 43 54 7 43 1 9 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 7 1 947 349 8 2 2 2 470 3 57 8...

Page 45: ...8 39 11 5479 1 24 89 7 3 947 5 149 7 8 9 4 1 9 5 9 5 5 7 2 1 7 459 43 1 94 7 38 1 9 43 9 8 431 5 7 892 39 1 5 7 14 7 1 3 7 4 91 9 433 9 43 1 9 3 8 55479 8 349 1 3 7 4 91 9 433 9 43 349 8 2 2 2 470 3...

Page 46: ...9 9 5 9 5 459 43 1 94 7 38 1 9 43 9 8 431 1 9 94 7 7 3 1 9 1 24 89 7 3 947 5 149 7 8 9 4 5 149 7 19 7 7 9 94 7 7 3 1 9 1 7 1 947 349 8 2 2 2 470 3 57 88 7 5 8 8 9 7 1 1 8 99 3 5 8 5 149 7 1 3 8 349 8...

Page 47: ...7 892 39 1 7 1 3 7 4 91 9 433 9 43 1 3 7 31 9 433 9 43 5 149 7 19 7 7 1 947 5 149 7 8 9 4 1 9 5 9 5 459 43 1 94 7 38 1 9 43 9 8 431 349 8 2 2 2 470 3 57 88 7 5 8 8 9 7 1 1 8 99 3 5 8 5 149 7 1 3 8 34...

Page 48: ...59 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 14 5 7 892 39 1 1 9 3 1 8 8 349 9 5 94 7 57 88 7 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 1 24 89 7 3 947 5 149 7 8 9 4 1 5 149 7 19 7 7 1 947 349 8 2 2 2 470 3 57 88...

Page 49: ...1 I 4 7 31 9 8 39 7 3 5479 4 7 31 9 24 39 3 41 8 I 4 7 31 9 1 3 7 31 9 433 9 43 9 5 I 4 7 4 91 9 7 1 1 459 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 14 5 7 892 39 1 1 9 3 1 8 8 349 9 5 349 8 2 2 2 470 3 5...

Page 50: ...4 7 43 1 9 9 5 9 5 I 4 7 31 9 8 39 7 3 5479 4 7 31 9 459 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 892 39 1 1 9 3 8 55479 8 349 4 349 1 9 7 7 57 88 7 9 43 1 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5 149 7 8 9 4...

Page 51: ...7 19 7 7 1 947 94 7 57 88 7 24 39 3 41 8 8 39 11 5479 1 24 89 7 3 947 5 149 7 8 9 4 1 9 5 9 5 I 4 7 31 9 8 39 7 3 5479 4 7 31 9 459 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 892 39 1 1 9 3 8 55479 8 349 4...

Page 52: ...5 I 4 7 31 9 459 43 1 94 7 38 1 9 43 8 4 3 9 8 431 5 7 14 5 7 892 39 1 1 9 3 1 8 8 349 4 349 1 9 7 9 5 7 57 88 7 9 43 1 1 9 94 7 7 3 1 9 7 9 94 7 7 3 1 9 5 149 7 8 9 4 5 149 7 19 7 1 7 1 947 349 8 2...

Page 53: ...1 8 8 349 4 349 1 9 7 9 5 7 57 88 7 9 43 1 12 0 GENERAL ARRANGEMENT ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com General Arrangement Dryer Model 5000ZPB NEMA 4 Drawing No 47597130 A 51 349...

Page 54: ...am Dryer Model and Serial Number must be provided when ordering 2 23702244 Display Board Panel 3 634083 Overlay Controller 4 47587161001 Power Supply 5VDC 24VDC 5 38052411 Transducer Cable 5 Ft Lead F...

Page 55: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 13 0 WIRING DIAGRAM Wiring Diagram NEMA 4 Standard Drawing No 47595562 53...

Page 56: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 54 13 0 WIRING DIAGRAM Wiring Diagram NEMA 4 MLC Drawing No 47595563...

Page 57: ...OLERANCES ARE CAD GENERATED DRAWING PROPRIETARY NOTICE NOTICE THIS DRAWING EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY ZEKS AND ALL PATENT RIGHTS AND DESIGN MANUFACTURING THE SAME ARE EXPRESSL...

Page 58: ...VE FV 2B RIGHT TOWER PURGE VALVE FV 1C LEFT TOWER OUTLET CHECK VALVE FV 2C RIGHT TOWER OUTLET CHECK VALVE FV 1P LEFT TOWER PURGE CHECK VALVE FV 2P RIGHT TOWER PURGE CHECK VALVE FV 4A LEFT TOWER INLET...

Page 59: ...IN GAUGE FO 1 PURGE ORIFICE FO 4 REPRESSURIZATION ORIFICE NOTE 3 FV 1A LEFT TOWER INLET VALVE FV 2A RIGHT TOWER INLET VALVE FV 1B LEFT TOWER PURGE VALVE FV 2B RIGHT TOWER PURGE VALVE FV 1C LEFT TOWER...

Page 60: ...IGHT TOWER PURGE MUFFLER FR 1 CONTROL AIR FILTER WITH REGULATOR AND BUILT IN GAUGE FLT 2 PREFILTER HIGH EFFICIENCY NOTE 4 FLT 3 AFTERFILTER DUST PARTICULATE NOTE 4 FO 1 PURGE ORIFICE FO 4 REPRESSURIZA...

Page 61: ...SURIZATION ORIFICE NOTE 3 FV 1A LEFT TOWER INLET VALVE FV 2A RIGHT TOWER INLET VALVE FV 1B LEFT TOWER PURGE VALVE FV 2B RIGHT TOWER PURGE VALVE FV 1C LEFT TOWER OUTLET CHECK VALVE FV 2C RIGHT TOWER OU...

Page 62: ...FFLER FR 1 CONTROL AIR FILTER WITH REGULATOR AND BUILT IN GAUGE FLT 2 PREFILTER HIGH EFFICIENCY NOTE 3 FLT 3 AFTERFILTER DUST PARTICULATE NOTE 3 FO 1 PURGE ORIFICE FO 4 REPRESSURIZATION ORIFICE NOTE 2...

Page 63: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 61 14 0 FLOW DIAGRAM Flow Diagram 1800 2700 ZPB NEMA 4 Drawing No 47634360 A...

Page 64: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 62 14 0 FLOW DIAGRAM Flow Diagram 3300 5000 ZPB NEMA 1 Drawing No 47634364 A...

Page 65: ...ZEKS EclipseTM 90 5 000ZPB Desiccant Dryers www zeks com 63 14 0 FLOW DIAGRAM Flow Diagram 3300 5000 ZPB NEMA 4 Drawing No 47634361 A...

Page 66: ...ENT AFTERFILTER PARTIC EC110G EC135G EC235G EC235G EC290G 1 1 1 2 DPI 2 3 GAUGE DIFF PRESSURE FILTER 634658 634658 634658 634658 634658 2 PI 1 2 3 GAUGE PURGE TOWER PRESS 680572 680572 680572 680572 6...

Page 67: ...C350H EC470H EC600H EC600H 1 1 1 2 FLT 3 ELEMENT AFTERFILTER PARTIC EC350G EC470G EC600G EC600G 1 1 1 2 DPI 2 3 GAUGE DIFF PRESSURE FILTER 634658 634658 634658 634658 2 PI 1 2 3 GAUGE PURGE TOWER PRES...

Page 68: ...920H EC1080H EC1350H EC1600H 1 1 1 2 FLT 3 ELEMENT AFTERFILTER PARTIC EC920G EC1080G EC1350G EC1600G 1 1 1 2 DPI 2 3 GAUGE DIFF PRESSURE FILTER 634658 634658 634658 634658 2 PI 1 2 3 GAUGE PURGE TOWER...

Page 69: ...C EF600G 3 EF600G 4 EF600G 5 EF600G 6 EF600G 7 EF600G 10 Qty 1 Set 1 Set 2 Sets DPI 2 3 GAUGE DIFF PRESSURE FILTER 633353 633353 633353 633353 633353 633353 2 PI 1 2 3 GAUGE PURGE TOWER PRESS 631324 6...

Page 70: ...O N O 47607077006 47607078006 47590672001 VALVE ANGLE 2 P O N C 47607077007 47607078007 47607080002 47590670001 VALVE ANGLE 2 P O N O 47607077008 47607078008 47590671001 VALVE ANGLE 2 P O N O 47607077...

Page 71: ...705001 SP Blue Moisture Indicator CONTROL AIR SOLENOID and FILTER REGULATOR ASSEMBLY Optional Dew Point Transmitter not shown PART NO DESCRIPTION 633671 Cable Transmitter 633691 Resistor 250 OHM R3 o...

Page 72: ...64 00 51 25 87 62 2 424 1 270 1500ZPB 1 500 1 200 243 4 NPT 78 00 54 76 80 00 2 974 1 600 1800ZPB 1 800 1 440 292 4 NPT 84 00 60 62 91 88 3 905 2 000 2100ZPB 2 100 1 680 340 4 NPT 84 00 60 62 91 88 4...

Page 73: ...1302 Goshen Parkway West Chester PA 19380 Phone 610 692 9100 800 888 2323 Fax 610 692 9192 Web www zeks com...