rreeefffrrriiigggeeerrraaattteeeddd aaiiirrr

COMPRESSED AIR SOLUTIONS
TM
R E F R I G E R AT E D A I R D R Y E R
TECHNICAL MANUAL
HEATSINK™ TRUE-CYCLING™
HIGH PRESSURE DRYER
MODELS 17-21SCFX
PATENT # 6,186,223
TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9
10.
INTRODUCTION
ABBREVIATED WARRANTY
REFRIGERATED DRYER NOMENCLATURE
RECEIVING AND INSPECTION
SAFETY AND OPERATION PRECAUTIONS
PRINCIPLES OF OPERATION
INSTALLATION AND INITIAL START-UP
SCHEDULED MAINTENANCE
TECHNICIAN MODE
TROUBLESHOOTING
A.
B.
C.
D.
ATTACHMENTS
WIRING DIAGRAMS
GENERAL ARRANGEMENT DRAWINGS
SPARE PARTS LIST
ENGINEERING SPECIFICATIONS
PAGE
1
1
2
3
4
5
14
17
20
23
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, Pennsylvania 19355
610-692-9100 800-888-2323
FAX 610-692-9192
TMSCFX-17-21-DPC
V0705
1.
INTRODUCTION
The ZEKS scfx HeatSink™ refrigerated air dryer removes moisture, oil vapor, and other
contaminants from compressed air. These contaminants are detrimental to pneumatically
operated appliances, controls, instruments, machinery and tools. This is accomplished by
cooling the air with a refrigeration unit to a temperature at which moisture in the air is
condensed and separated from the airstream. The temperature the air is cooled to,
normally between 36 and 40°F, is known as dew point. This dryer can be easily installed
into various pneumatic systems in which dry air is required or desired. Please refer to
Principles of Operation for complete operating details.
2.
ABBREVIATED WARRANTY
ZEKS refrigerated dryers are warranted to be free from defects in material and workmanship for a period of 12 months from the original date of shipment from the factory. To
allow the warranty to be in effect for 12 months from the date of equipment start-up, the
Warranty Registration Card must be completed and returned to ZEKS. Alternately, the
Warranty Registration Card may be completed online at www.zeks.com. The total
warranty period cannot exceed 18 months from the original date of shipment from the
factory.
Equipment must be installed and operated in accordance with ZEKS’ recommendations.
ZEKS liability is limited to repair of, refund of purchase price paid for, or replacement in
kind at ZEKS’ sole option, during the warranty time period stated above. IN NO EVENT
SHALL ZEKS BE LIABLE OR RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES, even if the possibility of such incidental or consequential damages has been
made known to ZEKS Compressed Air Solutions. In addition, the usual maintenance and
replacement type products are not covered by this warranty.
REFRIGERANT COMPRESSORS
A prorated warranty for the replacement of the refrigerant compressor will be extended to
a maximum of 60 months (5 years) from the original date of shipment from the factory.
Following the standard warranty terms, the available prorated compressor warranty is as
stated below. This prorated warranty applies to replacement compressor only and does
not cover any labor expenses.
Prorated coverage
19 to
25 to
37 to
49 to
of price from date of shipment from the factory:
24 months
70%
36 months
50%
48 months
30%
60 months
10%
1
HEAT EXCHANGERS
Dryers that utilize CFX heat exchanger technology are covered for a total of 10 years from
the original date of shipment from the factory. Following the standard warranty terms the
available warranty is as stated below. The exchanger warranty applies to the replacement
exchanger only and does not cover any labor expenses.
Prorated coverage
18 to
49 to
61 to
73 to
85 to
97 to
of prices from date of shipment from the factory:
48 months
100%
60 months
70%
72 months
50%
84 months
30%
96 months
20%
120 months
10%
Freight and labor coverage varies internationally. Refer to Distributor Warranty Guidelines
for limitations and detailed explanation of warranty coverage.
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.
3.
NOMINAL
FLOW
SCFM
17, 18, 19
20, 21
REFRIGERATED DRYER NOMENCLATURE
HIGH PRESSURE
CYCLING DRYER
CONDENSER
TYPE
SCFX= High Pressure Cycling
A=Air Cooled
W=Water Cooled
O = STANDARD
H = NEMA 4
W = WEATHERPROOF
O = STANDARD
Z = SPECIAL
2
POWER
4=460-3-60
5=230-3-60
6=575-3-60
OPTIONS
4.
RECEIVING AND INSPECTION
4.1
INSPECTION
Upon receiving your ZEKS air dryer, please inspect the unit closely. If rough handling
has been detected, please 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 damages will facilitate any insurance claims
4.2 UNPACKING AND HANDLING
Under no circumstances should any person attempt to lift heavy
objects without proper lifting equipment (i.e., crane, hoist, slings or
fork truck). Lifting any unit without proper lifting equipment, can
cause serious injury.
All dryer packages have been mounted on a base which provides for forklifting
between the two base channels to facilitate handling during shipment. Forks should
extend all the way through forklift channels to reduce unnecessary forces to the dryer
during moving. Slings can be used to lift the crates, but spreader bars must be used
to prevent the slings from exerting a force against the sides of the crates.
3
5.
SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in
operation or maintenance could be hazardous to personnel. In addition to obvious safety
rules that should be followed with this type of machinery, safety precautions as listed
below must be observed:
OSHA
Heading Descriptions
1.
Only qualified personnel shall be permitted to adjust,
perform maintenance or repair this air dryer.
2.
Read all instructions completely before operating unit.
3.
Pull main electrical disconnect switch and disconnect
any separate control lines, if used, before attempting to
work or perform maintenance on the unit.
4.
Do not attempt to service any part while machine 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 attempt to remove any part of the refrigeration
system without removing and containing refrigerant in
accordance with the EPA and local regulations.
7.
Do not operate the dryer at pressures in excess of its
rating.
8.
Do not operate the dryer without guards, shields and
screen in place.
9.
Inspect unit daily to observe and correct any unsafe
operating conditions.
“Warning” is used to indicate a
hazardous situation which has
some probability of death or
severe injury. Warning should
not be considered for property
damage accidents unless
personal injury risk is present.
CAUTION
“Caution” is used to indicate a
hazardous situation which may
result in minor or moderate
injury.
NOTICE
“Notice” is used to indicate a
statement of company policy
as the message relates directly
or indirectly to the safety of
personnel or protection of
property. Notice should not be
associated directly with a
hazard or hazardous situation
and must not be used in place
of “Danger,” “Warning,” or
“Caution.”
NOTICE
The user of any air dryer manufactured by ZEKS Compressed Air Solutions, is hereby
warned that failure to follow the above Safety and Operation Precautions may result in
personal injury or equipment damage. However, ZEKS Compressed Air Solutions
does not state as fact, nor does it mean to imply, that the preceding list of Safety and
Operating Precautions is all inclusive, and further, that the observance of this list will
prevent all personal injury or equipment damage.
4
6.
PRINCIPLES OF OPERATION
6.1
INTRODUCTION
ZEKS SCFX HEATSINK™ dryers remove moisture from compressed air by cooling
the air temperature to between 36° and 40°F (2 and 4°C). This causes vapors to
condense into liquid droplets which can then be easily removed from the air. The
major systems of the dryer which contribute to its operation are the Air System, the
Moisture Removal System, the Refrigeration System, the Thermal Mass Circulating
System and the Controls. The following paragraphs describe each of the systems in
greater detail.
6.2
AIR SYSTEM
The air system consists of the dryer components which are in contact with the
compressed air. Referring to Figure 1 and following the bold “AIR FLOW,” hot saturated
air from the compressor enters the precooler/reheater where the air temperature is
reduced prior to entering the chiller by the cool air exiting the air/moisture separator.
This precooling allows for the use of a smaller refrigeration system. The air then
goes into the chiller section where it is further cooled to the desired dew point by a
thermal mass fluid. The temperature of the thermal mass fluid is maintained by the
refrigeration circuit and controls. The air continues to the separator where moisture is
removed, thereby, allowing the cool, dry air to return to the precooler/reheater to be
heated by the incoming moist hot air. The air exiting the “reheater” portion of the
dryer should be approximately 15°- 20°F lower than the inlet air temperature based
on standard conditions at full rated flow.
FIGURE 1
FLOW DIAGRAM
DRAWING 500161
5
6.3
MOISTURE REMOVAL SYSTEM
Liquid droplets are removed from the air stream in the separator. As the air and
liquid mixture passes through the separator it spins, slows down and then changes
direction. This causes the condensate to fall out of the air stream and collect in the
bottom of the separator. The collected liquid is removed from the separator by a
high-pressure solenoid valve. The solenoid valve is controlled by the microprocessor
controller as described in Section 6. For adjustment please note the following:
• To obtain the optimum time values for operation of the solenoid drain valve, set
the off-time to three minutes and the on-time ten seconds via the controller.
• After running the unit under full rated flow for approximately 30 minutes, verify that
when the solenoid drain opens, all of the accumulated liquid is discharged and then
a small burst of air.
• If a small amount of liquid and a large amount of air is discharged, decrease the ontime setting or increase the off-time setting. If there is all liquid and no air has been
discharged, increase the on-time setting or decrease the off-time setting.
• The on/off time settings will vary according to seasonal operating conditions. During
the summer when more moisture is present in the air system a shorter on-time,
increasing the valve opening frequency, is required. A longer valve off-time may be
used during the winter months when moisture levels are lower.
6.4
REFRIGERATION SYSTEM
The Refrigeration System consists of all the components which handle R-22. This is
a hermetically sealed closed-loop system. Referring to Figure 1 and following the
phantom “REFRIG(R-22) FLOW,” refrigerant is shown leaving the evaporator section
where, in the process of removing heat, it is changed from a low pressure liquid into
a low pressure gas. This gas enters the suction side of the compressor where it is
compressed into a high pressure gas. The high pressure gas is cooled in the air
cooled or water cooled condenser section until it becomes a high pressure liquid. It
then goes through a permanent filter dryer that ensures the refrigeration system is
free of contaminants. A thermostatic expansion valve meters the refrigerant for
introduction into the evaporator. The refrigerant pressure is reduced upon entering
the evaporator where as it evaporates, heat is removed from the thermal mass fluid.
A solenoid valve in the liquid line eliminates the possibility of flooded starts.
6.5 THERMAL MASS CIRCULATING SYSTEM
The thermal mass fluid in a ZEKS HEATSINK™ dryer is continuously circulated in a
closed pump loop system. Referring to Figure 1 and following the dashed “THERMAL
MASS FLUID” line, the heat is removed from the fluid in the evaporator by the refrigeration system. The thermal mass reservoir is sized to minimize refrigeration cycles
during reduced air load periods. The thermal mass fluid is pulled from the bottom of
the reservoir and pumped through the chiller, removing heat from the air and returned
to the evaporator. The pump utilized on ZEKS’ HEATSINK™ dryer is a maintenancefree, quiet cartridge circulator pump similar to those used in residential water
systems. While the refrigeration system cycles on and off based on loading
conditions, the circulating pump runs continuously to maintain flow through the chiller
at all times.
6
6.6 CONTROLS
ZEKS’ 17-21SCFX Refrigerated Compressed Air Dryers are equipped with the Digital
Performance Controller (DPC™). This advanced microprocessor-based controller has
been engineered by ZEKS exclusively for use with ZEKS’ Compressed Air Dryers.
The DPC™ cycles the refrigeration system based on the dryer's Chiller Temperature.
A temperature sensor samples the thermal mass temperature as it enters the chiller
exchanger. The Chiller Temperature Set point is a user adjustable set point that is
used to set the Refrigeration Compressor Off temperature. Once the Chiller
Temperature has fallen below the Chiller Temperature Set point, the refrigeration
compressor will de-energize. The Operating Temperature Differential is factory set at
4°F above the Chiller Temperature Set point. Therefore, if a user adjusts the Chiller
Temperature at 36°F, the Refrigeration Compressor On temperature will be 40°F.
In addition to the operation of the HeatSink™ dryers as described above, the DPC™
permits monitoring of dryer parameters and enunciation of alarm conditions.
The list below summarize the features the DPC™:
• 1 X 16 Character Backlit LCD Display - Easy-to-read display provides continuous
indication of dryer default parameter. Standard backlight permits viewing of critical
information in low light environments.
• Electronic Drain with On/Off Time Adjustment: Included with DPC™-equipped scfx
HeatSink™ dryers is a high pressure solenoid drain valve. Control of the open and
close time of the valve is set via the DPC™ Controller.
• Remote Start / Stop: DPC™-equipped dryers offer a unique remote start / stop
feature. This feature allows the dryer to be operated via a remote user-supplied
switch.
• Remote Alarm Contact: DPC™-equipped dryers include a remote alarm contact to
provide indication of any of the dryers alarms described later in this manual.
Contact rated for 2A / 120V max.
The DPC™ Controller features three levels of access. The default level CUSTOMER
MODE permits adjustment of dryer parameters to address seasonal variations for
drain timing and pressure dew point temperature. A protected TECHNICIAN MODE
permits access to and manipulation of additional parameters to address the initial
machine set up. A password protected FACTORY MODE is also included for use with
ZEKS Service Personnel for troubleshooting the dryer.
7
The DPC™ controller includes a digital readout for monitoring the discharge pressure
of the refrigerant gas exiting the compressor. This reading will vary dependent upon
condenser type as indicated below:
• For air-cooled applications, condensing fans are cycled on and off by the DPC
based on the refrigerant discharge pressure. Primary fan(s) are cycled on at 235
psig and off at 195 psig. Should the discharge pressure continue to climb above
265 psig, the secondary condensing fans will cycle on. As discharge pressure is
reduced below 210 psig, the secondary fan(s) will cycle off. Note that on the
19SCFX, three condenser fans are used. For the 19SCFX, the center fan is the
primary controlled fan the outside fans are the secondary controlled fans.
• Water cooled condensers utilize a water regulating valve (Note Figure 2). The
water regulating valve comes pre-adjusted from the factory at 215 psig discharge
pressure. To compensate for water temperature variation, it may be necessary to
adjust the water regulating valve to maintain a 215 psig discharge pressure.
Adjustment can be done by rotating the adjusting screw counterclockwise for an
increase in discharge pressure. For conditions where low water temperature
and/or high water pressure are expected it is advisable to install a water pressure
regulator ahead of the condenser.
ADJUSTMENT SCREW
FIGURE 2
WATER REGULATING VALVE
Drawing 600562
8
6.6.1 BASIC USER INTERFACE
The DPC™ display provides the user with the operating parameters and their
corresponding values. The following illustration summarizes the keypad functions.
CHLLR TEMP: 37
BUTTONS
• RESET
Pressing once clears the local alarm indication and deenergizes the remote alarm contact. Should the alarm
condition persist, the alarm will return after the alarm
inhibit time has expired.
• ON
Places the dryer "On Line"; Energizes glycol pump on
HeatSink™ dryers. For HeatSink™ models, the
compressor will operate based on temperature;
• OFF
Places the dryer "Off Line"; Stops all automatic functions,
including circulating pump operation on HeatSink™ dryers.
• SET
Permits the adjustment of parameters in TECHNICIAN
and FACTORY MODES. In CUSTOMER MODE, allows
user to back through displays,
• SELECT DISPLAY
Allows the user to cycle through the available displays.
The last display selected will remain displayed as the
default display.
• ENTER
Used to accept changed parameters and set point
values.
• +/Allows user to increase set point values. Set point values
cycle through a fixed range. Also allows entering negative
numbers in FACTORY MODE.
• i
Restricted Level access for factory use only. Not used
for basic dryer functions. Not to be used by customer or
service technician.
• TEST
Allows user to manually activate the drain solenoid valve.
9
6.6.2 DISPLAY PARAMETERS
The DPC™ Controller is capable of displaying a number of system parameters.
The following summarizes the parameters that can be accessed by the user from
the DPC™ Controller:
• Chiller Temperature (CHLLR TEMP): For HeatSink Dryers, the Chiller
Temperature is the temperature, in degrees Fahrenheit, of the thermal mass fluid.
• Compressor Status (CMPRSSR): Displays whether the refrigeration compressor
is “ON” or “OFF”.
• Discharge Pressure (P disch): Displays the discharge pressure of the refrigeration
system.
• Suction Temperature (T suction): Displays the suction temperature, in deg. F, of
the refrigeration system. This value is useful in determining superheat of the
refrigerant.
• Suction Pressure (P suction): Displays the suction pressure, in psig, of the refrigeration system.
• Drain Interval (DRN INT): Displays the length of time, in minutes, between
operation of the solenoid drain.
• Drain On (DRN ON): Displays the length of time, in seconds, that the solenoid
drain is open.
• Percent Savings (% SVGS): Displays the length of time the compressor has been
operating versus the length of time the dryer has been on.
• Cumulative Dryer Hours (CUM DRYER HR): Displays the length of time, in hours,
that the dryer has been operational.
• Cumulative Compressor Operating Hours (CUM CMP HR): Displays the length of
time, in hours, that the refrigeration compressor has been energized.
Depressing the SELECT DISPLAY button repeatedly scrolls through the above
non-adjustable displays. The Customer Set Points appear at the end of the list
and may be adjusted by the end user to match seasonal refrigeration and drain
operation. These settings are as follows:
• Chiller Temperature (CHLLR TEMP)
• Drain Interval (DRN INT)
• Drain On (DRN ON)
10
6.6.3 DRYER SET POINTS AND ALARMS
The DPC™ Controller has several user adjustable set points that are displayed at
the end of the display parameter list. These set points allow the user to configure
the dryer to operate according to site conditions. The controller is shipped from the
factory with each parameter having its own default value. The following chart
summarizes the parameters that may be adjusted by the user:
SETPOINT
Drain Interval Time
Drain On Time
Chiller Off Temperature
Display
Parameter
Factory Setpoint
Description
Range
HeatSink NonCycle
DRN INT
3, 5, 10, 15, 20, 30, 60 min
3 MIN
3 MIN
DRN ON
3, 5, 7, 10, 12, 15 , 20, 30 sec. 10 SEC
10 SEC
CHLLR TEMP 32°F - 50°F; 1 °F increments
34°F
INACTIVE
6.6.4 ADJUSTING SET POINTS
Accessing and manipulating each of the set points in the CUSTOMER MODE is
accomplished as follows. The parameter is selected using the SELECT DISPLAY
button. After scrolling through the displays, the “Cust Set Points” screen is
displayed. The parameters after this screen may be adjusted by the user. Once
the desired parameter is displayed, depressing the “+/-” button changes the set
point. Once the new set point is displayed, depressing ENTER saves the set point.
Exiting the Customer Set Point routine is accomplished by depressing the SELECT
DISPLAY button until the END CUST SET PTS screen is displayed. The following
example illustrates the keystrokes required to change the Drain Closed Time from
the default value of 3 Minutes to 5 Minutes:
SELECT
DISPLAY
CHLLR TEMP:
SELECT
DISPLAY
Cust Set Points
36
Pressing SELECT DISPLAY will increment the display
through the available display parameters.
Continue pressing SELECT DISPLAY until the Customer
Set point screen is displayed. The parameters that follow
are the User Adjustable Parameters for the controller.
Press SELECT DISPLAY until “DRN INT” is displayed.
SELECT
DISPLAY
DRN INT:
3 min
+
-
DRN INT:
5 min
Depress “ + / -“ as required to change the DRN INT time
to 5 minutes.
ENTER
DRN INT:
5 min
Pressing “ENTER“ saves the set point.
SELECT
DISPLAY
SELECT
DISPLAY
End Cust Set Pts
CHLLR TEMP:
36
Press SELECT DISPLAY as necessary to display the End
Customer Set points Screen.
Press SELECT DISPLAY as necessary to return the DPC
to the desired display parameter.
11
6.6.5 ALARMS AND THEIR FUNCTIONS
There are several alarms detected by the DPC™ to alert the user of an out of
tolerance condition. Once each alarm is detected, a description of the alarm will
appear in the screen and the remote alarm contact will close. Note that during the
alarm condition, the SELECT DISPLAY button may be depressed to scroll through
the available parameters. After approximately 30 seconds, the alarm screen will
reappear, provided the alarm condition persists.
Alarm
HIGH PRESSURE CUTOUT
LOW PRESSURE CUTOUT
HIGH TEMPERATURE ALARM
LOW TEMPERATURE ALARM
HIGH DRAIN LEVEL ALARM
Display
HI PRESS CO
LO PRESS CO
HITEMP ALRM
LOTEMP ALRM
DRAIN LVL ALARM
Alarm Set Point
See Table 1
See Table 1
55 °F
30 °F
N/A
The alarm names and description of each are described in detail below. Note that
some alarms will enunciate only after a prescribed alarm delay. Refer to the
TECHNICIAN MODE section of this manual for factory default alarm delay periods.
HIGH TEMPERATURE ALARM (HITEMP ALARM)
When the thermal mass (glycol) temperature in an SCFX HeatSink™ dryer
reaches the factory alarm set point, after an alarm delay, the alarm will be
activated. This alarm condition may not necessarily damage the dryer when
subjected to long-term exposure. It may, however, have a significant impact on
downstream processes and thus should be investigated upon detection. Note that
this alarm will not shut down the dryer. This alarm will activate the remote alarm
contact and reset automatically once the alarm condition is rectified.
LOW TEMPERATURE SAFETY ALARM (LOWTEMP ALARM)
If the dryer chiller temperature falls to or below the factory set point and remains at
or below this set point for the factory delay time, the alarm routine will activate.
This alarm condition may cause damage to the dryer when subjected to continuous
or long-term exposure. Note that this alarm will shut down the dryer after a
response time delay. This alarm will activate the remote alarm contact and reset
automatically once the alarm condition is rectified.
HIGH PRESSURE CUTOUT ALARM (HPCO ALARM)
If the discharge pressure of the refrigerant is determined to be above the set point,
the alarm routine will activate. This alarm condition may cause damage to the
dryer when subjected to continuous or long-term exposure. Note that this alarm will
shut down the dryer after a response time delay. The operator must depress the
RESET button in order to clear the alarm and restart the refrigeration system.
LOW PRESSURE CUTOUT ALARM (LO PRESS CO)
If the suction pressure of the refrigerant is determined to be below the set point of
the LPCO alarm, the DPC alarm routine will activate. This alarm condition may
cause damage to the dryer when subjected to continuous or long-term exposure.
Note that once cleared, the compressor will restart automatically. However, if two
successive low-pressure conditions are determined, this alarm will shut down the
dryer after a response time delay and will display the alarm condition. The operator
must depress the RESET button in order to reinstate the compressor.
12
HIGH DRAIN LEVEL ALARM - OPTIONAL (DRAIN LVL ALARM)
On dryers equipped with the optional High Drain Level Alarm, should condensate
rise to a predetermined level in the separator, a liquid level switch will signal the
DPC and the High Drain Level Alarm will enunciate. In addition to indicating the
alarm on the LCD and closing the remote alarm contact, the High Drain Level Alarm
will open the solenoid drain in an attempt to correct the problem. The condition will
not shut off the dryer. Once the source of the problem has been addressed, the
alarm will automatically reset.
Parameter
FAN 1 ON
FAN 1 OFF
FAN 2 ON
FAN 2 OFF
HPCO (Air Cooled)
HPCO (Water Cooled)
LPCO
R-22
235 psig
195 psig
265 psig
210 psig
400 psig
320 psig
20 psig
R-404A
275 psig
195 psig
335 psig
235 psig
450 psig
320 psig
20 psig
R-407C
235 psig
195 psig
265 psig
210 psig
400 psig
320 psig
20 psig
TABLE - 1
6.6.6 START MODES
ZEKS dryers are capable of starting in one of three start modes. Note that to
protect the refrigeration compressor from repeated rapid starts, the DPC™ is
equipped with an an anti-short cycle (ASC) delay. The ASC delay will countdown
from the factory set point (see TECHNICIAN MODE). Only after the ASC delay
has timed out will the refrigeration system operate. Below are brief descriptions of
these various start modes.
6.6.6.1
Manual Mode
ZEKS dryers are shipped from the factory in the Manual Mode. After power is
supplied to the dryer, the user will be presented with the ASC delay, followed by the
“PRESS ON BUTTON” display. After the ASC delay has timed out, the dryer will
only start once the ON button is depressed. In this configuration, to restart the
dryer, the user must manually depress the ON button on the dryer’s control panel.
6.6.6.2
Auto Restart Mode
After power is applied to the dryer, and once an anti-short cycle delay has timed
out, the dryer will start automatically. In addition, this mode of operation allows
manual control of the dryer via the ON & OFF pushbuttons. This is useful for
applications where automatic restarting of the dryer is desired after a power failure
has occurred.
6.6.6.3
Remote Automatic Mode
This mode of operation allows the user to control the dryer remotely and requires
the installation of a customer-supplied contact and grounded 24V power supply.
With power applied to the dryer and once the anti-short cycle delay has timed out,
the dryer will start automatically once the switch is closed. In addition, this mode of
operation allows manual control of the dryer via the ON & OFF pushbuttons.
13
7.
INSTALLATION AND INITIAL START-UP
7.1
LOCATION AND MOUNTING
The dryer should not be located in an area where ambient temperature is likely
to exceed 113°F (45°C) or be less than 50°F (10°C). The dryer must be located in
an area that provides sufficient clearance from walls and other adjoining equipment
to allow easy access for servicing and maintenance requirements. A minimum of
18 inches is required to allow free flow of air to the condenser inlet.
On installations with a relatively steady flow rate, the dryer is normally connected
after the air receiver. If loads fluctuate widely, the dryer should be positioned ahead
of the receiver and sufficient storage capacity downstream is necessary to prevent
excessive air flow through the dryer.
When installed after any compressor that causes significant vibration or air pulsation,
such as reciprocating compressors, proper vibration isolation and pulsation
dampening devices should be added to protect the dryer.
NOTICE
Failure to comply to the above instructions may result in equipment malfunction
and will void warranty.
NOTICE
Always use a backup wrench when making any threaded connection to the dryer.
Failure to use a backup wrench may result in damaged tubing and components
internal to the cabinet.
7.2 PIPING AND VALVES
Install piping, fittings and accessories as required for specific site conditions and
requirements. Figure 3 indicates a typical piping arrangement for a refrigerated dryer,
including dryer and filter bypasses. This figure can be used as a guide for valve and
accessory placement in the system.
ZEKS 17 - 21 SCFX models come factory installed with a drain isolation valve (D).
The isolation valve permits maintenance of the automatic drain without isolating air
flow to the dryer. To operate dryer, all valves shown in Figure 3 are to be closed
except valves (B), (C) and (D). Valve (A) is used for bypass purposes and valve (E)
is for test and manual drain purposes.
7.3
FILTRATION
To protect the air dryer from gross contamination associated with compressor oil and
debris and ensure maximum dryer performance, a prefilter is recommended.
Prefilters and afterfilters sized to your drying application can be provided by ZEKS
and are available factory installed. Call your local distributor to select the filter that
best suits your filtration requirements. In addition to air filtration, condensate
discharge oil/water separators are also available to address stringent EPA regulations.
14
A
AIR
DRYER
B
C
AIR OUT
AIR IN
PREFILTER
E
D
DRAIN
VALVE
CHECK
VALVE
DRAIN
VALVE
CHECK
VALVE
CHECK
VALVE
OIL
SEPARATOR
CHECK
VALVE
UNIT AS DELIVERED
OPTIONAL ACCESSORY ITEMS
NOTE:
DRAIN TUBE MUST NOT RISE OR BE CONNECTED TO
EXCESSIVELY LONG PIPE WHICH MAY CREATE BACK PRESSURE
A CONNECTION TO OPEN FLOOR DRAIN IS REQUIRED
FIGURE 3
TYPICAL PIPING ARRANGEMENT
7.4
ELECTRICAL CONNECTION
Equipment is available in various electrical configurations. All customer connections
can be made at the terminal connections located in the customer electrical connection box on the rear of the dryer. (Refer to General Arrangement and appropriate
Wiring Diagrams.)
A suitable fused disconnect switch or circuit breaker, in accordance with national and
local code requirements, is recommended for all ZEKS equipment. Refer to the
Engineering Specifications section for voltage requirements and load.
CAUTION
Never wire directly or connect any additional wires to the compressor
junction box. This will cause severe system malfunction.
7.4.1 ZEKS dryers can be configured for three variations of start modes: Manual Mode,
Automatic Mode and Remote Mode. The instructions below describe the methods
to configure the dryer for a particular Start Mode.
A) Manual Mode (Factory Default) - No modification required to operate dryer in
Manual Mode. Once power is applied, dryer can be started or stopped by
depressing the local ON / OFF pushbuttons located on the front panel.
15
B) Auto Restart Mode - Auto Restart Mode permits the dryer to start after a brief
delay once power is applied to the dryer. In TECHNICIAN MODE, changing the
Auto Restart parameter from the default “N” to “Y” using the SET button enables
this mode of operation. Note that the dryer’s touch pad will still affect dryer
operation. Depressing the OFF button will de-energize the refrigeration
compressor and all other electrical components. After the OFF button has been
depressed, the user must depress the ON button to permit the dryer to operate.
C) Remote Mode - Remote Mode allows the dryer to be turned ON or OFF via a
remote switch supplied by the customer. This mode will work regardless of the
setting for Auto Restart. The dryer must be powered on for this feature to take
effect. To enable this feature:
• Install N.O. remote switch with grounded 24V power supply as indicated on
the appropriate wiring diagram.
• Customer-supplied contact should be rated at 1A at 24V. To operate dryer,
close switch or contact and allow dryer to start after an initial delay. The
local On / OFF pushbuttons may also be used at any time after contact
closure.
7.5
INITIAL START-UP
NOTICE
For water cooled models, the water valve must be manually opened
to ensure that the condenser is full of water prior to start-up.
CAUTION
Allow 8 hours of warm-up time for the crankcase heater prior to start up.
Crankcase heater is connected directly to the incoming power and is
energized at all times.
7.5.1 START- UP SEQUENCE
• Apply power to dryer. LCD Panel will illuminate. The Anti-Short Cycle delay will
commence counting down. Remaining time on the Crankcase heater will also
countdown.
NOTICE
After installation or a prolonged shutdown, start the dryer with no air load (no air flow).
This enables the dryer to reach its proper operating temperature in the shortest time
possible (typically within 30 minutes for HeatSink™ dryers).
• Start Dryer, using one of the following methods, depending on Start Mode setting:
16
Manual Mode - Press the ON pushbutton.
Auto Restart Mode - No additional action required
Remote Automatic Mode - Close the remote contact.
• For HeatSink™ dryers, the circulating pump will be energized and will run continuously. Provided the CHILLER TEMPERATURE is greater than the Compressor
Off Set point plus 4° F and the anti-short cycle delay and crankcase heater delay
have timed out, the refrigeration system will energize. As the system operates
and thermal mass temperature drops, the suction pressure will be lowered to
between 30 and 50 psig.
After the alarm delay, provided the Chiller Temperature is greater than the HIGH
TEMPERATURE ALARM set point, the dryer will go into HIGH TEMPERATURE
ALARM. The LCD panel will indicate the alarm and the refrigeration system will
continue to operate. Pressing the SELECT DISPLAY button will permit viewing of
the available dryer parameters during this alarm condition. Note that the alarm
condition screen will reappear after approximately 30 seconds until the alarm
condition is cleared.
The CHILLER TEMPERATURE will gradually drop as indicated on the display.
Once the temperature falls below the HIGH TEMPERATURE ALARM set point, the
alarm will reset and the LCD panel will return to its default display. After the refrigeration system shuts off, air flow may be slowly introduced to the dryer.
• Drain settings should be checked as described earlier in this manual
NOTICE
If power is removed from the dryer for less than two hours, the crankcase heater delay
will be automatically bypassed. If, however, the power is removed from the dryer for
more than two hours, the full crankcase heater delay must be observed.
8.0
SCHEDULED MAINTENANCE
8.1
INTRODUCTION
ZEKS HEATSINK™ refrigerated air dryers require little maintenance. These dryers
utilize hermetically sealed compressors which do not require any lubrication. Fan
motors require lubrication at both oil ports every six months. ZEKS recommends
component inspection and service at regular intervals to obtain maximum performance from your dryer.
8.2
REFRIGERANT CONDENSER
ZEKS dryers are equipped with an ambient air filter designed to protect the
condenser from dirt and debris that can accumulate on the condenser. For proper
operation, it is imperative that this filter be inspected and cleaned on a regular basis.
Annual replacement of the filter is recommended. For applications where excessive
dirt, dust or debris is encountered, more frequent inspection and cleaning may be
required.
17
8.3
CONDENSATE DISCHARGE SYSTEM
On a minimum of a monthly basis, the operation of the automatic drain should be
checked. The drain should be removed and cleaned as well to ensure no debris
from the system is trapped inside the strainer. Figure 4 illustrates the drain
assembly. To clean the drain, turn the Isolation Valve to the off position. Be sure
the valve is depressurized. Carefully remove the Strainer End Cap and remove the
Strainer. Clean the Strainer and remove any debris that is evident in the valve.
Replace the Strainer and reinstall the Strainer End Cap. Carefully open the
isolation valve and inspect the Strainer End Cap for leaks. Tighten as required.
If dryer is installed without a drain isolation valves (filter stop), failure to depressurize
the dryer may result in serious injury. Do not remove the drain valve without depressurizing the unit.
NOTE: Actual arrangement of drain components may vary
FIGURE 4
DRAIN DETAIL
DRAWING 749408
18
HIGH-PRESSURE SOLENOID VALVE
DISASSEMBLY AND REASSEMBLY
DEPRESSURIZE VALVE AND
TURN OFF ELECTRICAL SUPPLY
1. Remove retaining cap and slip the entire
solenoid enclosure off the solenoid base subassembly.
2. Unscrew solenoid base sub-assembly.
Remove core assembly, core spring and
solenoid base gasket.
3. Unscrew end cap. Remove end cap gasket
and piston spring. To remove the piston
assembly, a small hole is provided in the back
of the piston. Hook a vent piece of wire or
similar tool in the hole. Pull piston assembly
from valve body.
4. All parts are now accessible for cleaning or
replacement. Replace worn or damaged parts
with a complete Spare Parts Kit for best
results. Clean internal passageways in valve
body.
5. Reassemble in reverse order of disassembly
paying careful attention to the exploded views
provided for identification and placement of
parts.
HP SOLENOID VALVE
DETAIL
CLEANING
All solenoid operators and valves should be cleaned periodically. The time between cleaning will
vary depending on medium and service conditions. In general, if the voltage to the solenoid is
correct, sluggish valve operation, excessive noise or leakage will indicate that cleaning is
required. Clean strainer or filter when cleaning the valve.
CAUTION
Failure to periodically check and clean drain valve may result in drain becoming clogged.
Should this occur, moisture remaining within separator may travel downstream of dryer.
19
9.0
TECHNICIAN MODE
The DPC provides a protected TECHNICIAN MODE to manipulate several parameters not
accessible by the typical operator. This mode also permits viewing of the factory settings
to aid in troubleshooting of the dryer. Below is a list of parameters that can be accessed
and manipulated by the technician in the TECHNICIAN MODE:
Parameter
SOLENOID DRAIN ENABLE
CRANKCASE HEATER DELAY
AUTO RESTART ENABLE
Display
Set Point
DRAIN ENABLE
ON (or OFF)
CCH DLY
8 (or 0,2,4,12 hours)
AUTO RESTART
N (or Y)
In TECHNICIAN MODE, the following parameters can be viewed but not changed:
Parameter
Display
CONFIGURATION (# of sensors)
CONFIG #:
OPERATING MODE
OP MODE:
REFRIGERANT
REFRIG:
CONDENSER TYPE
COND:
OPERATING TEMPERATURE DIFFERENTIAL
T OP DIFF:
SHORT CYCLE DELAY
SHT CYC DLY:
HIGH PRESSURE CUTOUT
HPCO:
HIGH PRESSURE CUTOUT DELAY
HPCO DLY:
LOW PRESSURE CUTOUT
LPCO:
LOW PRESSURE CUTOUT DELAY
LPCO DLY:
HIGH TEMPERATURE ALARM
HITEMP ALRM:
LOW TEMPERATURE ALARM
LOWTEMP ALRM:
LOW TEMPERATURE ALARM DELAY
LOTEMP DLY:
FAN 1 ON PRESSURE
FAN1 ON:
FAN 1 OFF PRESSURE
FAN1 OFF:
FAN 2 ON PRESSURE
FAN2 ON:
FAN 2 OFF PRESSURE
FAN2 OFF:
ALARM LIST
BEGIN ALARM LIST
9.1
Set Point
1, 2, 4, 8
HS or NC
22 or 404 or 407
AC OR WC
4
03
See Table-1
10
See Table-1
10
55
30
2:00
See Table-1
See Table-1
See Table-1
See Table-1
N/A
ENTERING 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.
20
To enter the TECHNICIAN MODE, perform the following keystrokes:
2
3
SELECT
DISPLAY
Pressing the “2” and “3” buttons simultaneously enters
the TECHNICIAN MODE.
TECH SET MODE
Depressing SELECT DISPLAY scrolls through the
available parameters. The first three parameters viewed
are adjustable in TECHNICIAN MODE.
DRAIN ENABLE: ON
The DRAIN ENABLE parameter determines whether the DPC shall control an electronic
solenoid drain valve. A value of “ON” will permit the DPC to control the drain valve. A
value of “OFF” will disable this feature. This would be suitable for servicing the drain
valve or if an independent no air loss drain is to be used with the dryer. To change the
DRAIN ENABLE set point from the displayed set point, perform the following. Otherwise,
depress the SELECT DISPLAY button to advance to the next adjustable parameter:
SET
DRAIN ENABLE: OFF
ENTER
DRAIN ENABLE: OFF
SELECT
DISPLAY
For parameters with “ON / “OFF” or “Y” / “N” choices, the
set point is changed using the SET button. Pressing the
SET button changes the Drain Enable from ON to OFF.
Depressing ENTER saves the selected set point.
Depressing the SELECT DISPLAY button advances to
the next adjustable parameter for the Crankcase Heater
Delay. This parameter must not be altered unless
instructed by ZEKS Service personnel.
CCH DELAY: 8
NOTICE
The Crankcase Heater Delay set point must not be altered unless directed by ZEKS
Service Personnel. Improperly altering the set point may result in damage to the dryer.
Contact ZEKS Compressed Air Solutions before altering the default set point.
The AUTO RESTART feature permits the dryer to operate once power is applied to the
dryer without requiring operator intervention. This would be desirable should the user
wish to have the dryer restart automatically after a power outage. Note that the dryer will
energize once the ASC or CCH delay times out. To change the AUTO RESTART set point
from “N” (NO) to “Y” (YES), perform the following. Otherwise, depress the SELECT
DISPLAY button to advance to the next display:
SELECT
DISPLAY
AUTO RESTART: N
SET
AUTO RESTART: Y
ENTER
AUTO RESTART: Y
Depressing the SELECT DISPLAY button advances to
the next adjustable parameter for the Auto Restart
feature.
Depressing the SET button changes the AUTO RESTART
parameter from “N” to “Y”.
Depressing ENTER saves the selected set point.
21
Changing the AUTO RESTART feature to “Y” will permit the dryer to operate automatically once power is applied and after a brief delay. Proper warning signs should be
affixed to the dryer to alert users and service personnel that dryer may start without
warning. Failure to do so may result in serious injury.
SELECT
DISPLAY
Depressing the SELECT DISPLAY button displays the
END TECH SET PTS display.
END TECH SET PTS
The remaining non-adjustable parameters may be viewed by depressing the SELECT
DISPLAY button as required to arrive at the desired display. .
NOTICE
To exit the TECHNICIAN MODE at any time, depress the “BLANK” button located
above the SET button to return to the CUSTOMER MODE.
9.2
ALARM LIST
At the end of the list of non-adjustable parameters, the DPC™ displays a list of the
most recent 20 alarm conditions. This list can facilitate troubleshooting the dryer
SELECT
DISPLAY
SELECT
DISPLAY
SELECT
DISPLAY
SELECT
DISPLAY
At the end of the list of parameters, depressing the
SELECT DISPLAY button displays the beginning of the
ALARM LIST.
BEGIN ALARM LIST
Depressing the SELECT DISPLAY button displays the
alarms that the dryer has experienced, with the most
recent alarm displayed first. The actual display will
depend on the most recent alarm detected by the DPC.
HPCO ALARM
The list of alarms can be scrolled by depressing the
SELECT DISPLAY button as needed. At the end of the
alarm list, the END ALARM LIST screen is displayed.
END ALARM LIST
BEGIN ALARM LIST
Depressing the SELECT DISPLAY list displays the
ALARM LIST screen at the top of the ALARM LIST.
The Alarm List will repeat as long as the SELECT DISPLAY button is depressed. To EXIT
the ALARM LIST, perform the following:
Depressing the BLANK button (located above the SET
button) returns the controller to the top of the TECHNICIAN MODE.
TECH SET MODE
Depressing the BLANK button again returns the controller
to the default display of the CUSTOMER MODE.
CHLLR TEMP: 37
22
10. TROUBLESHOOTING
10.1
INTRODUCTION
ZEKS HEATSINK™ dryers are designed for reliable, trouble-free operation. In the
event of any dryer malfunction, the guide below has been developed to facilitate
problem identification and corrective actions.
An air dryer always operates under pressure. Any maintenance procedure that involves
disassembly of pipe fittings, valves or any other components requires the dryer be
isolated from the compressed air stream and fully depressurized.
Prior to working on the unit, make sure that all circuit breakers or disconnected switches
are tagged “Out of Service.”
10.2
PROBLEM / ACTION GUIDE
PROBLEM
Moisture down stream
SYMPTOM(S)
POSSIBLE
CAUSE
Dryer is properly
Drain failure or timer
cooling air stream
adjustment is required
(Check Chiller Temp on
controller)
Excessive flow
Inlet and outlet temper- Dryer by-pass valve
atures are the same.
not closed
No power to the dryer
High suction pressure
Refrigerant leak
Compressor not
running and fan is
running
23
CORRECTIVE ACTION
Depress “TEST” button - if drain
valve operates then adjust timing
(See Section 6.3)
Depress “TEST” button - if DRAIN
TEST is displayed but valve does
not open, ensure wiring connections are secure and power is being
applied to the solenoid coil. If valve
continues not to open, clean as
described in Maintenance Section
of this manual.
Depress “TEST” button - if display
does not indicate DRAIN TEST,
contact distributor.
Check inlet and outlet pressures
and system design capacity.
Correct cause of excessive flow.
Close by-pass valve
Check power supply and
fuses/circuit breakers
Check and clean ambient air filter.
Check suction pressure gauge if
reading is 0 psig, turn dryer off and
contact your distributor
Check and clean ambient air filter.
Check ambient temperature and
reduce below 113°F
PROBLEM
Moisture down
stream
Apparent controller
display malfunction
High pressure drop
across dryer
SYMPTOM(S)
POSSIBLE CAUSE
CORRECTIVE ACTION
Inlet and outlet
Compressor and fan not
temperatures are the running.
same.
Compressor and fan not
running. Controller indicates
compressor is ON.
Check Chiller Temperature
Check MAIN CONTROL fuse.
Compressor and fan Defective Pump
are running,
exchanger temp high,
pump not running
Display Blank
Blown Fuse
Board Failure
Contact your local distributor for further
assistance.
Compressor relay may be bad, replace
relay
Check for loose wire connections at
contactor or loss of power at control
board
Defective control board - replace as
necessary
Contact your local distributor for further
assistance.
Check Fuses
Contact your local distributor for further
assistance.
Unrealistic tempera- Probe loose,off connection or Inspect probe cable and terminal
ture displayed
connection
defective probe
Replace probe
Erratic or inaccurate Probe not completely in
Inspect probe and check readings
temperature readings thermal well
against independent source (eg.
temperature analyzer/pyrometer/ice
bath) both in temperature well and to
ambient
Replace probe
Defective probe
Unrealistic pressure Transducer loose, off connec- Inspect transducer cable and terminal
displayed
connection
tion or defective transducer
Replace transducer
Outlet pressure
Open valves
Inlet and outlet valves not
substantially lower
completely open
than inlet pressure
Inlet and outlet filters blocked Change filter elements
System operating
up
temperature is above
32°F
Outlet pressure
Compressor relay / contactor Replace relay / contactor.
substantially lower
stuck.
than inlet pressure
Replace relay
DPC relay bad
System operating
Inspect probe and check readings
Probe not completely in
temperature is below thermal well
against independent source (eg.
32°F
temperature analyzer/pyrometer/ice
bath) both in exchanger well and to
ambient
Turn dryer off and consult your local
Problem persists
distributor for further assistance
24
Download PDF

advertising