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Table of Contents
- 1 Table of Contents
- 2 Abbreviated Warranty
- 3 Introduction
- 4 Refrigerated Dryer Nomenclature
- 5 Receiving and Inspection
- 6 Safety and Operation Precautions
- 7 Principles of Operation
- 8 Installation and Initial Start-Up
- 9 Scheduled Maintenance
- 10 Technician Mode
- 11 ZEKS Compressed Air Solutions
- 12 10. Troubleshooting
- 13 Heatsink
- 14 Wiring Diagrams
- 15 General Arrangement
- Download this manual
Those operating the machine or performing
maintenance should read and understand the
decals positioned on the machine and
contents of this Technical Manual.
Ensure that this Technical Manual is not
removed permanently from the machine.
DPC
NOTICE
TECHNICAL MANUAL
HeatSink
True-Cycling Refrigerated
Compressed Air Dryers
HSF Models
1000-1600 SCFM
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, PA 19380
Phone: 610-692-9100
800-888-2323
Fax:
610-692-9192
Web:
www.zeks.com
Form: TM 1000-1600HSF-DPC-0513
TM
Patent No.: 6,186,223
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Table of Contents
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Summary of Contents for ZEKS 1000HSFA400
- Page 1 HeatSink True-Cycling Refrigerated Compressed Air Dryers HSF Models 1000-1600 SCFM Patent No.: 6,186,223 ZEKS Compressed Air Solutions NOTICE 1302 Goshen Parkway Those operating the machine or performing West Chester, PA 19380 maintenance should read and understand the decals positioned on the machine and Phone: 610-692-9100 contents of this Technical Manual.
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Page 2: Table Of Contents
SAFETY AND OPERATION PRECAUTIONS PRINCIPLES OF OPERATION INSTALLATION AND INITIAL START-UP SCHEDULED MAINTENANCE TECHNICIAN MODE TROUBLESHOOTING WIRING DIAGRAMS GENERAL ARRANGEMENT PARTS IDENTIFICATION ENGINEERING SPECIFICATIONS ZEKS Compressed Air Solutions 1302 Goshen Parkway West Chester, PA 19380 Phone: 610-692-9100 800-888-2323 Fax: 610-692-9192 Web: www.zeks.com... -
Page 3: Introduction
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... -
Page 4: Refrigerated Dryer Nomenclature
HEAT EXCHANGERS Dryers that utilize CFX heat exchanger technology (HSF, HSG, NCE & NCG) 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. -
Page 5: Receiving And Inspection
RECEIVING AND INSPECTION 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... -
Page 6: Safety And Operation Precautions
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... -
Page 7: Principles Of Operation
PRINCIPLES OF OPERATION INTRODUCTION ZEKS 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... - Page 8 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 “...
- Page 9 ZEKS’ 1000-1600HSF 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.
- Page 10 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.
- Page 11 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 • ON Pressing once clears the local alarm indication and de- Places the dryer "On Line";...
- Page 12 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.
- Page 13 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.
- Page 14 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.
- Page 15 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).
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Page 16: Installation And Initial Start-Up
This figure can be used as a guide for valve and accessory placement in the system. ZEKS 1000 through 1600 HSF 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. - Page 17 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.
- Page 18 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.
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Page 19: Scheduled Maintenance
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 perfor- mance from your dryer. - Page 20 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.
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Page 21: Technician Mode
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 when in TECHNICIAN MODE: Parameter Display... -
Page 22: Zeks Compressed Air Solutions
ZEKS Service personnel. 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. - Page 23 WARNING Changing the AUTO RESTART feature to “Y” will permit the dryer to operate automati- cally 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.
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Page 24: 10. Troubleshooting
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. WARNING 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. - Page 25 PROBLEM SYMPTOM(S) POSSIBLE CAUSE CORRECTIVE ACTION Moisture down Inlet and outlet Check Chiller Temperature Compressor and fan not stream temperatures are the running. Check MAIN CONTROL fuse. same. Compressor and fan not Compressor relay may be bad, replace relay running. Controller indicates compressor is ON.
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Page 26: Wiring Diagrams
WIRING DIAGRAMS... -
Page 32: General Arrangement
GENERAL ARRANGEMENT... - Page 33 SPARE PARTS...
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