ZEKS CFX NC Series Technical Manual
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ZEKS CFX NC Series Technical Manual

Refrigerated air dryer
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COMPRESSED AIR SOLUTIONS
NC SERIES NON-CYCLING
NCE MODELS 500 - 800

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TM
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, Pennsylvania 19380
610-692-9100
800-888-2323
FAX 610-692-9192
WWW.ZEKS.COM
PATENT # 6,186,223
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NCTM500-800NCE-DPC V2/04

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Summary of Contents for ZEKS CFX NC Series

  • Page 1: Table Of Contents

    SAFETY AND OPERATION PRECAUTIONS PRINCIPLES OF OPERATION INSTALLATION AND INITIAL START-UP SCHEDULED MAINTENANCE TECHNICAIN MODE TROUBLESHOOTING WIRING DIAGRAMS GENERAL ARRANGEMENT PARTS IDENTIFICATION ENGINEERING SPECIFICATIONS ZEKS Compressed Air Solutions 1302 Goshen Parkway West Chester, Pennsylvania 19380 610-692-9100 800-888-2323 FAX 610-692-9192 WWW.ZEKS.COM NCTM500-800NCE-DPC V2/04...

  • Page 2: 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 3: Refrigerated Dryer Nomenclature

    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 of price from date of shipment from the factory: 19 to 24 months 25 to 36 months 37 to 48 months...

  • Page 4: 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 uncrated immediately. Obtaining the delivery person’s signed agreement to any noted damages will facilitate any insurance claims.

  • Page 5: 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 6 Air Under Pressure Will Cause Injury, Death Or Property Damage • Relieve Press. Before Servicing. • Condensate Drain Discharges Under Pressure. Air Under Pressure Will Cause HIGH VOLTAGE Can Cause Severe • Drain Requires Periodic Injury, Death Or Property Damage. Injury Or Death.
  • Page 7 ELECTRICAL CONNECTION BOX • All Customer Connections To Be Made At This Location. • See Attached Terminal Connection Diagram. LA BOÎTE DE CONNEXION • Be Certain To Follow All NEC, State, Local and Other Applicable ÉLECTRIQUE CONTIENT DE LA Codes During Installation. HAUTE TENSION ·...

  • Page 8: Principles Of Operation

    PRINCIPLES OF OPERATION INTRODUCTION ZEKS Non-Cycling dryers remove moisture from compressed air by cooling the air temperature to 36° (2.2°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 and the Controls.
  • Page 9 76 psig, which corresponds to a chiller temperature of 34°F, thus preventing freeze-up. 6.5 CONTROLS ZEKS’ 500-800NCE 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.
  • Page 10 FACTORY MODE is also included for use by ZEKS Service Personnel for troubleshooting the dryer. All ZEKS Non-Cycling dryers include a Hot Gas By-Pass (HGBP) Valve to maintain suction pressure and temperature. This valve is necessary during low load applications to prevent freeze-up in the chiller section.
  • Page 11 Any suction pressure setting above 90 psig is not recommended. ZEKS air cooled models utilize a microprocessor-controlled fan contactor to control the condensing temperature. This contactor controls the condensing temperature by cycling the fan based on refrigerant discharge pressure. When the unit reaches 275 psig, the microprocessor energizes the fan contactor that will run the fan until the discharge pressure is reduced to 195 psig.
  • Page 12 6.5.1 BASIC USER INTERFACE The DPC™ display provides the user with the operating parameters and their corresponding values. When power is supplied to the dryer, the DPC™ will illumi- nate and default to the “Standby” mode, displaying the “Press ON” prompt. The following illustration summarizes the keypad functions.
  • Page 13 6.5.2 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 depending on the DPC™ version: • Chiller Temperature (CHLLR TEMP): The Chiller Temperature is the temperature, in degrees Fahrenheit, of the air at the coldest point in the air circuit.
  • Page 14 6.5.3 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 15 6.5.5 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 16 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).

  • Page 17: Installation And Initial Start-Up

    This figure can be used as a guide for valve and accessory placement in the system. ZEKS 500 through 800 NCE 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 18 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.
  • Page 19 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.

  • Page 20: Scheduled Maintenance

    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.
  • Page 21 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 5 illustrates the drain assembly.
  • Page 22 SOLENOID VALVE • Loosen connector screw to allow the electrical connector assembly to be removed from the D.I.N. unit solenoid. • Remove retainer nut and separate the valve body from the D.I.N. unit solenoid. • Unthread the plunger tube assembly in a counter-clockwise direction until plunger separates from valve body.

  • Page 23: Technicain 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 in the TECHNICIAN MODE: Parameter Display...
  • Page 24 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 25 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.

  • Page 26: 10. Troubleshooting

    10. TROUBLESHOOTING 10.1 INTRODUCTION ZEKS dryers are designed for reliable, trouble-free operation. In the event of any dryer malfunction, the guide below has been developed to facilitate problem identifi- cation 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.
  • Page 27 PROBLEM SYMPTOM(S) POSSIBLE CAUSE CORRECTIVE ACTION Moisture down Inlet and outlet Compressor and fan not Check Chiller Temperature stream temperatures are the running. Check MAIN CONTROL fuse. same. Compressor and fan not Compressor relay may be bad, replace running. Controller indicates relay compressor is ON.

  • Page 28: Wiring Diagrams

    WIRING DIAGRAMS...

  • Page 32: General Arrangement

    GENERAL ARRANGEMENT...

  • Page 33: Parts Identification

    PARTS IDENTIFICATION 500 NCE 600 NCE 700 NCE 800 NCE Exchanger Assy 748065 748069 748056 748056 Solenoid Drain Valve 682657 682657 682657 682657 Drain Valve Repair Kit 683006 683006 683006 683006 Filter Stop 682438 682438 682438 682438 PARTS OVERVIEW TM500NCEA4000...

This manual is also suitable for:

Cfx nce 500Cfx nce 800

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