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Table of Contents
- 1 Table of Contents
- 2 Introduction
- 3 Abbreviated Warranty
- 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 Troubleshooting
- 11 Wiring Diagrams
- 12 General Arrangement
- 13 Parts Identification
- 14 Engineering Specifications
- Download this manual
NOTICE
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.
TECHNICAL MANUAL
HeatSink
True-Cycling Refrigerated
Compressed Air Dryers
HSG Models
200-400 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 200-400HSG-0118
TM
Patent No.: 6,186,223
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Table of Contents
Related Manuals for ZEKS HeatSink HSG Series
Summary of Contents for ZEKS HeatSink HSG Series
- Page 1 HeatSink True-Cycling Refrigerated Compressed Air Dryers HSG Models 200-400 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
TECHNICAL MANUAL HeatSink True-Cycling Refrigerated Compressed Air Dryers HSG Models 200-400 SCFM TABLE OF CONTENTS PAGE INTRODUCTION ABBREVIATED WARRANTY REFRIGERATED DRYER NOMENCLATURE RECEIVING AND INSPECTION SAFETY AND OPERATION PRECAUTIONS PRINCIPLES OF OPERATION INSTALLATION AND INITIAL START-UP SCHEDULED MAINTENANCE TROUBLESHOOTING WIRING DIAGRAMS GENERAL ARRANGEMENT PARTS IDENTIFICATION ENGINEERING SPECIFICATIONS... -
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 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 receipt of your ZEKS air dryer, inspect the unit closely. If rough handling is detected, note it on your delivery receipt, especially if the dryer will not be uncrated immediately. Obtaining the delivery person’s signed agreement to noted damages will facilitate insurance claims. -
Page 6: Safety And Operation Precautions
Inspect unit daily to observe and correct any unsafe operating conditions. 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 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 8 WARNING ATTENTION ! Retirer les fusibles ne déconnectera pas Removing fuses will not l'électricité de l'appareil disconnect power from TOUJOURS déconnecter toutes les sources dryer. Always disconnect d'électricité avant la mise en marche de power from ALL sources l'appareil before performing service. LIRE LE MANUEL D'INSTRUCTIONS! ! READ INSTRUCTION MANUAL !
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Page 9: Principles Of Operation
15°F - 20°F lower than the inlet air temperature based on standard conditions at full rated flow. ZEKS offers a Cold Mist Eliminator option on all 200-400 G-Series dryers. This filter, located after the dryer’s separator, coalesces moisture at the coldest point in the system for maximum efficiency. - Page 10 ZEKS recommends changing the element in the Cold Mist Eliminator (ZEKS P/N 683532) at 6 psid. Access to the element is gained by removing the top panel of the dryer and removing the flange bolts from the element housing. After replacement of the filter element, reinstall flange and flange bolts and reattach dryer top panel.
- Page 11 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 ”...
- Page 12 6.6 CONTROLS The ZEKS HeatSink™ dryer incorporates automatic controls for proper operation. The standard microprocessor is the Compustat Controller. NOTE: For dryers equipped with the optional DPC Plus Controller, refer to the DPC Supplement that accompanies this Technical Manual for specific instruction on operating the HeatSink™...
- Page 13 • When the refrigeration system is running, the suction pressure will pull down between 50 and 60 psig, depending on load and ambient conditions. After the thermal mass fluid has been cooled and the refrigeration system is cycled off, the system pressure will equalize with a gauge reading typically between 80 and 150 psig - depending on ambient temperature.
- Page 14 • ALARM RESET Press this button to open the optional relay for the remote alarm. This does not correct the alarm condition which is indicated by the flashing alarm light. • DRAIN TEST Press this button to verify drain operation. •...
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Page 15: Installation And Initial Start-Up
WEATHERPROOF PACKAGE (OPTIONAL) Dryers equipped with the optional Weatherproof Package are designed to operate in ambient conditions as low as 35°F. This package incorporates a fan cycling switch that operates the refrigeration system at optimal condensing temperatures. The fan switch controls the condensing temperature by cycling the fan based on refrigerant discharge pressure. - Page 16 ZEKS 200 - 400 HSG models come with a drain isolation valve (D) factory installed. 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).
- Page 17 CAUTION Never wire directly, or connect any additional wires, to the compressor junction box. This will cause severe system malfunction. INITIAL START-UP For water cooled models, the water valve must be manually opened to ensure that the condenser is full of water prior to start-up. Exchanger temperature should never be set lower than 35°...
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Page 18: Scheduled Maintenance
REFRIGERATION CONDENSER ZEKS dryers can be equipped with an optional ambient air filter that is designed to protect the condenser from the accumulation of dirt and debris. For proper operation, it is imperative that this filter be inspected and cleaned on a regular basis. For applications where excessive dirt, dust or debris is encountered, frequent inspection and cleaning may be required. - Page 19 FIGURE 4 DRAIN DETAIL DRAWING 737486 B CLEANING INSTRUCTIONS - SOLENOID DRAIN VALVE • Be sure dryer is depressurized or ...isolation valve is closed. • Disconnect drain body from filter stop. • Loosen connector screw to allow the electrical connector assembly to be removed from the D.I.N.
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Page 20: Troubleshooting
9. TROUBLESHOOTING 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 21 PROBLEM SYMPTOM(S) POSSIBLE CAUSE CORRECTIVE ACTION Compressor not running Check and clean ambient air filter. Moisture down Inlet and outlet and fan is running stream temperatures are the Check ambient temperature and same. reduce below 120°F Compressor and fan not Controller adjustment required.
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Page 22: Wiring Diagrams
WIRING DIAGRAMS... -
Page 24: General Arrangement
GENERAL ARRANGEMENT... -
Page 25: Parts Identification
PARTS IDENTIFICATION 200HSG 250HSG 300HSG 400HSG 230/1/60 230/3/60 460/3/60 230/3/60 460/3/60 230/3/60 460/3/60 230/3/60 460/3/60 Exchanger Assy 748280 748280 748280 748282 748282 728686-SP 728686-SP 748211 748211 Evaporator Assy 748820 748820 748820 748820 748820 748649 748649 748649 748649 Glycol Pump 684879 684879 684879 684879...