SPX FLOW Deltech ZP Series Instruction Manual
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SPX FLOW Deltech ZP Series Instruction Manual

Blower purge desiccant compressed air dryer
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ZP Series
Blower Purge Desiccant Compressed Air Dryer
F O R M N O . : 3 1 5 8 1 4 8
R E V I S I O N : 1 2 / 2 0 1 7
RATED
MODELS
FLOW
ZP500
500 SCFM
ZP600
600 SCFM
ZP750
750 SCFM
ZP900
900 SCFM
ZP1050
1050 SCFM
ZP1300
1300 SCFM
ZP1500
1500 SCFM
ZP1800
1800 SCFM
ZP2200
2200 SCFM
ZP2600
2600 SCFM
ZP3200
3200 SCFM
ZP3600
3600 SCFM
ZP4300
4300 SCFM
R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
MODEL
REFERENCE
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
3600
4300
I N S T R U CT I O N M A N UA L

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Summary of Contents for SPX FLOW Deltech ZP Series

  • Page 1 I N S T R U CT I O N M A N UA L ZP Series Blower Purge Desiccant Compressed Air Dryer F O R M N O . : 3 1 5 8 1 4 8 R E V I S I O N : 1 2 / 2 0 1 7 R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.

  • Page 2: Table Of Contents

    Contents 1.0 General Safety Information ......1 2.0 Receiving, Storing, and Moving ..... 1 3.0 Description ............ 2 4.0 Installation ............. 2 5.0 Instrumentation ..........7 6.0 Operation ............11 7.0 Maintenance ..........28 8.0 Troubleshooting ..........30 DRAWINGS Electrical Schematic – 460VAC, 3 phase ....33 Electrical Schematic –...

  • Page 3: General Safety Information

    CAUTION—Hazard or unsafe practice which could result 1.0 General Safety Information in minor injury or in product or property damage. The dryer data plate, attached to the electrical control This equipment is designed and built with safety as a box, contains critical safety and identification informa- prime consideration;...

  • Page 4: Description

    be required upstream of the Oil Removal Filter if heavy 3.0 Description liquid or solid loads are present. To ensure downstream air purity (prevent desiccant dust 3.1 Function from traveling downstream) adequate filtration down- Blower purge type regenerative dryers are an economi- stream of the dryer is required.
  • Page 5 Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilter Receiver Figure 1 Typical System Configuration Remove all mounting bolts from blower base which Dryer bypass piping may be installed to allow uninter- MAY have been used for shipping purposes. The rupted airflow during servicing. If the downstream appli- blower is designed to vibrate freely on its vibration cation cannot tolerate unprocessed air for short periods, pad during operation.
  • Page 6 Dimensions and Connections – Dryer Only Figure 2 (continued on next page) (For construction purposes, contact factory to request certified drawings when mounted filters are included with order)
  • Page 7 Dimensions and Connections Figure 2 (continued from previous page)
  • Page 8 • For the common alarm to activate on either a dryer 3. Refer to Table 1 for desiccant quantity per tower. fault condition or a service reminder, the jumper at When using Table 1 you will find the desiccant quan- JP6 is removed.

  • Page 9: Instrumentation

    5.5 Dew Point Transmitter 5.0 Instrumentation This option monitors and displays outlet pressure dew points and provides an alarm signal if the dew point The following instrumentation helps in monitoring dryer exceeds user-specified set point. Recommended operation and performance. Instruments which are calibration interval is 12 months.
  • Page 10 ENERGY MANAGEMENT SENSOR LOCATION (OPTIONAL) PURGE INLET CHECK VALVE TOP VIEW HOT PIPE INSULATION HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE ASME CODE TAG HEATER WITH INSULATION TOWER INLET PURGE SUCTION VALVE FILTER SILENCER PURGE BLOWER AND MOTOR REAR VIEW...
  • Page 11 ENERGY MANAGEMENT SENSOR LOCATION (OPTIONAL) REPRESS VALVE TOP VIEW HOT PIPE INSULATION HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) PURGE INLET CHECK VALVE (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE HEATER WITH ASME CODE TAG INSULATION PURGE SUCTION CHAMBER INLET FILTER SILENCER VALVE PURGE BLOWER AND MOTOR...
  • Page 12 HEATER INLET ENERGY MANAGEMENT TEMPERATURE SWITCH SENSOR LOCATION (OPTIONAL) OUTLET CHECK VALVE TOP VIEW ASME RELIEF VALVE HOT PIPE INSULATION REPRESS VALVE PURGE INLET CHECK VALVE HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE HEATER WITH INSULATION PURGE SUCTION FILTER SILENCER...

  • Page 13: Operation

    through the right tower, and exits through the Right 6.0 Operation Purge Valve V4. The Blower intake air is filtered to keep dust and dirt from entering the dryer. The 6.1 Controls Blower M and Heater H1 are de-energized when A solid-state controller controls valve and heater opera- the temperature at the bottom of the right tower, tion, monitors all critical operating conditions, and indi-...
  • Page 14 SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION PR&G SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG 45 PSIG SET @ SET @ 5 PSIG 5 PSIG EXH.
  • Page 15 6.3.1 Energy Management Control (optional) from entering the dryer. The Blower M and Heater H1 are de-energized when the temperature at the Operation of the Energy Management Control cycle is bottom of the left tower, as sensed by the Left Tower identical to the fixed cycle except the cycle is extended Temperature Sensor RTD1, reaches the Heat Ter- until the desiccant bed in the on-line tower has been fully...
  • Page 16 6.4 Control Board Jumpers 7. JP7 – Download Language Text Jumper JP7 is factory installed in the OFF position In the upper left hand corner of the control board there to disable Language Text download. The jumper is are eight two-pin jumpers labeled JP1 through JP8. Only installed in the ON position to allow for language text six of the eight jumper pairs are utilized.
  • Page 17 Filter Service / Left Tower Pressure Maintenance LED Switch LED: On=Tower Pressurized Filter Service / Maintenance LED Left Tower Drying LED Right Tower Pressure Left Purge Valve LED Switch LED: On=valve open On=Tower pressurized Off=valve closed Left Inlet Valve LED Right Tower Drying LED On=valve open Off=valve closed...
  • Page 18 b. SEVERE Service Intervals are: Screen 7: Set Point for Dew Point Demand Control i. 2000 hours for filters (This feature is only active when JP3 is “on”) ii. 4000 hours for desiccant DPNT CNTL SETPT iii. 4000 hours for valves ±XX°C ±XXX°F 2.
  • Page 19 2. When finished, press to acknowledge the selec- 5. When finished, press to acknowledge the selec- tion and scroll to the pressure set point screen. tion and move to next screen. Exit Program Mode when there are no more active screens to display. 3.
  • Page 20 6.5.6 Alarm & Service Mode d. On alarm condition, the blower and heater are de-energize, the cycle sequence is stopped, a 1. Alarm & Service Mode is active when the controller local alarm is displayed and the common alarm is in Display Mode. It is not active in Program Mode, relay is de-energized.
  • Page 21 ALARM MESSAGES LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER DRYING DRYING OVER-TEMPERATURE LOW PRESSURE LOW PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER REGENERATING REGENERATING LOW TEMPERATURE HIGH PRESSURE HIGH PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM ENRGY MGNT...
  • Page 22 10. Heater Over-Temperature d. On alarm condition, a. RTD3 is used to detect Heater Over-Temperature. i. Local alarm is displayed and the common alarm relay is de-energized. b. Alarms anytime that the Heater temperature ii. If dryer is set up for Dewpoint Control, the dryer exceeds 650°F (343°C).
  • Page 23 6.5.7 Display Mode Service Due Messages 1. Display Mode is active when the user exits Program 14. There are two service levels (normal and severe) Mode or Setup Mode and no alarms are active (un- as described in Program Mode. Each service level less MANUAL CYCLE was selected in Setup Mode).
  • Page 24 DRYER STATUS SCREENS LEFT TOWER DRYING RIGHT TOWER DRYING LT DRYING LT DEPRESSURIZE RT DEPRESSURIZE RT DRYING LT DRYING LT HEATING RT HEATING RT DRYING LT DRYING LT COOLING RT COOLING RT DRYING LT DRYING LT REPRESSURIZE RT REPRESSURIZE RT DRYING LT DRYING LT HOLDING RT HOLDING...
  • Page 25 6.5.8 Test Mode 5. To exit Test Mode: 1. Test Mode is active when the user exits Program a. Press and hold for 3 seconds to exit Test Mode after selecting operation in MANUAL CYCLE. Mode. The display switches to Screen 2 of Setup Mode.
  • Page 26 TEST MODE SCREENS Screen 1: Step 1 Screen 7: Step 7 TEST1: LT DRYING TEST7: RT DRYING XX°C XXX°F XX°C XXX°F Screen 2: Step 2 Screen 8: Step 8 TEST2: DEPR RT TEST8: DEPR LT XX°C XXX°F XX°C XXX°F NOTE: Sequence step will not advance to HEAT until NOTE: Sequence step will not advance to HEAT until tower has fully depressurized.
  • Page 27 6.6 Start-up 6.7.5 Process Valves Determine if air control valves are operating and 6.6.1 Controller Settings sequencing correctly. Set or verify settings on Controller. Detailed operational 6.7.5.1 Valves – Models 500 and 600 points are presented in section 6.5. Inlet switching valves are normally open, pneumatically WARNING - Enclosure may have live electric parts.
  • Page 28 6.10 Operating Parameters The tower pressure gauge of the on-line tower should read line pressure. Air should not be leaking from the Control valves are designed so that upon loss of power purge-repressurization valve of the on-line tower. the air dryer is capable of drying air until the desiccant exposed to the airflow is saturated.
  • Page 29 Example: ASCII representation of the humidity sensor If jumper 8, 5, and 1 are installed, a value of 128+16+1 relative humidity (%) = 145 is returned To decode, the algorithm: xxxx ASCII representation of the dew point reading (°F) · If (number >= 128) è jumper 8 = on ·...

  • Page 30: Maintenance

    e. Utilizing an appropriate sized funnel, fill each 7.0 Maintenance desiccant tower as follows: 1) Install the required quantity of tabular support WARNING - This equipment is a pressure-containing (model 4300 only) or activated alumina in device. Depressurize before servicing. layer 1 of each tower.
  • Page 31 2. Procedure for element replacement a. Isolate dryer from air supply b. Depressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/ repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter.

  • Page 32: Troubleshooting

    8.0 Troubleshooting WARNING - A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS. Some of the troubleshooting checks may require gaining access to the dryer’s electrical enclosure(s) while the power supply is energized and should be performed by a qualified electrical technician. WARNING - Before performing any electrical or mechanical repairs or maintenance, or removing or disassembling any component, be sure to de- energize and depressurize the dryer.
  • Page 33 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION High Pressure Alarm 1. Faulty regenerating tower pressure 1. Check pressure switch operation using tower pressure Left Tower or Right Tower Re- switch gauge for comparison. Replace switch if defective. generating 2. Regenerating tower Depressurization 2.
  • Page 34 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION Outlet Dew Point Alarm 1. Inlet air flow higher than the sizing 1. Reduce inlet flow to sizing condition. Left Tower or Right Tower condition. 2. Liquids entering the dryer inlet. 2. Check the inlet air line for liquids. Inspect prefilter and drain valve.

  • Page 35: Electrical Schematic - 460Vac, 3 Phase

    Electrical Schematic – 460VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) +12VDC EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT CUSTOMER PROVIDED MOTOR 460VAC, 3 PHASE FUSE AS PER TABLE 249 OHM 1/8W BLACK 1HTR LOW TENSION 0.5 AMP NOTE:...

  • Page 36: Electrical Schematic - 575Vac, 3 Phase

    Electrical Schematic – 575VAC, 3 phase (Contact factory to request certified drawings) DETAIL A CUSTOMER PROVIDED MOTOR (2-WIRE DEWPOINT TRANSMITTER) 575VAC, 3 PHASE +12VDC FUSE AS PER TABLE EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT 1HTR 249 OHM 1/8W 2HC1 USED ON MODELS 2HTR 3200, 3600 &...

  • Page 37: Electrical Data - Fusing & Wire Sizing

    Electrical Data – Fusing & Wire Sizing Electrical Service: 460VAC, 3 phase Electrical Service: 575VAC, 3 phase F.L.A. SUGGESTED F.L.A. SUGGESTED MODEL COMPONENT RATING MODEL COMPONENT RATING @460VAC FUSING @575VAC FUSING HEATER 10 KW 12.6 20 AMPS HEATER 10 KW 10.0 15 AMPS MOTOR...

  • Page 38: P&Id Schematic - Models 500 Through 600

    P&ID Schematic - Models 500 through 600 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG...
  • Page 39 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD CHAMBER RTD (LEFT &...

  • Page 40: P&Id Schematic - Models 750 Through 4300

    P&ID Schematic - Models 750 through 4300 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION SET AT 100 PSIG (225°F) SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG...
  • Page 41 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) SOL 'C' FLOW CONTROL VALVE PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) SOL 'D' PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD...

  • Page 42: Replacement Parts Models 500 Through 600

    Replacement Parts – Models 500 through 600 REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: +1 724 745 8647 Email: ft.dehydration.order.entry@spxflow.com Web: www.spxflow.com/deltech...
  • Page 43 MODEL MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK2-04 ZPMK2-06 All the contents of the 2 Year Kit, Pressure Year 3 Maintenance Kit ZPMK3-04 ZPMK3-06 Switches, Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK4-04 ZPMK4-06...

  • Page 44: Models 750 Through 1800

    Replacement Parts – Models 750 through 1800 MODEL 750 1 1A REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: +1 724 745 8647 Email: ft.dehydration.order.entry@spxflow.com Web: www.spxflow.com/deltech...
  • Page 45 MODEL 1050 1300 1500 1800 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK2-08 ZPMK2-10 ZPMK2-12 ZPMK2-14 ZPMK2-16 ZPMK2-18 All the contents of the 2 Year Kit, Pressure Year 3 Maintenance Kit ZPMK3-08 ZPMK3-10 ZPMK3-12 ZPMK3-14 ZPMK3-16 ZPMK3-18 Switches, Valve Repair Kits, Blower Hose...

  • Page 46: Models 2200 Through 2600

    Replacement Parts – Models 2200 through 2600 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: +1 724 745 8647 Email: ft.dehydration.order.entry@spxflow.com Web: www.spxflow.com/deltech...
  • Page 47 MODEL 2200 2600 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK2-20 ZPMK2-22 All the contents of the 2 Year Kit, Pressure Year 3 Maintenance Kit ZPMK3-20 ZPMK3-22 Switches, Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK4-20 ZPMK4-22...

  • Page 48: Models 3200 Through 4300

    Replacement Parts – Models 3200 through 4300 42 43 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: +1 724 745 8647 Email: ft.dehydration.order.entry@spxflow.com Web: www.spxflow.com/deltech...
  • Page 49 MODEL 3200 3600 4300 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK2-24 ZPMK2-26 ZPMK2-28 All the contents of the 2 Year Kit, Pressure Year 3 Maintenance Kit ZPMK3-24 ZPMK3-26 ZPMK3-28 Switches, Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit ZPMK4-24...

  • Page 51: Warranty

    WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen (18) months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period.
  • Page 52 4647 S.W. 40th Avenue Ocala, Florida 34474-5788 U.S.A. P: (724) 745-8647 F: (724) 745-4967 E: deltech.americas@spxflow.com www.spxflow.com/deltech Improvements and research are continuous at SPX FLOW, Inc. Specifications may change without notice. ISSUED 12/2017 Form No.: 3158148 Revision: L COPYRIGHT ©2017 SPX FLOW, Inc.

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