Related Manuals for Sullivan-Palatek ZL Drain 32 V
Summary of Contents for Sullivan-Palatek ZL Drain 32 V
- Page 1 Original installation and operation manual EN-US ZL Drain 32 V Document: SPZL_32V_manual_EN_09_2025 01-4744 Issued: January, 2025...
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Page 2: Table Of Contents
ZL Drain 32 V Original installation and operation manual Table of contents 1. Notes about the documentation .....................5 1.1 Contact ............................5 1.2 Information about this installation and operation manual .............5 2. Safety ..............................6 2.1 Use .............................6 2.1.1 Intended use ............................6 2.1.2 Reasonably foreseeable inappropriate use ................. - Page 3 Original installation and operation manual ZL Drain 32 V 6. Installation ............................ 25 6.1 Warning notices ........................25 6.2 Installation requirements ...................... 25 6.3 Installation work ........................27 7. Electrical installation ........................29 7.1 Warning notices ........................29 7.2 Connection work ........................29 7.2.1 Connecting the power supply ......................30...
- Page 4 ZL Drain 32 V Original installation and operation manual 15. Troubleshooting .......................... 52 16. Appendices ..........................53 16.1 Certificates ........................... 53 17. Notes ............................54 4 | 56...
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Page 5: Notes About The Documentation
Original installation and operation manual ZL Drain 32 V 1. Notes about the documentation This documentation contains all the necessary steps for the use and operation of the product and the accessories. 1.1 Contact Manufacturer Customer service and tools INFORMATION Country-specific manufacturer representation You can contact the country-specific manufacturer's representative via the address listed ... -
Page 6: Safety
2.1 Use The ZL Drain 32 V, also referred to in the following as the product or ZL Drain, is an electronically level-controlled condensate drain used for discharging condensate in pressurised systems. The ZL Drain is able to drain condensate at operating pressure with no pressure loss. -
Page 7: Reasonably Foreseeable Inappropriate Use
Original installation and operation manual ZL Drain 32 V 2.1.2 Reasonably foreseeable inappropriate use A case of reasonably foreseeable inappropriate use is deemed to have occurred if the product or the accessories are used in any other way than that described in the "Intended use” section. Reasonably foreseeable inappropriate use includes the use of the product or the accessories in a manner not intended by the manufacturer or supplier but which may result from foreseeable human behaviour. -
Page 8: Target Group And Personnel
ZL Drain 32 V Original installation and operation manual 2.3 Target group and personnel This manual addresses the personnel listed below who are involved with work on the product or the accessories. INFORMATION Personnel requirements • Minors are strictly prohibited from working with and on the product and its accessories. -
Page 9: Explanation Of The Symbols Used
Original installation and operation manual ZL Drain 32 V 2.4 Explanation of the symbols used The symbols used below indicate safety-relevant and important information which must be adhered to when handling the product and to ensure safe and optimum operation. -
Page 10: Safety Instructions And Warning Notices
ZL Drain 32 V Original installation and operation manual 2.5 Safety instructions and warning notices This section provides an overview of all the important safety aspects for personal protection as well as for the safe and problem-free operation of the product and accessories. -
Page 11: Sudden Escape Of Pressurised Fluids
Original installation and operation manual ZL Drain 32 V 2.5.3 Sudden escape of pressurised fluids The following situations may result in serious injury or death: • Contact with fast or suddenly escaping fluids • Bursting system parts • Whipping of pressurised hoses and pipes For the safe handling of pressurised systems, observe the following: •... -
Page 12: Transport And Storage
ZL Drain 32 V Original installation and operation manual 2.5.5 Transport and storage Inappropriate transport or storage may result in personal injury or damage to property. In order to ensure safety during the transport and storage of the product and accessories, observe the following: •... -
Page 13: Maintenance
Original installation and operation manual ZL Drain 32 V 2.5.7 Maintenance Inappropriate completion of maintenance and repair work may result in serious personal injuries or death. For safe maintenance and repairs, observe the following: • Before starting work, depressurise the pressurised product and accessories and secure them against unintentional pressurisation. -
Page 14: Working On Electronic Components
ZL Drain 32 V Original installation and operation manual 2.5.9 Working on electronic components Electrostatic discharge (ESD) can cause damage to electronic components, and malfunctions, device failures or material damage are possible. • Take proper measures to prevent electrostatic discharge (e.g. earthing, potential equalisation, ESD-compatible dissipative work pads etc.). -
Page 15: Product Information
Original installation and operation manual ZL Drain 32 V 3. Product information 3.1 Product description The ZL Drain is an electronically level-controlled condensate drain used for draining off condensate in pressurised systems. The ZL Drain is able to drain condensate at operating pressure with no pressure loss. The ZL Drain has a dry contact on the power supply board. It can be used to display a fault message at a remote maintenance centre. -
Page 16: Product Overview
ZL Drain 32 V Original installation and operation manual 3.3 Product overview Pos. Pos. Description / explanation Description / explanation Control unit, complete Condensate drain Control panel Right cable gland Condensate inlet Left cable gland 3.4 Scope of delivery The table below shows the scope of delivery of the product:... -
Page 17: Exploded Drawing
Original installation and operation manual ZL Drain 32 V 3.5 Exploded drawing Pos. Pos. Description / explanation Description / explanation Screw 3.5 x 10 mm [11] Service-Unit Top cover [12] 20 x 2 mm O-ring Moulded seal [13] Intermediate adapter... -
Page 18: Function Description
ZL Drain 32 V Original installation and operation manual 3.6 Function description Illustration Description / explanation The condensate flows via the condensate inlet [C] into the ZL Drain and collects in the housing [X1]. The filling level in the housing [X1] is continuously monitored by a capacitive sensor in the sensor tube [X2]. - Page 19 Original installation and operation manual ZL Drain 32 V Illustration Description / explanation Once the pre-set waiting time has expired, the controller switches the pilot valve [X3]. The area above the membrane [X4] is depressurised. The membrane [X4] lifts off the valve seat and the excess pressure in the housing [X1] presses the condensate into the condensate drain [D].
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Page 20: Technical Data
ZL Drain 32 V Original installation and operation manual 4. Technical data 4.1 Operating parameters ZL Drain 32 V Relative ambient humidity 10 … 80 %, without condensation 3000 m Maximum operating height 3280.84 yd 0.8 … 16 bar(g) Minimum / maximum operating pressure 12 …... -
Page 21: Storage And Transportation Parameters
Original installation and operation manual ZL Drain 32 V 4.2 Storage and transportation parameters ZL Drain 32 V +1 … +70 °C Minimum / maximum temperature, storage and transport +34 … +158 °F 4.3 Materials ZL Drain 32 V Housing Aluminium and plastic, glass fibre reinforced... -
Page 22: Dimensions
ZL Drain 32 V Original installation and operation manual 4.5 Dimensions Pos. No. ZL Drain 32 V 179 mm [X1] 7.05 in 164.7 mm [X2] 6.48 in 88.6 mm [Y1] 3.49 in 130 mm [Y2] 5.12 in 117.6 mm [Y3] 4.63 in... -
Page 23: Installation Dimensions
Original installation and operation manual ZL Drain 32 V 4.6 Installation dimensions Illustration Description / explanation Allow sufficient assembly space above the top cover at the place of installation so that the LEDs are visible and the TEST button can be pressed. 4.7 Terminal diagram Illustration Power supply N.O. -
Page 24: Transport And Storage
ZL Drain 32 V Original installation and operation manual 5. Transport and storage 5.1 Warning notices Personnel Skilled technical personnel - transport and storage (see section “2.3 Target group and personnel” on page 8) CAUTION Inappropriate transport or storage Inappropriate transport or storage may result in personal injury or damage to the device. -
Page 25: Installation
Original installation and operation manual ZL Drain 32 V 6. Installation 6.1 Warning notices Personnel Skilled technical personnel - pressure equipment and systems (see section “2.3 Target group and personnel” on page 8) DANGER Sudden escape of pressurised fluids There is a danger of death or serious personal injury resulting from contact with fast or suddenly escaping fluids or through bursting system parts. - Page 26 ZL Drain 32 V Original installation and operation manual Wrong Correct Description / explanation Manifold design • The cross-section of the manifold must be at least equal to the sum of the individual cross- sections of the connected inlet lines.
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Page 27: Installation Work
Original installation and operation manual ZL Drain 32 V 6.3 Installation work For installation and mounting work to be carried out, the following prerequisites must be met, and the preparatory tasks must have been completed. Prerequisites Tools Material Protective equipment •... - Page 28 ZL Drain 32 V Original installation and operation manual Installation work Illustration Description / explanation Recommendation: 4. To ensure easy maintenance of the product, install a shut-off valve [X6] in the condensate inlet line [X5]. 5. For the condensate inlet line [X5], apply sealant to the end of a pressure-resistant pipe and screw the latter in at the condensate inlet [C].
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Page 29: Electrical Installation
Original installation and operation manual ZL Drain 32 V 7. Electrical installation 7.1 Warning notices Personnel Skilled technical personnel - electrical engineering (see section “2.3 Target group and personnel” on page 8) DANGER Electric voltage Contact with electrically live components can result in death or serious injury. -
Page 30: Connecting The Power Supply
ZL Drain 32 V Original installation and operation manual 7.2.1 Connecting the power supply Connection work Illustration Description / explanation 1. Loosen the 3 screws [1]. 2. Lift the top cover [2] off. 3. Unscrew the counter nut [6] from the right cable gland [E]. - Page 31 Original installation and operation manual ZL Drain 32 V Connection work Illustration Description / explanation Connection cable [X9] 8. Connect the connection cable [X9] according to the terminal diagram (see “4.7 Terminal diagram” on page 23). 9. Draw the connection cable [X9] taut.
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Page 32: Connecting The Dry Contact
ZL Drain 32 V Original installation and operation manual 7.2.2 Connecting the dry contact Illustration Description / explanation 1. Loosen the 3 screws [1]. 2. Lift the top cover [2] off. 3. Unscrew the counter nut [6] from the left cable gland [F]. - Page 33 Original installation and operation manual ZL Drain 32 V Illustration Description / explanation Connection cable [X10] 8. Connect the dry contact cable [X10] as shown in the terminal diagram (see “4.7 Terminal diagram” on page 23). 9. Draw the connection cable [X10] taut.
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Page 34: Connecting The External Test Button
ZL Drain 32 V Original installation and operation manual 7.2.3 Connecting the external TEST button Illustration Description / explanation 1. Loosen the 3 screws [1]. 2. Lift the top cover [2] off. 3. Unscrew the counter nut [6] from the left cable gland [F]. - Page 35 Original installation and operation manual ZL Drain 32 V Illustration Description / explanation Connection cable [X10] 8. Connect the connection cable for the external TEST button [X10] as shown in the terminal diagram (see “4.7 Terminal diagram” on page 23).
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Page 36: Start-Up Procedure
ZL Drain 32 V Original installation and operation manual 8. Start-up procedure 8.1 Warning notices Personnel Skilled technical personnel - pressure equipment and systems and skilled technical personnel - electrical (see section “2.3 Target group and personnel” on page 8) -
Page 37: Operation
Original installation and operation manual ZL Drain 32 V 9. Operation 9.1 Warning notices Personnel Operating personnel (see section “2.3 Target group and personnel” on page 8) DANGER Electric voltage Contact with electrically live components can result in death or serious injury. - Page 38 ZL Drain 32 V Original installation and operation manual Illustration Description / explanation n = ∞ Alarm mode (condensate drain malfunction) • The red ALARM LED flashes • The green POWER LED is on (50 % brightness) Alarm Alarm 0 The solenoid valve cycles every 4 minutes...
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Page 39: Maintenance
Original installation and operation manual ZL Drain 32 V 10. Maintenance 10.1 Warning notices Personnel Skilled technical personnel - product servicing (see section “2.3 Target group and personnel” on page 8) DANGER Sudden escape of pressurised fluids There is a danger of death or serious personal injury resulting from contact with fast or suddenly escaping fluids or through bursting system parts. -
Page 40: Maintenance Work
ZL Drain 32 V Original installation and operation manual 10.3 Maintenance work For maintenance work to be carried out, the following prerequisites must be fulfilled and the preparatory tasks must have been completed. Prerequisites Tools Material Protective equipment • Screwdriver – flat head • Sealants Always to be worn: size 2.5 mm (0.09 in) • Lubricant for greasing the O-rings •... - Page 41 Original installation and operation manual ZL Drain 32 V Replacement work Illustration Description / explanation 3. Press the TEST button [A] on the control unit and hold it for at least 5 seconds. 0 The green POWER LED flashes Alarm TEST 4. Once the green POWER LED is permanently lit, release...
- Page 42 ZL Drain 32 V Original installation and operation manual Replacement work Illustration Description / explanation 8. Remove the Service-Unit from the condensate inlet pipe by undoing the screws [14]. 9. Pull the Service-Unit towards you first and then lift it up and off the rail as shown. 10. Dispose of the old Service-Unit properly (see “14.
- Page 43 Original installation and operation manual ZL Drain 32 V Replacement work Illustration Description / explanation 18. Install the hose fitting [9] with the hose [X7]. 19. Check to confirm that the sealing mat [19] with contact springs [X12] is clean, dry and free of foreign objects. 20. Insert the sensor of the control unit [A] into the sensor tube opening.
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Page 44: Functional Test
ZL Drain 32 V Original installation and operation manual 10.3.2 Functional test Illustration Description / explanation Alarm Press the TEST button for 2 … 5 seconds. TEST 0 The green POWER LED lights up Power Service 0 The valve opens and condensate is drained 10.3.3 Visual inspection... -
Page 45: Cleaning
Original installation and operation manual ZL Drain 32 V 10.3.5 Cleaning 10.4 Warning notices CAUTION Personal injury through inappropriate use of cleaning media Inappropriate use of cleaning media may result in minor injuries and damage to health. • Never clean the device with a dripping wet cloth. -
Page 46: Consumables, Accessories And Spare Parts
Drain kit on demand Mounting bracket for wall and floor on demand 11.3 Spare parts Description / explanation Material no. ZL Drain 32 V S-unit on demand Set of seals on demand Design shell on demand Connection adapter on demand 46 | 56... -
Page 47: Shut-Down Procedure
Original installation and operation manual ZL Drain 32 V 12. Shut-down procedure 12.1 Warning notices Personnel Skilled technical personnel - product servicing (see section “2.3 Target group and personnel” on page 8) DANGER Sudden escape of pressurised fluids There is a danger of death or serious personal injury resulting from contact with fast or suddenly escaping fluids or through bursting system parts. -
Page 48: Shut-Down Steps
ZL Drain 32 V Original installation and operation manual 12.2 Shut-down steps Illustration Description / explanation 1. Interrupt the condensate feed at the condensate inlet line [X5] (e.g., by closing the recommended shut-off valve [X6]). 2. Press the TEST button briefly multiple times. 0 The ZL Drain is depressurised 0 The condensate remaining in the ZL Drain is... -
Page 49: Dismounting
Original installation and operation manual ZL Drain 32 V 13. Dismounting 13.1 Warning notices Personnel Skilled technical personnel - product servicing (see section “2.3 Target group and personnel” on page 8) DANGER Sudden escape of pressurised fluids There is a danger of death or serious personal injury resulting from contact with fast or suddenly escaping fluids or through bursting system parts. - Page 50 ZL Drain 32 V Original installation and operation manual Dismounting steps Illustration Description / explanation 1. Remove the hose [X7] from the hose fitting [9]. 2. Remove the condensate inlet line [X5] and recommended shut-off valve [X6] from the condensate inlet [C] and disassemble. 3. Disconnect all electrical connections.
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Page 51: Disposal
Original installation and operation manual ZL Drain 32 V 14. Disposal At the end of their useful life the product and the accessories must be sent for disposal e.g. by a specialist company. Materials such as glass, plastics and some chemical compounds are mostly recoverable, reusable or recyclable. -
Page 52: Troubleshooting
ZL Drain 32 V Original installation and operation manual 15. Troubleshooting Error or fault pattern Possible causes Troubleshooting • Read off the operating voltage on the type plate and check it • Check whether voltage is present at the Alarm • All LEDs are off TEST terminals of the sensor board (L, N) -
Page 53: Appendices
Original installation and operation manual ZL Drain 32 V 16. Appendices 16.1 Certificates Symbol Description / explanation Marcado FCC El marcado FCC identifica un producto que cumple con los requisitos de la Comisión Federal de Comunicaciones (FCC, por sus siglas en inglés) y para cuya fabricación se han cumplido los requisitos de seguridad y salud fundamentales. El producto puede ser vendido en el mercado estadounidense. Marcado cTÜVus El marcado cTÜVus identifica un producto que cumple con los requisitos del TÜV Rheinland para los mercados canadiense y estadounidense y para cuya fabricación se han cumplido los requisitos ... -
Page 54: Notes
ZL Drain 32 V Original installation and operation manual 17. Notes 54 | 56... - Page 55 Original installation and operation manual ZL Drain 32 V 55 | 56...
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