ZEKS CFX NC Series - User Manual

TABLE OF CONTENTS PAGE
1.INTRODUCTION 1
2.ABBREVIATED WARRANTY 1
3.REFRIGERATED DRYER NOMENCLATURE 2
4.RECEIVING AND INSPECTION 3
5.SAFETY AND OPERATION PRECAUTIONS 4
6.PRINCIPLES OF OPERATION 7
7.INSTALLATION AND INITIAL START-UP 16
8.SCHEDULED MAINTENANCE 19
9.TECHNICAIN MODE 22
10.TROUBLESHOOTING 25
11.WIRING DIAGRAMS 27
12.GENERAL ARRANGEMENT 31
13.PARTS IDENTIFICATION 32
14.ENGINEERING SPECIFICATIONS 35
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
NC SERIES NON-CYCLING
NCE MODELS 500 - 800
COMPRESSED AIR SOLUTIONS
TM
PATENT # 6,186,223

Summary

Warranty Information

Abbreviated Warranty Details

Details the warranty period for ZEKS refrigerated dryers, typically 12 months from shipment.

Heat Exchanger Warranty Coverage

Covers heat exchangers for 10 years from shipment, with prorated coverage after the first 12 months.

Refrigerant Compressor Warranty Coverage

Offers a prorated warranty for replacement refrigerant compressors, up to 60 months from shipment.

Dryer Identification and Setup

Refrigerated Dryer Nomenclature

Explains model designations, condenser types, voltage options, and other specifications.

Receiving and Inspection Procedures

Instructions for inspecting the dryer upon receipt and noting any damages for insurance claims.

Unpacking and Handling Guidelines

Procedures for safely unpacking and handling the dryer unit, including lifting precautions.

Safety and Hazard Warnings

General Safety and Operation Precautions

Lists essential safety rules for operating, maintaining, and repairing the air dryer.

Warning and Caution Label Meanings

Explains the meaning of WARNING, CAUTION, and NOTICE labels used in the manual.

User Responsibility for Safety

Warns users about potential injury or damage from failing to follow precautions.

Critical Hazard Warnings (DANGER;PELIGRO)

Displays critical DANGER and PELIGRO warnings regarding pressure and high voltage hazards.

Electrical System and Safety

Electrical Connection Box Overview

Outlines the customer connection point and required code compliance.

Electrical Connection Requirements

Details electrical connection requirements, including disconnect switches and code compliance.

Electrical Connection Safety Caution

Warns against incorrect wiring to the compressor junction box, which can cause malfunction.

Principles of Dryer Operation

Introduction to Dryer Operation

Explains how the dryer removes moisture by cooling air to its dew point.

Air System Description

Details the components and airflow path within the dryer system.

Moisture Removal System Function

Explains how condensate is separated and drained from the air stream.

Refrigeration System Function

Describes the closed-loop refrigerant system and its components.

Digital Performance Controller Overview

Introduces the Digital Performance Controller (DPC) used in the dryers.

DPC Controller Features

Lists features of the DPC, including display, drain control, and remote functions.

Hot Gas By-Pass (HGBP) Valve Operation

Explains the purpose and adjustment of the HGBP valve for pressure regulation.

Condensing Control and Pressure Regulation

Details fan control, high-pressure cutouts, and discharge pressure monitoring.

User Interface and Control Settings

DPC Controller Keypad Functions

Explains the function of each button on the DPC controller keypad.

DPC Displayable System Parameters

Lists and describes parameters displayed by the DPC, including temperatures and pressures.

Customer Set Points Overview

Identifies user-adjustable set points like Drain Interval and Drain On time.

Adjusting Dryer Set Points

Details user-adjustable set points like Drain Interval, Drain On Time, and Chiller Off Temperature.

Procedure for Adjusting Set Points

Step-by-step guide on how to access and change customer set points using the DPC controller.

Dryer Alarms and Start Modes

System Alarms and Their Functions

Details alarms like High Temperature, Low Temperature, and High Pressure Cutout, and their behavior.

High Drain Level Alarm Function

Describes the optional High Drain Level Alarm and its activation.

Dryer Start Mode Configurations

Explains the three available start modes: Manual, Auto Restart, and Remote Automatic.

Installation and Initial Start-Up

Location and Mounting Requirements

Specifies ideal location criteria, including temperature range and clearance for servicing.

Installation Notices and Tool Usage

Provides critical notices regarding compliance and proper tool usage during installation.

Piping and Valve Arrangement Guide

Guides on installing piping, fittings, and valves, referencing typical arrangements.

Filtration Recommendations

Recommends prefilters and afterfilters for dryer protection and performance.

Configuring Dryer Start Modes

Instructions on how to configure the dryer for Manual, Automatic, or Remote start modes.

Initial Dryer Start-Up Sequence

Outlines the step-by-step process for initial dryer start-up after installation.

Start-Up Tip for No Air Load

Advises starting the dryer without air load after installation or shutdown for optimal temperature reach.

Scheduled Maintenance Procedures

Introduction to Maintenance

Briefly covers the low maintenance requirements of the dryers.

Refrigerant Condenser Filter Maintenance

Details inspection and cleaning of the ambient air filter for the refrigerant condenser.

Condensate Discharge System Maintenance

Instructions for checking, cleaning, and maintaining the condensate drain assembly.

Solenoid Valve Maintenance

Detailed steps for disassembling, cleaning, and reassembling the solenoid drain valve.

Technician Mode and Alarm Management

Technician Mode Parameters Overview

Lists parameters adjustable and viewable only in the protected Technician Mode.

View-Only Technician Parameters

Lists parameters that can be viewed but not modified by technicians.

Procedure for Entering Technician Mode

Provides the specific keystrokes required to enter the protected Technician Mode.

Modifying Technician Mode Set Points

Explains how to change adjustable parameters like Drain Enable, Crankcase Heater Delay, and Auto Restart.

Viewing Non-Adjustable Parameters

Describes how to navigate and view non-adjustable parameters in Technician Mode.

Exiting Technician Mode

Instructions on how to exit the Technician Mode and return to Customer Mode.

Viewing the Alarm List

Details how to access and scroll through the list of recent alarm conditions for troubleshooting.

Troubleshooting Guide

Troubleshooting Guide Introduction

Introduces the guide for identifying and correcting dryer malfunctions.

Troubleshooting Safety Precautions

Emphasizes safety procedures, including depressurizing and lockout/tagout, before maintenance.

Problem;Action Troubleshooting Guide

Lists common problems, symptoms, causes, and corrective actions for dryer issues.

Wiring Diagrams

General Dryer Electrical Wiring Diagram

Presents the main electrical wiring diagram for the dryer's components and connections.

Wiring Diagram for 700-800 NCE Models

Provides the electrical wiring diagram specifically for the 700-800 NCE models.

Wiring Diagram for 500-600 NCE Plus Models

Presents the electrical wiring diagram for 500-600 NCE Plus models.

Wiring Diagram for 700-800 NCE Plus Models

Shows the electrical wiring diagram for 700-800 NCE Plus models.

Physical Arrangement and Parts

Dryer General Arrangement Views

Illustrates the physical layout and dimensions of the dryer unit from multiple perspectives.

Control Panel and Connection Points Identification

Identifies the location of controls, displays, and customer connection points on the dryer.

Major Parts Identification

Identifies key components like Exchanger Assy, Solenoid Drain Valve, and Filter Stop with part numbers.

Detailed Parts List by Model and Voltage

Lists detailed parts and their corresponding part numbers for various models and voltage configurations.

Engineering Specifications

Engineering Specifications Table

Provides detailed engineering specifications including electrical ratings, compressor/fan data, and refrigerant type.

ZEKS CFX NC Series Specifications

General

Model	CFX NC Series
Capacity	25 to 3000 SCFM
Air Flow	25 - 3000 SCFM (depending on the model)
Dimensions	Varies by model
Weight	Varies by model