ZEKS Eclipse 90ZPB - User Manual

TECHNICAL MANUAL
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: ZEKS ZPB V0121
ZPB Heatless Purge
Desiccant Compressed Air Dryers
90-5,000 scfm
NOTICE
Those operating the machine or performing
maintenance should read and understand
the decals positioned on the machine and
the contents of this Technical Manual.
Ensure that this Technical Manual is not
removed permanently from the machine.
TM

Summary

1.0 INTRODUCTION

2.0 ABBREVIATED WARRANTY

3.0 NOMENCLATURE

4.0 RECEIVING AND INSPECTION

4.1 INSPECTION

Procedure for checking the dryer unit for any visible damage upon receipt.

4.2 UNPACKING AND HANDLING

Guidelines for safe unpacking and handling of the dryer unit to prevent damage or injury.

5.0 SAFETY AND OPERATION PRECAUTIONS

5.1 SAFETY PRECAUTIONS LIST

Lists essential safety precautions to be observed when operating or maintaining the air dryer.

6.0 PRINCIPLES OF OPERATION

6.1 INTRODUCTION

Describes the basic operation of ZPB series dryers using two desiccant towers.

6.2 DRYING CYCLE

Explains how wet compressed air is dried by passing through desiccant material.

6.3 REGENERATION CYCLE

Details the process of removing adsorbed water vapor from the desiccant.

6.4 SETTING THE REGENERATION AIR FLOW

Instructions on how to properly adjust the purge air flow for effective regeneration.

6.5 TOWER RE-PRESSURIZATION

Procedure to repressurize the tower after regeneration before switching.

6.6 VALVES

Describes the types of valves used and their functions in the dryer operation.

6.7 TIMING SEQUENCE

Outlines the timing cycles for -40°F and -80°F/-100°F dew point dryer operations.

6.7.1 TIMING CYCLE FOR -40°F DEW POINT DRYERS

Details the standard timing cycle for -40°F dew point dryer operations.

6.7.2 TIMING CYCLE FOR -80°F AND -100°F DEW POINT DRYERS

Details the standard timing cycle for -80°F and -100°F dew point dryer operations.

6.8 PURGESYNC FUNCTION (with NEMA 4;Digital Controller option)

Explains the PurgeSync™ function for reducing purge cycle based on compressor demand.

6.9 DRYER CONTROLS

Describes dryer control methods for NEMA 1 (SST) and NEMA 4 (Digital Controller) configurations.

6.9.1 OPERATING THE OPTIONAL DIGITAL CONTROLLER

Explains how to operate the NEMA 4/Digital Controller, including keypad functions.

6.9.2 DIGITAL DRYER CONTROLLER DISPLAY PARAMETERS

Details the controller display interface, menu icons, and parameter change instructions.

6.9.2.1 TOWER STATUS INDICATION LEGEND

Provides a legend for understanding tower status indications on the dryer controller.

6.9.3 HOME

Describes the HOME screen display of dryer status, sequence, alarms, and drain test.

6.9.4 TECHNICIAN MODE

Enables trained users to set parameters for alarms, functions, and troubleshooting.

TECHNICIAN MODE SCREEN 6;12

Settings for Operation Mode, Dew Point Adjust, and Purge Sync.

TECHNICIAN MODE SCREEN 7;12

Settings for Differential Transmitter, Restart Last, and Restart Auto.

TECHNICIAN MODE SCREEN 8;12

Settings for High/Low Dew Point Alarms and Setpoints.

TECHNICIAN MODE SCREEN 9;12

Settings for Inlet Temperature Alarms and Remote Start/Stop.

TECHNICIAN MODE SCREEN 10;12

Settings for Fail-To-Shift and Low Pressure Setpoint.

TECHNICIAN MODE SCREEN 11;12

Setting for High Pressure Setpoint for Fail-To-Shift function.

TECHNICIAN MODE SCREEN 12;12

Setting for Date Format and LTA Time for PurgeSync™.

6.9.5 ALARM INDICATION;EVENT LOGGING

Logs events like alarms, reminders, and dryer activation/shutdown with timestamps.

6.9.6 MAINTENANCE ALERTS

Provides general reminders for filter element replacement and drain inspection.

MAINTENANCE ALERTS SCREEN 2;5

Displays desiccant and filter/regulator element status and remaining life.

MAINTENANCE ALERTS SCREEN 3;5

Shows dryer operating hours, purge hours, and purge time percentage.

MAINTENANCE ALERTS SCREEN 4;5

Reminders for inlet and outlet filter service intervals.

MAINTENANCE ALERTS SCREEN 5;5

Reminders for desiccant and control air filter/regulator element service.

6.9.7 GENERAL SETTINGS

Access to set Time & Date, Language, and Backup Solenoid drain adjustment.

GENERAL SETTINGS SCREEN 1;3

Settings for Language and Units.

GENERAL SETTINGS SCREEN 2;3

Settings for Time and Date.

GENERAL SETTINGS SCREEN 3;3

Settings for Moisture Load Control (MLC) functionality.

6.9.8 COMMUNICATIONS

Configuration settings for remote communication, including Modbus RTU.

COMMUNICATIONS SCREEN 1;4

Settings for Modbus RTU, COM PORT, and NETWORK ID.

COMMUNICATIONS SCREEN 2;4

Settings for communication timeouts and retries.

COMMUNICATIONS SCREEN 3;4

Settings for Baud Rate, Data Bits, and Parity.

COMMUNICATIONS SCREEN 4;4

Settings for Stop Bits, IP Address, Subnet Mask, and Default Gateway.

6.9.9 OPERATING STATUS

Displays real-time information on sensors, valve activation, and drain status.

OPERATING STATUS SCREEN 1;7

Shows tower status, step, time, and Load Time Average (LTA) status.

OPERATING STATUS SCREEN 2;7

Indicates inlet/outlet valve positions and tower pressure (Fail-To-Shift).

OPERATING STATUS SCREEN 3;7

Shows tower pressure indication (Fail-To-Shift) and tower status.

OPERATING STATUS SCREEN 4;7

Displays tower status, MLC status, and dryer inlet temperature.

OPERATING STATUS SCREEN 5;7

Shows tower status, pressures, and alarm status.

OPERATING STATUS SCREEN 6;7

Indicates inlet/outlet filter status and pressure.

OPERATING STATUS SCREEN 7;7

Displays inlet filter drain status.

7.0 ALARMS AND INDICATORS

7.1 MOISTURE INDICATOR

Explains the function of the Blue Moisture Indicator (BMI) for dew point monitoring.

7.2 HIGH HUMIDITY ALARM (Optional)

Alerts the operator to high humidity levels indicating potential dryer malfunction.

7.3 FAILURE-TO-SHIFT ALARM (Optional)

Indicates a valve switching failure during the drying/regeneration cycle.

7.4 FAIL-TO-SHIFT AND TOWER PRESSURE ALARM MONITORING (with NEMA 4;Digital Controller option)

Monitors tower pressures for valve switching and operating integrity.

7.5 MOISTURE LOAD CONTROL (with NEMA 4;Digital Controller option)

Minimizes purge air use during low flow conditions using dew point monitoring.

7.6 ALARM STATES

Details alarm conditions, causes, control sequences, and recommended actions.

Alarm Item 1: Fail-To-Shift

Indicates valve switching failure or incorrect tower pressure.

Alarm Item 2: Low Tower Pressure

Alerts if tower pressure is below the required limit for operation.

Alarm Item 3: Muffler Clog Warning

Warns of a clogged purge muffler, potentially affecting regeneration.

Alarm Item 4: Inlet Filter Pressure Drop Warning (Optional)

Indicates a high pressure drop across the inlet filter element.

Alarm Item 5: Outlet Filter Pressure Drop Warning (Optional)

Indicates a high pressure drop across the outlet filter element.

Alarm Item 6: High Inlet Temperature

Triggers if compressed air inlet temperature exceeds the setpoint.

Alarm Item 7: Low Inlet Temperature Warning (Optional)

Warns if the inlet temperature falls below the specified minimum.

Alarm Item 8: Inlet Temperature Fault (Optional)

Indicates the temperature sensor is operating outside its normal range.

Alarm Item 9: Filter Drain Alarm (Optional - Electronic No Air Loss Drain)

Triggers if the electronic no-air-loss drain alarm contact is activated.

Alarm Item 10: Dew Point (DP) Sensor Fault (Optional)

Indicates the DP sensor is operating outside its normal measurement range.

Alarm Item 11: High Dew-point Warning (Must be equipped with MLC Option)

Alerts when the measured dew point exceeds the MLC set-point value.

Alarm Item 12: MLC Off Warning (Must be equipped with MLC Option)

Warns if the DP sensor is out of range when MLC option is active.

Alarm Item 13: Pressure Sensor fault

Indicates the tower pressure transducer is out of range.

Alarm Item 14: Inlet Filter Service Reminder

Alert to remind user to replace the inlet filter element.

Alarm Item 15: Outlet Filter Service Reminder

Alert to remind user to replace the outlet filter element.

Alarm Item 16: Desiccant Service Reminder

Alert to remind user to inspect the desiccant charge.

Alarm Item 17: Filter;Regulator Element Service Reminder

Alert to remind user to replace the Filter/Regulator element.

8.0 INSTALLATION AND START-UP

8.1 APPLICATION AND CHECK ANALYSIS

Ensures proper dryer performance by verifying installation and application requirements.

8.2 LOCATING AND MOUNTING

Provides guidance on selecting a suitable location and mounting the dryer unit.

8.3 PIPING

Details compressed air piping connections for inlet, outlet, and bypass systems.

8.4 FILTRATION

Specifies the requirement for pre-filters and after-filters for dryer protection.

8.4.1 FILTER DRAIN VALVE (With Factory Installed Filters)

Instructions for configuring automatic drain valves on factory-installed filters.

8.5 ELECTRICAL CONNECTION

Instructions for making correct electrical connections to the dryer unit.

8.6 DESICCANT LEVEL VERIFICATION

Procedure for checking and verifying the desiccant level in each tower.

8.7 DEW POINT MONITOR (Available with the NEMA 4 option)

Guidance on installing the Dew Point Transmitter after initial dryer operation.

8.8 START-UP PROCEDURE

Step-by-step guide for safely starting up the dryer after installation.

9.0 MAINTENANCE AND SYSTEM CHECK

9.1 SCHEDULED MAINTENANCE

Daily, monthly, semi-annual, and annual maintenance functions for the dryer.

DAILY MAINTENANCE FUNCTIONS:

Daily checks including pressure, flow, operation, and indicators.

MONTHLY MAINTENANCE FUNCTIONS:

Monthly checks including muffler condition and pilot air filter regulator.

SEMI-ANNUAL MAINTENANCE FUNCTIONS:

Semi-annual checks for outlet dew point and control air filter.

ANNUAL MAINTENANCE FUNCTIONS:

Annual checks for desiccant, valves, electrical components, and drains.

EVERY TWO YEARS:

Preventive maintenance for valves and actuators every two years.

9.2 PREFILTERS AND AFTERFILTERS

Guidelines for prefilter and afterfilter element maintenance and replacement.

9.2.1 FLANGED FILTER ELEMENT REPLACEMENT (Factory Installed Option)

Step-by-step instructions for replacing flanged filter elements.

9.3 CONTROL AIR SOLENOID VALVES AND FILTER;REGULATOR

Recommendations for replacement intervals of control air valves and filter/regulators.

9.4 MUFFLER CHANGEOUT PROCEDURE

Procedure for safely changing out the dryer mufflers.

9.5 ANGLE-SEAT PURGE AND SWITCHING VALVES

Details on the operation and connection of angle-seat purge and switching valves.

9.6 OUTLET CHECK VALVES

Procedure for verifying the sealing of outlet check valves.

9.7 DESICCANT CHANGEOUT PROCEDURE

Step-by-step guide for replacing the desiccant in the dryer towers.

DESICCANT FILL INSTRUCTIONS

Instructions and chart for filling desiccant into dryer towers.

10.0 TROUBLESHOOTING

Elevated Dew-point

Troubleshooting steps for elevated dew point issues, including purge flow and valve operation.

Blue Moisture Indicator (BMI) Turns Gray

Corrective actions for the Blue Moisture Indicator turning gray due to moisture.

Excessive Pressure in Tower Designated For Regeneration (Above 3 PSI)

Troubleshooting steps for high regeneration tower pressure, checking mufflers and air leaks.

Inability to Maintain Line Pressure On Drying Tower

Troubleshooting steps for maintaining line pressure on the drying tower, checking check valves.

11.0 PURGE CHARTS

12.0 GENERAL ARRANGEMENT

General Arrangement: 90 ZPB-120 ZPB NEMA 1

Dimensional layout for 90ZPB-120ZPB NEMA 1 models, showing component placement.

General Arrangement: 90 ZPB-120 ZPB NEMA 4

Dimensional layout for 90ZPB-120ZPB NEMA 4 models, showing component placement.

General Arrangement: 160 ZPB-200 ZPB NEMA 1

Dimensional layout for 160ZPB-200ZPB NEMA 1 models, showing component placement.

General Arrangement: 160 ZPB-200 ZPB NEMA 4

Dimensional layout for 160ZPB-200ZPB NEMA 4 models, showing component placement.

General Arrangement: 250 ZPB-300 ZPB NEMA 1

Dimensional layout for 250ZPB-300ZPB NEMA 1 models, showing component placement.

General Arrangement: 400 ZPB NEMA 1

Dimensional layout for 400ZPB NEMA 1 models, showing component placement.

General Arrangement: 1500 ZPB NEMA 1

Dimensional layout for 1500ZPB NEMA 1 models, showing component placement.

General Arrangement: 2700 ZPB NEMA 1

Dimensional layout for 2700ZPB NEMA 1 models, showing component placement.

General Arrangement: 5000 ZPB NEMA 4

Dimensional layout for 5000ZPB NEMA 4 models, showing component placement.

DRYER MAIN PANEL

Dryer Main Panel Components

Diagram and part list for the dryer main control panel components.

13.0 WIRING DIAGRAM

Wiring Diagram NEMA 4 Standard

Standard wiring diagram for NEMA 4 enclosures.

Wiring Diagram NEMA 4 MLC

Wiring diagram for NEMA 4 enclosures with Moisture Load Control.

Wiring Diagram NEMA 1

Wiring diagram for NEMA 1 enclosures.

14.0 FLOW DIAGRAM

Flow Diagram 90-600 ZPB NEMA 1

Pneumatic flow diagram for 90-600 ZPB NEMA 1 dryers.

Flow Diagram 90-600 ZPB NEMA 4

Pneumatic flow diagram for 90-600 ZPB NEMA 4 dryers.

Flow Diagram 800-1500 ZPB NEMA 1

Pneumatic flow diagram for 800-1500 ZPB NEMA 1 dryers.

Flow Diagram 1800-2700 ZPB NEMA 1

Pneumatic flow diagram for 1800-2700 ZPB NEMA 1 dryers.

Flow Diagram 3300-5000 ZPB NEMA 4

Pneumatic flow diagram for 3300-5000 ZPB NEMA 4 dryers.

15.0 SPARE PARTS

ANGLE VALVE REBUILD PARTS

Parts list for rebuilding angle valves used in the dryer system.

HIGH PERFORMANCE BUTTERFLY VALVE REBUILD PARTS

Parts list for rebuilding high-performance butterfly valves.

CONTROL AIR SOLENOID and FILTER;REGULATOR ASSEMBLY

Spare parts for the control air solenoid and filter/regulator assembly.

MOISTURE LOAD CONTROL (MLC) REPLACEMENT PARTS

Replacement parts for the Moisture Load Control (MLC) system.

16.0 ENGINEERING SPECIFICATIONS

ZEKS Eclipse 90ZPB Specifications

General

Brand	ZEKS
Model	Eclipse 90ZPB
Category	Dehumidifier
Language	English