ZEKS Eclipse 1000ZPB, Technical Manual

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8.0 INSTALLATION AND START-UP
ZEKS Eclipse TM 90-5,000ZPB Desiccant Dryers
www.zeks.com
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8.1 APPLICATION AND CHECK ANALYSIS
To achieve the best dryer performance, carefully check and verify
that each design and installation requirement outlined below is
satis fi ed.
The dryer is designed to operate with a compressed air inlet
temperature ranging from 80ºF to 120ºF and an operating
pressure ranging between 80 PSI and 150 PSI. The air
compressor that feeds air to the dryer must be su ffi ciently sized
to meet the process air demand as well as provide the volume
necessary for desiccant regeneration.
The standard ZPB series heatless desiccant dryer is rated for a
maximum allowable working pressure of 150 PSIG. If the dryer
is to be operated at pressures below 80 PSIG, the factory should
be consulted to verify sizing and con fi guration.
The standard dryer is rated to operate at an inlet temperature
and pressure of 100ºF @ 100 PSI. Installations with elevated
inlet air temperatures may require a dryer with greater capacity to
achieve expected dew point performance. When compressed air
at lower temperatures is supplied to the dryer, performance will
be reduced. The compressed air supply must have a minimum
temperature of 80ºF at the dryer inlet to assure proper dryer
operation. The operating conditions should be veri fi ed prior to
dryer installation and operation to ensure it is properly sized.
The dryer should be installed indoors where the ambient
temperature does not drop below 50ºF or rise above 120ºF.
Consult factory for outdoor installations where additional
provisions may be required for low ambient temperatures.
8.2 LOCATING AND MOUNTING
Using a forklift, lift the dryer only at the lift points identi fi ed with
labeling. Use care to avoid damage to manifold.
Bolt the dryer to the foundation using the bolt holes provided in
the base frame. Anchor bolts should project a minimum of 3.5
inches above the foundation. Refer to SECTION 12, GENERAL
ARRANGEMENT DRAWINGS, for details.
8.3 PIPING
Pipe the compressed air lines to the dryer inlet and outlet
connection points. Locate a pre fi lter as close as possible to the
dryer inlet. Ensure the positioning allows access and room to
service and maintain the dryer. Refer to the General Arrangement
drawing.
Note that the wet air inlet is at the dryer’s lower manifold, while
the dry air outlet is at the dryer’s upper manifold. In situations
where air supply is required 24 hours a day (where it is
undesirable to interrupt the air fl ow), a three valve by-pass system
is recommended to bypass the dryer. To keep pressure drop at
a minimum, use the fewest number of elbows possible. THE
BYPASS SHOULD BE USED WHEN TROUBLESHOOTING
THE AIR COMPRESSOR OR WHEN SERVICING THE ZPB
DRYER TO PREVENT FLOODING OF THE DESICCANT BED.
When all piping is connected, all joints, including those on the
dryer, should be soap bubble tested at line pressure to ensure
no joints have been damaged in transit or during site placement.
All installed piping must be self-supported. The dryer manifold
piping cannot be used to support interconnecting piping.
8.4 FILTRATION
NOTE: A Pre
fi lter and an After fi lter must be provided in your
dryer installation.
A coalescing Pre fi lter, mounted before the dryer, will protect
desiccant beds from contamination by oil, entrained water and
pipe scale to extend dryer desiccant life and assure proper dryer
operation. Locate Pre fi lter as close to the dryer as possible.
Pre fi lter drain must be inspected periodically to ensure proper
operation. Drain maintenance is not covered in the Warranty.
It is recommended that a mechanical separator with a properly
functioning drain be installed immediately preceding the Pre fi lter
to remove bulk liquid and entrained water.
Installation of a Particulate After
fi lter mounted after the dryer will
help eliminate carryover of desiccant dust into the air system.
8.4.1 FILTER DRAIN VALVE (With Factory Installed Filters)
When 90-1,500 SCFM dryers come from the factory with fi lters
installed,the Automatic Drains (PN: 24335028) must be checked
for correct con fi guration prior to pressurization of the dryer:
• Filters must be oriented vertically for proper operation.
• The drain stem must be properly adjusted as follows:
Twist the drain stem (No. 18 in Figure 2) to set for AUTOMATIC
(Normal) or MANUAL (Test) operation (See Figure 1 below).
• Twist the stem fully clockwise (when viewed from bottom
of fi lter bowl) for AUTOMATIC draining of condensate.
This is the Normal position.
• Twist the stem fully counter-clockwise (when viewed from
bottom of fi lter bowl) for MANUAL draining of condensate
(Test/Bleed) or if connected to an external drain.
Minimum operating pressure of 22 psig is required for the fl oat
that’s within the drain assembly to seat properly. Pressures
below 22 psig will allow air to escape from the drain. This will
occur when the compressed air system is being pressurized.
!
NOTICE
The standard dryer is not rated for any gas other than air.
!
NOTICE
ZEKS recommends the mu ffl ers be cleaned after initial dryer start-
up to remove desiccant dust that may have been generated during
dryer shipment. Following the fi rst 30 minutes of dryer operation,
de-energize and depressurize the dryer and remove the mu ffl ers.
Disassemble and clean the removable insert inside each mu ffl er
core. Reassemble and reinstall mu ffl ers prior to resuming dryer
operation. To prevent additional clogging, periodic inspection of
mu ffl ers is recommended.
!
NOTICE
All ZPB model dryers must have proper fi ltration. Liquid water
and oil must be removed before compressed air enters the
dryer. Ensure separators, Pre fi lters and drains are in good
working order. Failure to do so will void warranty.
Figure 1
AUTOMATIC MANUAL