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2.

ABBREVIATED WARRANTY

ZEKS refrigerated dryers are warranted to be free from defects in material and 
workmanship for a period of 12 months from the original date of shipment from the factory.
To allow the warranty to be in effect for 12 months from the date of equipment start-up,
the Warranty Registration Card must be completed and returned to ZEKS.  Alternately, 
the Warranty Registration Card may be completed online at www.zeks.com.  The total
warranty period cannot exceed 18 months from the original date of shipment from 
the factory.

Equipment must be installed and operated in accordance with ZEKS’ recommendations.
ZEKS liability is limited to repair of, refund of purchase price paid for, or replacement in
kind at ZEKS’ sole option, during the warranty time period stated above.  IN NO EVENT
SHALL ZEKS BE LIABLE OR RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES, even if the possibility of such incidental or consequential damages has been
made known to ZEKS Compressed Air Solutions.  In addition, the usual maintenance and
replacement type products are not covered by this warranty. 

REFRIGERANT COMPRESSORS 
A prorated warranty for the replacement of the refrigerant compressor will be extended 
to a maximum of 60 months (5 years) from the original date of shipment from the factory.
Following the standard warranty terms, the available prorated compressor warranty is as
stated below.  This prorated warranty applies to replacement compressor only and does
not cover any labor expenses.

Prorated coverage of price from date of shipment from the factory:

19 to 24 months

70%

25 to 36 months

50%

37 to 48 months

30%

49 to 60 months 

10%

2

1.

INTRODUCTION

ZEKS HeatSink™ refrigerated air dryers remove moisture, oil vapor, and 
other contaminants from compressed air.  These contaminants are detrimental 
to pneumatically operated appliances, controls, instruments, machinery and
tools.  This removal is accomplished by cooling the air with a refrigeration unit
to a temperature at which moisture in the air is condensed and separated from the air
stream.  The temperature the air is cooled to, normally between 34°F and 38°F (1°C -
3°C), is known as dew point.  This dryer can be easily installed into various pneumatic
systems in which dry air is required or desired.  Please refer to Principles of
Operation for complete operating details.

•   For warning label information with French translations, refer to pages 5 and 6.
•   Pur obtenir l’informatione des etiquettes dangereuses avec la traductione en francais, s’il vous plait

consul ter les pages 5 and 6.

Summary of Contents for HeatSink 200HSG

Page 1: ...A 19380 Phone 610 692 9100 800 888 2323 Fax 610 692 9192 Web www zeks com Form TM 200 400HSG 0118 Patent No 6 186 223 NOTICE Those operating the machine or performing maintenance should read and under...

Page 2: ...ERATION PRECAUTIONS 5 6 PRINCIPLES OF OPERATION 8 7 INSTALLATION AND INITIAL START UP 14 8 SCHEDULED MAINTENANCE 17 9 TROUBLESHOOTING 19 10 WIRING DIAGRAMS 21 11 GENERAL ARRANGEMENT 23 12 PARTS IDENTI...

Page 3: ...efrigerant compressor will be extended to a maximum of 60 months 5 years from the original date of shipment from the factory Following the standard warranty terms the available prorated compressor war...

Page 4: ...delines for limitations and detailed explanation of warranty coverage The warranties expressed above are in lieu of and exclusive of all other warranties There are no other warranties expressed or imp...

Page 5: ...ttempt to lift heavy objects without proper lifting equipment i e crane hoist slings or fork truck Lifting any unit without proper lifting equipment may cause serious injury To facilitate handling dur...

Page 6: ...excess of its rating 8 Do not operate the dryer without guards shields and screen in place 9 Inspect unit daily to observe and correct any unsafe operating conditions 5 WARNING is used to indicate a h...

Page 7: ...trainer la mort Ne pas exc der le taux de pression Rel cher la pression avant la mise en service de l appareil Ne pas modifier r parer ou retravailler Le taux de pression des vaisseaux est conforme au...

Page 8: ...er from ALL sources before performing service READ INSTRUCTION MANUAL WARNING ATTENTION Retirer les fusibles ne d connectera pas l lectricit de l appareil TOUJOURS d connecter toutes les sources d lec...

Page 9: ...by the cool air exiting the air moisture separator This precooling allows for the use of a smaller refrigeration system The air then goes into the chiller section where it is further cooled to the des...

Page 10: ...followed by a short burst of air If a small amount of liquid and a large amount of air is discharged decrease the ON time setting or increase the OFF time setting If only liquid and no air discharges...

Page 11: ...ntering the evaporator where as it evaporates heat is removed from the thermal mass fluid 6 5 THERMAL MASS CIRCULATING SYSTEM The thermal mass fluid in a ZEKS HeatSink dryer is continuously circulated...

Page 12: ...h is provided for all HSG series dryers This switch is factory set to open at 30 psig If the refrigerant suction pressure draws below 30 psig the LPCO opens to shut off the refrigerant compressor Once...

Page 13: ...ed off the system pressure will equalize with a gauge reading typically between 80 and 150 psig depending on ambient temperature All water cooled units come with a high pressure cut out HPCO switch Th...

Page 14: ...F Illuminated when readings are in degrees Fahrenheit DEG C Illuminated when readings are in degrees Celsius HIGH TEMP ALARM When this light is on it indicates that the exchanger temperature has rise...

Page 15: ...city downstream is necessary to prevent excessive air flow through the dryer When installed after any compressor that causes significant vibration or air pulsation such as reciprocating compressors pr...

Page 16: ...s recommended for all ZEKS equipment Refer to Section 13 for voltage requirements and load 15 ZEKS 200 400 HSG models come with a drain isolation valve D factory installed The isolation valve permits...

Page 17: ...y until the thermal mass fluid in the chiller reaches 50 F After the temperature is reduced below 50 F the HIGH TEMP ALARM light will go out After the refrigeration system shuts off air flow may be in...

Page 18: ...n and cleaning may be required Annual replacement of the filter is recommended 17 8 3 CONDENSATE DISCHARGE SYSTEM On a minimum of a monthly basis operation of the automatic drain should be checked The...

Page 19: ...alve body Clean beveled washer thread gasket spring assembly and strainer with soap and water Do NOT use solvents of any kind as failure to the seals will occur Be especially careful to clean the cent...

Page 20: ...epress Drain Test button if Drain Open Light does not come on contact distributor Check inlet and outlet pressures and system design capacity Correct cause of excessive flow Close by pass valve Check...

Page 21: ...ome clogged System operating temperature is below 32 F CORRECTIVE ACTION Check and clean ambient air filter Check ambient temperature and reduce below 120 F Controller adjustment required Disconnect p...

Page 22: ...21 10 WIRING DIAGRAMS Wiring Diagram 200HSGA W COMPUSTAT 230 1 60HZ 220 1 50HZ Drawing TM500976 A...

Page 23: ...22 Wiring Diagram 200 400HSGA W COMPUSTAT 208 230 460 575 3 60HZ 200 220 380 400 415 440 3 50HZ Drawing TM500977B...

Page 24: ...EMENT General Arrangement Drawing TM500368 C NOTE Drawings and dimensions shown are for standard NEMA 1 dryers Dimensions for dryers with optional NEMA 4 enclosures and or 575V transformers differ fro...

Page 25: ...0 Fan Blade 697187 697187 697187 697187 697187 697187 697187 697187 697187 11 Fan Bracket 682444 682444 682444 682444 682444 682444 682444 682444 682444 12 Filter Dryer 600384 600384 600384 600384 600...

Page 26: ...3 8 1 588 7 4 3 1 1 2 3 6 16 1 1 6 0 5 1 2 300HSGA400 460 3 60 630 286 4 0 1 814 10 6 2 2 4 3 16 1 1 6 0 5 1 2 300HSGA500 230 3 60 630 286 4 0 1 814 18 11 5 2 7 9 38 1 1 6 1 3 300HSGA600 575 3 60 630...

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