EC OPTION LDP OPTION 3V OPTION
Contents
1. 35 6 1 DEWPOINT HAS 35 6 2 HIGH HUMIDITY ALARM OR SENSOR 36 6 3 PRESSURE DROP TOO HIGH 36 6 4 SWITCHING FAILURE ALARM cttm emen enne 36 7 DRA WINGS 39 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 27103522 Rev 06 28 February 2007 1 INTRODUCTION 1 4 GENERAL This adsorption dryer includes the latest technology and safety features use however can endanger life and limb and can lead to considerable damage to the equipment and other material assets if e itis operated by personnel not instructed in its use e itis improperly used itis improperly maintained or serviced Furthermore ignorance of its use and maintenance can result in the loss of any claim for damage This adsorption dryer is designed for neutral media such as air or nitrogen which is free of aggressive water oil and solid elements Zander accepts no liability for corrosion damage or malfunctions caused by aggressive media Applications other than those mentioned in this manual must be agreed to by Zander and confirmed in writing Zander reserves the right to make changes at any time as ma2. 5 25 4 EES 25 44 1 Daly Check 29 2 12 Weekly CHECK skates vided 25 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC 2103522 Rev 06 28 February 2007 4 1 3 Quarterly Check Every Three 25 414 Annual Check us a ia hanan aaa a u wau am Qh hua uska aaa E e aa AG 26 4 2 CHANGING THE FILTER 26 4 3 REPLACEMENT OF THE DESICCANT 27 E d did d IL E EE 29 5 1 PARTS FOR ZEH400 ZEH650 cccccccssscssccecesssssscesececsesesseessesscessecsecsessecesecsssusssssceceesssesssseseseessssesesesseeses 29 5 2 PARTS FOR 820 0 7 223 05 sess 30 3 3 PARTS FOR 7 500 27 2 00 0 31 3 4 7 2500 27 9500 0 32 6 FAULTS AND TROUBLESHOOTINGCG
3. 15 3 2 1 Dryer Statsion 16 3 2 2 Alarm Information ue IR ettet tees dur esee vee sua Due vene ebd eve ques 17 3 2 3 Dryer Operation Modes teret e te ree epu tes tee RE DES Ere Pte Rod etaed 18 3 2 4 Heater Sheath Information tt e eter e perdue u ebd 18 3 2 2 Heater Outlet Information iii dde excel depot aqa rede ebbe pasen noia eroe R 19 3 2 6 Regeneration Outlet Information adeste e e tee epe dette eure eno aet 19 3 2 7 Dryer Off Dryer On EC On 3 Position Switch 19 328 Status LAMPS C R m 20 329 PHOS SUE RA 20 3 3 INITIAL START UP e R M 20 3 3 1 Pressurizing 20 3 3 2 Energizing Dryer Controls Fin eee ette tene up hr eese dus 21 3 3 3 Pressure Switch Adjustment 21 Rm 22 344 SHORT TERM SHUTDOWN sscsscostestvcndsvosacessustiensivssnsvssuscanessnsscevevecesseiersscencevcescvsecuasencntdsceesedsesurseassbeusouncaueseeseteues 23 3 5 SHUTDOWN IN CASE OF A FAULT OR FOR 24 3 6 RESTARTING 529 X 24 4
4. Both temperatures are in degrees F Displays the actual heater outlet temperature HEATER OUTLET XXXX F XXXX and the high outlet temperature HEAT OVERTEMP VVVV F alarm setting VVVV Both temperatures are in degrees F 3 2 6 REGENERATION OUTLET INFORMATION The F8 button accesses regeneration outlet information On this screen the actual temperature in degrees Fahrenheit is displayed and so are the control setpoints for end of heating and end of cooling The setpoints cannot be changed at the panel MESSAGE IDENTIFICATION MESSAGE DESCRIPTION Displays the actual regeneration outlet REGEN OUTLET XXXX F temperature XXXX and the end of heating HEAT SETPOINT YYYY F mode temperature setting YYYY Both temperatures are in degrees F Displays the actual regeneration REGEN OUTLET XXXX F temperature XXXX and the end of cooling COOL SETPOINT 2227 F mode temperature setting ZZZZ Both temperatures are in degrees F 3 2 7 DRYER OFF DRYER ON EC ON 3 POSITION SWITCH This 3 position switch provides for manual selection of dryer basic functions Ensure that the switch is set at DRYER OFF before beginning the initial startup procedure USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 3 2 8 STATUS LAMPS A green light announces that there is POWER at the control panel when lit A red light announces that there is an ALARM condition when lit
5. ZANDER ZEH External Heat Regenerated Compressed Air Dryer sar Manual For ZEH3500 This dryer configuration includes equipment options as selected X below X EC OPTION _ LDP OPTION OPTION This manual is part number 2103160 Rev 05 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 FOREWORD Reading this user manual will fully familiarize you with the Zander adsorption dryer You will be better able to run this equipment in accordance with its intended use This manual contains important information for safe proper and economic dryer installation start up operation and maintenance Always keep it within reach where the adsorption dryer is being used It is necessary to follow all instructions as written Careful reading will avert danger avoid unnecessary downtime and minimize work for yourself and wear on the equipment In addition to carefully reading this technical manual in its entirety you must understand your National State and local rules and regulations regarding safety in the workplace their necessary precautions and procedures Each person responsible for the set up start up operation maintenance or repair of this adsorption dryer must have first read and understood this user manual including all the safety tips NOTE Zander recommends that installation start up and maintenance be carried out by its factory tra
6. s 400 scfm 500 scfm 650 scfm 820 scfm Chamber Outer Diameter 18 inches 18 inches 18 inches 20 inches Standard no LDP option 100 Activated Alumina Desiccant Bed 272 350 433 660 Composition amp With LDP option Layered Pounds per Chamber 3396 Mol Sieve bottom 67 Activated Alumina top 1 MS 90 1 MS 115 1 MS 143 1 MS 218 and AA 182 and AA 235 2nd AA 290 and AA 442 Inlet Connection 2 in NPT 2 in NPT 2 in NPT 3 in RF FLG Outlet Connection 2 in NPT 2 in NPT 2 in NPT 3 in RF FLG Standard Electric Rqmt 460 Vac 3 phase 60 Hz Heater 6 kW 6 kW 8 kW 12 kW Cycle Time 8 Hour Cycle 4 Hours Drying 4 Hours Regeneration Outlet Pressure Dewpoint 40 F PDP 100 F LDP EC Control Setting 40 F PDP 100 F LDP High Humidity Alarm 35 F PDP 95 F LDP Pressure Switch Setpoints PSL 10 psig PSH 30 psig below line pressure Flow Directions Purge Pressure Setting 70 psig 65 psig 55 psig 55 psig Low Purge Alarm Setpoint 60 psig 55 psig 45 psig 45 psig Heater Outlet Setpoint 425 F End Heating Temperature 180 F End Cooling Temperature 120 F Heater Sheath Alarm 1000 F Downward Drying Upward Regeneration p A USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 1 4 2 MopELs ZEH1000 To ZEH1800 Composition amp Pounds per Chamber Model ZEH1000 ZEH1225 ZEH1
7. 6 7 44 Dryer Flow Capaciti s ei t eet bte 7 12 OVEREOADING DUI PI e verte 8 nt SEE 8 1 7 STORAGE EE 8 1 8 USE OF A PREFILTER AND AFTERFILTER teodesuscbacecestences se asducendentes 8 2 INSTADDATION u I Q W sss 9 pa IJU T P 9 2 2 MECHANICAL ASSEMBLY NE 9 2 3 FILTER INSTALLATION RR 10 2 3 1 Prefilter Installation Shipped 1 0 10 2 3 2 Afterfilter Installation Shipped 11 2 3 3 Filter Skid with 3 Valve Bypass If Dryer Includes 3V 11 2 4 ELECTRICAL 11 2 5 2 ETIESE ESETE ESS 12 3 EQUIPMENT OPERATION 13 3 1 GENERAL OPERATING PRINCIPLES L 13 3 1 4 Dryer Cer Mg me E 14 3 2 OPERATOR CONTROLS LOW VOLTAGE CONTROL
8. ALARM message will appear If more than one alarm is active a flashing arrow will appear on the right side of the display To access the messages press the green arrow on the right side of the panel In order to reset non active alarms press the F4 key When all the alarm conditions have been cleared the NO ALARM message will appear MESSAGE IDENTIFICATION MESSAGE DESCRIPTION HEATER OUTLET OVER TEMPERATURE Heater outlet temperature is above the setpoint THERMOCOUPLE MODULE IN ERROR Indicates the thermocouple module has lost it s 24Vdc supply THERMOCOUPLE OUT OF RANGE Indicates a thermocouple connected to the module is defective or open HEATER FAILURE ALARM FAIL REACH SETPOINT OVERSHEATH ALARM SHEATH TEMPERATURE TOO HIGH The heater has failed to reach the setpoint temperature within 15 minutes The heater sheath temperature is above the setting DEPRESS FAILURE ON LEFT CHAMBER The left chamber did not reach the low setting of the pressure switch within time limit DEPRESS FAILURE ON RIGHT CHAMBER The right chamber did not reach the low setting of the pressure switch within time limit REPRESS FAILURE ON LEFT CHAMBER The left chamber did not reach the high setting of the pressure switch within time limit REPRESS FAILURE ON RIGHT CHAMBER The right chamber did not reach the high setting of the pressure switch within time limit HIGH HUMIDITY ALARM Indic
9. Cooling 120 F Temperature Heater Sheath Alarm 1000 F Flow Directions Downward Drying Upward Regeneration USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 1 4 4 DRYER FLOW CAPACITIES The specific size model of your dryer was selected to meet performance requirements based on an analysis of air supply and demand capacities The model selection chart provided following should confirm that this dryer remains suitable for its intended use The table following is based on 40 PDP 8 hour cycle activated alumina and average inlet air flow for non LDP equipped dryers with EC Consult our factory for rated air flows on LDP equipped dryers Design Rated inlet air flow scfm at given pressures psig MODEL 2 Based upon 100 F inlet air temperature psig 60 70 80 90 100 110 120 130 140 ZEH400 150 220 265 310 355 400 440 480 520 550 ZEH500 150 305 355 400 460 500 550 590 645 680 ZEH650 150 360 435 505 580 650 705 790 850 905 ZEH820 150 460 550 640 735 820 905 990 1070 1150 ZEH1000 150 615 715 805 920 1000 1140 1255 1325 1420 ZEH1225 150 690 825 955 1100 1225 1360 1490 1610 1735 ZEH1500 150 785 960 1150 1275 1500 1600 1730 1875 2010 ZEH1800 150 1010 1210 1405 1610 1800 1995 2190 2375 2535 ZEH2100 150 1095 1345 1600 1835 2100 22
10. February 2007 NOTE System isolation and bypass valves should be installed If not supplied by Zander as part of the equipment package i e 3V option see paragraph 1 2 they should be supplied and installed by others Ensure that this bypass facility is installed so that future servicing of the dryer system off line may take place e Full flow relief valves to protect the system from over pressure must be customer provided in accordance with local regulations The purge exhaust on the ZEH650 and smaller dryers is equipped with an exhaust muffler silencer If required the silencer can be removed and purge exhaust can be connected to a vent header Follow recommendations for pipe sizing listed below The purge exhaust connection on the 2 20 and larger dryers must be connected to a vent header To ensure satisfactory regeneration of the desiccant chambers the purge exhaust piping should be sized as follows to prevent back pressure build up EXTENDED LENGTH PIPE SIZE REQUIRED TO 10 FEET SAME SIZE AS DRYER EXHAUST TO 25 FEET 1 SIZE LARGER THAN DRYER EXHAUST TO 50 FEET 2 SIZES LARGER THAN DRYER EXHAUST TO 100 FEET 3 SIZES LARGER THAN DRYER EXHAUST Caution AN The noise at the outlet of the exhaust header may exceed 100 dBa and the flow velocity will be high Exhaust must be piped to an area where these flow velocities and noise levels can be safely tolerated 2 3 FILTER INSTALLATION Pre and afterfilters for th
11. MopELs ZEH2100 TO ZEH3500 Model ZEH2100 ZEH2500 ZEH3000 ZEH3500 flow 100 psig amp 5405 scfm 2500 3000 3500 scfm inlet conditions Chamber Outer Diameter 30 inches 36 inches 40 inches 40 inches Standard no LDP option 100 Activated Alumina Desiccant Bed 1485 1722 2310 2805 Composition amp With LDP option Layered Pounds per Chamber 33 Mol Sieve bottom 67 Activated Alumina top 1 MS 490 1 8 568 1 MS 762 1 MS 926 219 AA 995 219 AA 1154 2 1548 2 1879 Inlet Connection 4 in RF FLG 4 in RF FLG 6 RF FLG RF FLG Outlet Connection 4 in RF FLG 4 in RF FLG 6 FLG 6 in RF FLG Recommended Prefilter SWH 2100 SWH 2750 SWH 4100 SWH 4100 Recommended Afterfilter SWF 2100 SWF 2750 SWF 4100 SWF 4100 Pilot Air Filter SWF 20 SWF 20 SWF 20 SWF 20 Standard Voltage 460 Vac 3 phase 60 Hz Heater 30 kW 36 kW 43 kW 50 kW Cycle Time 8 Hour Cycle 4 Hours Drying 4 Hours Regeneration Outlet Pressure Dewpoint 40 F PDP 100 LDP EC Control Setting 40 F PDP 100 F LDP High Humidity Alarm 35 F PDP 95 F LDP 7 PSL 10 psig PSH 30 PSIG below line pressure Purge Pressure Settin 60 psi 70 psi 65 psig 60 psi Purge Aane 50 psig 60 psig 55 psig 50 psig Heater Outlet Set Point 425 F End Heating 180 Temperature End
12. Refer to the operator monitor to determine the cause 3 2 9 PRESSURE GAUGES Three gauges are mounted in a row above the low voltage control panel The two outside read the pressure within each each chamber left side for left chamber right for right and the middle gauge shows the purge pressure 3 3 INITIAL START UP Attention All pipes and wire connections must be tightened Furthermore before start up e The pipes must be cleaned of scale abraded material from the threading or other similar impurities e All isolation valves upstream of the prefilter and downstream of the afterfilter should be closed The bypass valve if installed should be open e The ambient temperature must not be less than 33 F NOTE Failure resulting from faulty installation or start up does not qualify under the Zander warranty obligation Start up by factory trained personnel is recommended 3 3 1 PRESSURIZING DRYER Prior to pressurizing the dryer system verify the following e DRYER OFF DRYER ON EC ON switch is the DRYER OFF position e System outlet block valve is closed e Prefilter afterfilter and pilot air filter vent valves are closed e Desiccant chamber vent valve is closed e Pilot air isolation valve is open Hygrometer adjustment isolation valves are closed 20 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 7103522 Rev 06 28 February 2007 Slightly open the inlet isolation valve to slowly admit comp
13. Solenoid Block V005 204 1 V005 204 1 V005 204 1 Gasket RGASK03002 4 RGASK03002 4 RGASK03002 4 Outlet Valve Valve Kit V004 024K1 1 V004 024K1 1 V004 024K1 1 Check Valve V004 024V 2 V004 024V 2 V004 024V 2 Gasket RGASK03002 4 RGASK03002 4 RGASK03002 4 Purge Purge Valve V004 036V 2 V004 036V 2 V004 036V 2 Purge Valve Gasket RGASK03002 4 RGASK03002 4 RGASK03002 4 Exhaust Valve V002 535 2 V002 535 2 V002 535 2 Exhaust Valve Kit V002 535K1 2 V002 535K1 2 V002 535K1 2 3V Bypass Option Manual Butterfly Valve Kit V012 130K1 3 V012 130K1 3 V012 130K1 3 Gasket 3 inch RGASK03002 4 RGASK03002 4 RGASK03002 4 Bypass Valve V012 130 3 V012 130 3 V012 130 3 EC Digital Panel Meter 006 071 1 J006 071 1 J006 071 1 Probe J006 052 1 J006 052 1 J006 052 1 Replacement Parts Pressure Gauge B002 025 3 B002 025 3 B002 025 3 PLC C020 019 1 020 019 1 020 019 1 Power Supply C020 008 1 C020 008 1 C020 008 1 Text Display C020 010 1 C020 010 1 C020 010 1 Thermocouple C020 017 1 C020 017 1 C020 017 1 Relief Valve V006 010 2 V006 010 2 V006 010 2 Temperature Indicator B001 009 2 B001 009 2 B001 009 2 Heater H001 137 1 H001 134 1 H001 139 1 Pressure Regulator B007 027 1 B007 027 1 B007 027 1 30 p A USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 ZANDER ZEH820 ZE
14. TO OPEN OPEN RIGHT CHAMBER INLET VALVE EV 1R 8 EV 11L VALVE TO MOVE 10 SEC TIMER VALVE TO OPEN 10 SEC PASS LEFT 10 SEC PASS RIGHT CHAMBER ABOVE 60 psig CHAMBER ABOVE 60 psig CLOSE RIGHT CLOSE LEFT CHAMBER STEP 2 CHAMBER INLET VALVE STEP 9 INLET VALVE EV 1L amp EV 11R WAIT 5 SEC EV 1R amp EV 11L WAIT 5 SEC FOR FOR VALVE TO CLOSE VALVE TO CLOSE 5 SEC PASS 5 SEC PASS DEPRESSURIZE DEPRESSURIZE STEP 3 RIGHT CHAMBER STEP 10 LEFT CHAMBER EV 2L amp EV 3L IF L C 10 psig EV 2R amp EV 3R IF R C 10 psig ENERGIZE EV 1R amp EV 11L ENERGIZE EV 1L amp EV 11R 10 SEC PASS AFTER RIGHT CHAMBER BELOW 30 psig RIGHT CHAMBER kaa 21 STEP 4 HEATING PERIOD STEP 1 1 START L C HEATING MODE FOR 140 MINUTES MAXIMUM FOR 140 MINUTES MAXIMUM ENERGIZE EV 1L AND EV11R ENERGIZE EV 1R amp EV11L HEATING TIMER FINISH OR PURGE HEATING TIMER FINISH OR PURGE OUTLET TEMP ABOVE 200 DEG F OUTLET TEMP ABOVE 200 DEG F RIGHT CHAMBER LEFT CHAMBER COOLING PERIOD COOLING PERIOD STEP 5 START R G COOLING MODE FOR STEP 12 START L C COOLING MODE FOR 100 MINUTES MAXIMUM 100 MINUTES MAXIMUM 60 MINUTES MINIMUM 60 MINUTES MINIMUM ENERGIZE EV 1L 8 EV 11R ENERGIZE EV 1R amp EV 11L IF COOLING TIMER DONE 100 MINUTES OR PURGE IF COOLING TIMER DONE 100 MINUTES OR PURGE OUTLET TEMP BELOW 120 DEG AND 60 MINUTES PASSED OUTLET TEMP BELOW
15. and passes a leak test prior to shipment 1 3 SAFETY INSTRUCTIONS This manual contains basic tips which must be followed during set up operation and servicing t is most important that it be read by the assembly technician before installation and start up as well as by the specialist operator in charge It must always be within reach at the place where the adsorption dryer is being used 1 3 1 IDENTIFICATION OF SIGNS AND SYMBOLS IN THIS MANUAL The safety tips contained in this manual whose disregard could endanger people and equipment are indicated by a general danger sign and the additional markings Danger or Attention or Warning AN Danger Attention Safety sign in accordance with DIN 4844 W9 Warning high voltage Safety sign in accordance with DIN 4844 W8 Safety tips printed directly on the adsorption dryer must be heeded at all times and must be kept completely legible USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 1 3 2 GENERAL SAFETY TIPS FOR ASSEMBLY INSPECTION AND MAINTENANCE The purchaser is to ensure that all assembly maintenance and inspection work is carried out by personnel qualified to do it The personnel involved in assembly operation maintenance and inspection must have the corresponding qualifications to do this work Areas of responsibility and supervision of the personnel must be clearly established by the purchaser Should the person
16. 1 Pressure Switch C002 011 5 C002 011 5 C002 011 5 Light Bulb E004 058 24 2 E004 058 24 2 E004 058 24 2 Transformer Primary Fuse E009 058 2 E009 058 2 E009 058 2 Transformer Secondary Fuse E009 136 1 E009 136 1 E009 136 1 Heater Fuses E009 436 3 E009 436 3 E009 436 3 Control Fuses E009 051 1 E009 051 1 E009 051 1 29 p A USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 ZANDER Description ZEH400 ZEH500 ZEH650 Control Relay E009 320RO E009 320RO 2 E009 320RO 2 Heater Contactor E002 140 1 002 140 1 002 140 1 5 2 PARTS FOR ZEH820 2 1225 ZEH820 ZEH1000 ZEH1225 Part Qty Part Qty Part Qty Consumables Prefilter Element Only 3075XP 1 5075XP 1 5075XP 1 Afterfilter Element Only 3075ZP 1 5075ZP 1 5075ZP 1 Muffler 006 015 2 006 015 2 006 015 2 Activated Alumina Pounds 001 019 1320 001 019 1650 001 019 1980 Pilot Air Filter Element K009AO 1 K009AO 1 K009AO 1 Probe Recalibration J006 052X 1 J006 052X 1 J006 052X 1 LDP Option Activated Alumina Pounds 001 019 882 001 019 1106 001 019 1326 Molecular Sieve 4A Pounds 001 011 436 001 011 544 001 011 654 Inlet Valve Inlet Valve Kit V012 200K1 2 V012 200K1 2 V012 200K1 2 Inlet Valve V012 200 2 V012 200 2 V012 200 2
17. 120 DEG F AND 60 MINUTES PASSED REPRESSURIZE REPRESSURIZE STEP 6 RIGHT CHAMBER STEP 13 LEFT CHAMBER ENERGIZE EV 1L amp EV 11R ENERIZE EV 1R amp EV 11L 120 SEC PASS amp BOTH 120 SEC PASS 8 BOTH CHAMBERS ARE ABOVE 60 psig CHAMBERS ARE ABOVE 60 psig RIGHT CHAMBER LEFT CHAMBER STEP 7 STANDBY STEP 14 STANDBY ENERGIZE EV 1L amp EV 11R ENERGIZE EV 1R 8 EV11L DRYER HALF CYCLE COMPLETED 240 DRYER HALF CYCLE COMPLETED 240 MINUTES OR BAD DEWPOINT OR DDS OFF MINUTES OR BAD DEWPOINT OR DDS OFF amp BOTH CHAMBERS ABOVE 60 psig BOTH CHAMBERS ARE ABOVE 60 psig 8 STEP 1 FIGURE 1 DRYER PROGRAMMED STEPS 14 USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 3 2 OPERATOR CONTROLS LOW VOLTAGE CONTROL PANEL The operator status display and control interface i e monitor is detailed in Figure 2 It is provided to allow the operator to manually cycle through the programmed steps and to indicate system status The system operating setpoints cannot be changed at this panel SIEMEN 200 DISPLAY F5 F6 F7 F8 Ft F2 F3 F4 SHIFT pee A ENTE F1 DRYER STATUS F2 MANUAL STEP AHEAD MANUAL MODE ONLY DRYER ALARM STATUS F4 ALARM RESET SHIFT In order to choos
18. 500 ZEH1800 ba e 1000 scfm 1225 scfm 1500 scfm 1800 scfm Chamber Outer Diameter 24 inches 24 inches 28 inches 28 inches Standard no LDP option 10096 Activated Alumina Desiccant Bed 825 990 1055 1320 With LDP option Layered 33 Mol Sieve bottom 67 Activated Alumina top 1 MS 272 1 MS 327 1 MS 348 1 MS 436 219 553 2 0AA 663 2 AA 707 2 AA 884 Inlet Connection 3 in RF FLG 3 in RF FLG 3 in RF FLG 4 in RF FLG Outlet Connection 3in RF 3in RF FLG 3 in RF FLG 4 in RF FLG Standard Electric 460 Vac 3 phase 60 Hz Heater 17 kW 21 kW 25 kW 28 kW Cycle Time 8 Hour Cycle 4 Hours Drying 4 Hours Regeneration Outlet Pressure Dewpoint 40 F PDP 100 F LDP EC Control Setting 40 F PDP 100 F LDP High Humidity Alarm 35 F PDP 95 F LDP Low Purge Alarm Setpoint Pressure Switch Setpoints PSL 10 PSIG PSH 30 PSIG below line pressure Purge Pressure Setting 70 psig 60 psig 65 psig 70 psig Low Purge Alarm Setpoint 60psig 50psig 55psig 60 psi 50 psi 55 psi 60 psi Heater Outlet Set Point 425 F End Heating Temperature 180 F End Cooling Temperature 120 F Heater Sheath Alarm 1000 F Flow Directions Downward Drying Upward Regeneration USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 1 4 3
19. 51 1 Control Relay E009 320RO 1 E009 320RO 1 E009 320RO 1 Heater Contactor E002 143 1 E002 148 1 E002 148 1 5 4 PARTS FOR ZEH2500 TO ZEH3500 ae ZEH2500 ZEH3000 ZEH3500 DESCHPHOR Part Qty Part Qty Part Qty Consumables Prefilter Element Only 3075XP 3 350AA 4 350AA 4 Afterfilter Element Only 3075ZP 3 350AR 4 350AR 4 Muffler F006 016 2 F006 016 2 F006 016 2 Activated Alumina Pounds 001 019 3444 001 019 4620 001 019 5610 Pilot Air Filter Element K009AO 1 K009AO 1 K009AO 1 Probe Recalibration J006 052X 1 J006 052X 1 J006 052X 1 LDP Option Activated Alumina Pounds 001 019 2308 001 019 3096 001 019 3758 Molecular Sieve 4 Pounds M001 011 1136 M001 011 1524 M001 011 1852 Inlet Valve Inlet Valve Kit V012 201K1 2 V012 202K1 2 V012 202K1 2 Inlet Valve V012 201 2 V012 202 2 V012 202 2 Solenoid Block V005 203 1 V005 207 1 V005 207 1 Outlet Valve Valve Kit V004 025K1 1 V004 026K1 1 V004 026K1 1 Check Valve V004 025V 2 V004 026V 2 V004 026V 2 Gasket RGASK04004 4 RGASKO06007 4 RGASKO06007 4 Purge Check Valve Kit V004 024K1 1 V004 025K1 1 V004 025K1 1 Purge Valve V004 024M 2 V004 025M 2 V004 025M 2 Purge Valve Gasket RGASK03002 4 RGASK04004 4 RGASK04004 4 Exhaust Valve V012 200 2 V012 201 2 V012 201 2 Exhaust Valve Kit V012 200K1 2 V012 201K1 2 V012 201K1 2 3V Bypass Option Manual Butterfly Valve Kit V012 131K1 3 V012 132K1 3 V012 132K1 3 Gasket RGASK04004 6 RGASKO06007 6 RGASKO06007 6 USER MANUAL Model
20. 75 2500 2700 2890 ZEH2500 150 1480 1735 1985 2270 2500 2820 3100 3355 3585 ZEH3000 150 1685 2015 2340 2680 3000 3330 3645 3960 4235 ZEH3500 150 1900 2300 2700 3095 3500 3845 4195 4570 4890 Higher pressures are optionally available Consult factory To correct for an inlet temperature other than 100 F multiply dryer capacity by the temperature correction factor listed below CORRECTION FACTOR FOR INLET TEMPERATURE TEMPERATURE DEGREES F 80 90 100 105 110 115 120 Correction Factor 1 1 1 1 1 0 0 85 0 69 0 565 0 455 Example To size for an inlet flow of 950 SCFM 105 F and 110 psig 1 Select model that produce at least 950 SCFM at 110 psig This case would be the ZEH1000 which can dry 1140 SCFM 2 Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer corrected for pressure and temperature 1140 X 0 85 969 SCFM 3 Confirm model selection Model ZEH1000 can flow 969 SCFM at the inlet conditions specified requirements of 950 SCFM are less ZEH1000 is correct USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 7103522 Rev 06 28 February 2007 NOTE Settings for EC Standard Dryers EC Control 40 F 40 C High Humidity 32 F 35 C LDP Dryers EC Control 100 F 74 C High Humidity 95 F 69 C 1 5 OVERLOADING Attention Prot
21. GASK03002 4 RGASK03002 4 RGASK03002 4 Exhaust Valve V012 200 2 V012 200 2 V012 200 2 Exhaust Valve Kit V012 200K1 2 V012 200K1 2 V012 200K1 2 3V Bypass Option Manual Butterfly Valve Kit V012 130K1 3 V012 131K1 3 V012 131K1 3 Gasket RGASK03002 6 RGASK04004 6 RGASK04004 6 Bypass Valve V012 130 3 V012 131 3 V012 131 3 EC Digital Panel Meter J006 071 1 J006 071 1 J006 071 1 Probe J006 052 1 J006 052 1 J006 052 1 Replacement Parts Pressure Gauge B002 025 B002 025 3 B002 025 PLC 020 019 1 020 019 1 020 019 1 31 gt USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 32 ZANDER ZEH1500 ZEH1800 ZEH2100 Power Supply C020 008 1 C020 008 C020 008 Text Display C020 010 1 C020 010 1 C020 010 1 Thermocouple C020 017 1 C020 017 1 C020 017 1 Relief Valve V006 012 2 V006 012 2 V006 012 2 Temperature Indicator B001 009 2 B001 009 2 B001 009 2 Heater H001 142 1 H001 122 1 H001 127 1 Pressure Regulator B007 027 1 B007 027 1 B007 027 1 Pressure Switch C002 011 5 C002 011 5 C002 011 5 Light Bulb E004 058 24 2 E004 058 24 2 E004 058 24 2 Transformer Primary Fuse E009 058 2 E009 058 2 E009 058 2 E009 136 1 009 136 1 009 136 1 Heater Fuses E009 064 3 E009 064 3 E009 064 3 Control Fuses E009 051 1 E009 051 1 E009 0
22. H1000 ZEH1225 Pressure Switch C002 011 5 C002 011 5 002 011 5 Light 004 058 24 2 004 058 24 2 004 058 24 2 Transformer Primary Fuse E009 058 2 E009 058 2 E009 058 2 nee E009 136 1 009 136 1 009 136 1 Heater Fuses E009 065 3 E009 067 3 E009 150 3 Control Fuses E009 051 1 E009 051 1 E009 051 1 Control Relay E009 320RO 1 E009 320RO 1 E009 320RO 1 Heater Contactor E002 140 1 E002 140 1 E002 140 1 5 3 PARTS FOR ZEH1500 TO ZEH2100 Description ZEH1500 ZEH1800 ZEH2100 Part Qty Part Qty Part Qty Consumables Prefilter Element Only 5075XP 1 3075XP 2 3075XP 3 Afterfilter Element Only 50752 1 30752 2 30752 3 Muffler 006 015 2 006 016 2 006 016 2 Activated Alumina Pounds M001 019 2110 M001 019 2640 M001 019 2970 Pilot Air Filter Element K009AO 1 K009AO 1 K009AO 1 Probe Recalibration J006 052X 1 J006 052X 1 J006 052X 1 LDP Option Activated Alumina Pounds 001 019 1414 001 019 1768 001 019 1990 Molecular Sieve 4A Pounds M001 011 696 M001 011 872 M001 011 980 Inlet Valve Inlet Valve Kit V012 200K1 2 V012 201K1 2 V012 201K1 2 Inlet Valve V012 200 2 V012 201 2 V012 201 2 Solenoid Block V005 203 1 V005 203 1 V005 203 1 Outlet Valve Valve Kit V004 024K1 1 V004 025K1 1 V004 025K1 1 Check Valve V004 024V 2 V004 025V 2 V004 025V 2 Gasket RGASK03002 4 RGASK04004 4 RGASK04004 4 Purge Check Valve Kit V004 024K1 1 V004 024K1 1 V004 024K1 1 Purge Valve V004 024M 2 V004 024M 2 V004 024M 2 Purge Valve Gasket R
23. HING FAILURE ALARM CONTINUED POSSIBLE CAUSE REMEDY Check operation of solenoid Replace if not functioning Solenoid valve not energizing Check wiring from panel to the solenoid for an open or short circuit Repair if necessary Shut down and depressurize dryer Inspect valve seats and seals for damage or wear Repair or replace if necessary While valve is disassembled check the actuator stops to ensure that valve is fully closing butterfly valves only Check valve internals are worn or Shut down and depressurize dryer Repair damaged or replace valves Inspect purge depressurization mufflers and replace if necessary Off line desiccant chamber inlet valve or outlet check valve leaking Inspect as described above Regenerating chamber depress exhaust Switching failure on depressurization valve failed to open Check associated solenoid valve operation as described above Online chamber outlet check valve leaking Inspect and repair as described above Excessive purge flow Check the purge pressure setting Exhaust or depressurization valves not closing or are leaking Check solenoid operation as listed above Check valve failure as listed above Switching failure on repressurization Insufficient purge flow Check purge pressure settings Check automatic purge isolation valve for correct operation Check the setpoint of the pressure switches Readjust if necessary Check the operatio
24. Muffler 006 015 2 006 015 2 006 015 2 Activated Alumina Pounds 001 019 544 001 019 700 001 019 866 Probe Recalibration J006 052X 1 J006 052X 1 J006 052X 1 LDP Option Activated Alumina Pounds 001 019 364 001 019 470 001 019 580 Molecular Sieve 4A Pounds 001 011 182 001 011 230 001 011 286 Inlet Valve Inlet Valve V002 532K1 2 V002 532K1 2 V002 532K1 2 Inlet Valve V002 532 2 V002 532 2 V002 532 2 Solenoid Block V005 200 1 V005 200 1 V005 200 1 Gasket RGASK02002 4 RGASK02002 4 RGASK02002 4 Outlet Valve Valve Kit V004 036VK1 1 1 V004 036VK1 1 1 V004 036VK1 1 1 Check Valve V004 036V 2 V004 036V 2 V004 036V 2 Gasket RGASK02002 4 RGASK02002 4 RGASK02002 4 Purge Purge Exhaust Valve Kit V002 535K1 2 V002 535K1 2 V002 535K1 2 Purge Valve V004 090 1 V004 090 1 V004 090 1 Purge Exhaust Valve V002 537 2 V002 537 2 V002 537 2 3V Bypass Option Ball Valve V001 086 3 V001 086 3 V001 086 3 EC Digital Panel Meter J006 071 1 02250148 225 1 02250148 225 1 Probe J006 052 1 02250149 692 1 02250149 692 1 Replacement Parts Pressure Gauge B002 025 3 B002 025 3 B002 025 3 PLC C020 019 1 C020 019 1 C020 019 1 Power Supply C020 008 C020 008 C020 008 Text Display C020 010 1 C020 010 1 C020 010 1 Thermocouple 020 017 1 020 017 1 020 017 1 Relief Valve V006 010 2 V006 010 2 V006 010 2 Temperature Indicator B001 006 2 B001 006 2 B001 006 2 Heater H001 144 1 H001 144 1 H001 143 1 Pressure Regulator B007 027 1 B007 027 1 B007 027
25. N COOLING MODE LEFT CHAMBER DRYING R C IN REPRESS MODE Depressurizing the right chamber Heating the right chamber for regeneration Cooling the right chamber Pressurizing the right chamber LEFT CHAMBER DRYING Right chamber in standby until the end of the H C IN STANDBY MODE half cycle The dryer is in EC mode on the left chamber LEFT CHAMBER IN EC MODE This will extend the half cycle for a maximum R C IN STANDBY MODE of 12 hours or until the outlet dewpoint goes higher than 40 F SELECT RIGHT CHAMBER Opening the right chamber inlet valve DRYING Closing the left chamber inlet valve 2 Depressurizing the left chamber RIGHT CHAMBER DRYING IN HEATING MODE RIGHT CHAMBER DRYING L C IN COOLING MODE RIGHT CHAMBER DRYING Heating the left chamber for regeneration Cooling the left chamber L C IN REPRESS MODE Pressurizing the left chamber RIGHT CHAMBER DRYING Left chamber in standby until the end of the L C IN STANDBY MODE half cycle The dryer is in EC mode on the right RIGHT CHAMBER IN EC MODE chamber This will extend the half cycle for a L C IN STANDBY MODE maximum of 12 hours or until the outlet dewpoint goes higher than 40 F USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 3 2 2 ALARM INFORMATION The F3 button is pressed to display the status of the dryer alarms If there is no alarm a NO
26. RESSURE SWITCH ADJUSTMENT 3 3 4 EC START UP Refer to the general assembly drawing provided in section 7 and to figure 4 The EC hygrometer probe has been shipped inside of its own sealed package to ensure that the probe does not become saturated with ambient air during storage and transport Do not remove probe from the package until dryer system has been started and probe is to be inserted into the sample cell e Check that the sample line is connected from the dryer outlet to the inlet valve on the humidity probe sample cell e Check that the humidity probe is installed into the sample cell e Connect the cable to the humidity probe 22 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 e Fully open the inlet valve to the sample cell e Partially open the discharge valve of the sample cell to vent off a small amount of sample air Do not fully open discharge valve e Perform a soap bubble test to check for leaks on all parts of the sample line connections and the humidity sample cell e The digital display will now read the dewpoint of the dryer system It will take a short period of time for a humidity probe to be purged of humidity INLET VALVE HUMIDITY CELL OUTLET VALVE FIGURE 4 HYGROMETER PROBE ASSEMBLY NOTE The dryer should be operated in the DRYER ON position at the time of initial start up and at all times when the hygrometer or humidity probe are removed
27. TERIORATED POSSIBLE CAUSE REMEDY Incoming air temperature above design condition Check compressor after cooler and cooling system Adjust as necessary to reduce the inlet temperature to dryer specification Incoming air flow too high Problem external to dryer Verify inlet flow rate and reduce as necessary to dryer specification Inlet pressure below design pressure Check compressed air system Correct if necessary Liquid water entering dryer Check prefilter elements and seals for damage Replace if necessary Check operation of drain trap Ensure proper drainage Repair or replace drain if necessary Desiccant degraded or coated with oil Replace desiccant Inspect desiccant is coated with oil prefilter if Insufficient regeneration due to 1 Heater failure 2 Heater contactor failure 3 Incorrect purge flow 4 Temperature setting incorrect Inspect and replace as necessary Inspect and replace as necessary Check purge flow setting Check setpoints of heater and purge exhaust Leaks at piping tubing connections downstream of the dryer Soap bubble test dryer and repair all leaks 35 USER MANUAL lt Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 6 2 HIGH HUMIDITY ALARM OR SENSOR FAILURE POSSIBLE CAUSE REMEDY Hygrometer probe out of calibration Replace hygrometer probe Open circuit on probe electric
28. al Inspect and repair connection Incorrect flow across sensor Refer to EC start up paragraph 3 3 4 Check sensor tubing and probe filter for Excessive moisture on sensor buildup of moisture Allow tubing to dry and replace filter element 6 3 PRESSURE DROP TOO HIGH POSSIBLE CAUSE REMEDY Broken or fouled desiccant Inspect desiccant and replace if required Inlet flow exceeding design flow rate Reduce inlet flow as necessary Depressurize filters and inspect elements Pre or after filter element dirty or clogged Replace if dirty or clogged 6 4 SWITCHING FAILURE ALARM If a switching failure alarm occurs refer to paragraph 3 2 1 in order to determine where in the dryer cycle the alarm occurred Also refer to the program step functions paragraph 3 1 1 to assist in finding which component led to the switching failure POSSIBLE CAUSE REMEDY Close pilot air isolation valve depressurize pilot air filter and inspect element If clogged or dirty replace Check that pilot air isolation valve is fully Pilot air insufficient open Check that pilot air regulator is set at 100 psig Inspect pilot air tubing for kinks or breaks Repair if necessary Inlet air pressure below setpoint of Correct the low pressure problem to the pressure switches dryer 36 USER MANUAL lt Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 6 4 SWITC
29. ates the outlet dewpoint is above alarm setpoint NO ALARM Indicates no alarm is active USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 3 2 3 DRYER OPERATION MODES The F5 button is pressed to display the dryer mode of operation The actual mode will be displayed whether it is in automatic or manual mode To change the actual mode of the dryer press F2 when in the dryer mode screen The actual mode will change from one to the other each time the F2 button is pressed If the dryer mode screen is left unattended for thirty seconds it will automatically switch to the dryer status screen In manual mode the READY TO STEP AHEAD PRESS F2 TO CONTINUE message will be shown when the dryer is ready to perform the next step In order to go to the next step in manual mode you must not be in the dryer operation mode screen Failure to do so will simply change the operating mode of the dryer MESSAGE IDENTIFICATION MESSAGE DESCRIPTION The dryer is in automatic mode The dryer DRYER IN AUTO MODE will perform its cycle without any external intervention except in case of alarm The dryer is in manual mode The dryer will need external intervention in order to do to the following step If no external intervention is provided the dryer will stay in that step The dryer is ready to go to the next step READY TO STEP AHEAD when in manual mode The user must wait PRESS F2 TO CONTINUE for th
30. cooling cycle is completed the purge exhaust valve is closed and the off line tower is repressurized Once at line pressure the dryer is ready to switch drying from one chamber to the other Dryer models ZEH3000 and 3500 have purge control valves which close once at line pressure and prior to switching from one chamber to the other The purge air is controlled by a purge adjusting valve and purge orifice located in the purge line Purge pressure is indicated on the purge pressure gauge Zander high efficiency prefilters and reverse flow afterfilters are designed to remove solids oil and water condensate from compressed air and other neutral compressed gases These filters provide high flows and low differential pressures Solids are filtered out by impact or by the effect of inertia whereas oil particles and drops of moisture are filtered out by the effect of coalescence By the force of gravity the contaminants collect in the lower filter vessel and are drained automatically or manually P d USER MANUAL Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 3 1 1 DRYER PROGRAM STEPS This automatic dryer is equipped with a PLC which retains last position data in the event of a power failure or fast shutdown The dryer will restart at the last position or can be manually cycled on the operator interface to reset at step 1 OPEN LEFT CHAMBER INLET VALVE EV 1L EV 11R VALVE TO MOVE 10 SEC TIMER VALVE
31. e ZEH dryer must be purchased separately These filters are available loose or as part of a separate bypass skid with the 3V Option i e 3 valve bypass assembly with mounted filters 2 3 1 PREFILTER INSTALLATION SHIPPED LOOSE e Mount prefilter in such a way as to allow clearance for the element installation and removal Locate the prefilter as close to the dryer inlet connection as possible e The filter must be piped so that the correct flow direction indicated on the filter is followed USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 7103522 Rev 06 28 February 2007 e Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection e Connect drain port to a condensate collector Use an easily visible collector to aid in operational inspection 2 3 2 AFTERFILTER INSTALLATION SHIPPED LOOSE Mount afterfilter in such a way as to allow clearance for the element installation and removal e The filter must be piped so that the correct flow direction indicated on the filter is followed e Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection 2 3 3 FILTER SKID WITH 3 VALVE BYPASS IF DRYER INCLUDES OPTION e Filters skid should be located as close to dryer as possible Use the skid bolt holes to secure the assembly Ensure that the skid is located such that the 3 valve bypass will bypass the dryer and filters when
32. e one of the next four options the SHIFT button must be pressed first An s in the lower right corner indicates the upper row is now active F5 DRYER OPERATING MODE MENU F6 HEATER SHEATH TEMPERATURE AND SETPOINT F7 HEATER OUTLET TEMPERATURE AND SETPOINTS F8 REGENERATION OUTLET TEMPERATURE AND SETPOINTS A v Arrows allow user to scroll up or down within the display A flashing arrow on the right side of the screen indicates that more information is available in the direction of the arrow and can be accessed by using the scroll arrows ESC ACCESSES THE MENU MODE ACCESS IS NOT REQUIRED ENTER NO FUNCTIONALITY FOR THIS BUTTON FIGURE 2 OPERATOR MONITOR 15 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 3 2 1 DRYER STATUS The F1 key is pressed to display the present status of the dryer This allows you to see which step of the program cycle is currently engaged A message can appear below the dryer status at any time when in manual mode A blinking arrow on the right side of the display will indicate this To access the messages press the green arrow on the right side of the interface MESSAGE IDENTIFICATION MESSAGE DESCRIPTION Opening the left chamber L C inlet valve See se OHANBPER DRYING Closing the right chamber R C inlet valve LEFT CHAMBER DRYING R C IN DEPRESS MODE LEFT CHAMBER DRYING R C IN HEATING MODE LEFT CHAMBER DRYING R C I
33. eater assembly should be inspected to determine that no moisture has accumulated in the heater enclosure or terminations 1000 meg ohmmeter should be used to determine the phase to ground insulation resistance for each phase A minimum value of 500 kohms should exist EC CONTROL CONNECTION A probe sample line must be run from downstream of the afterfilter A 10 ft length of 1 8 in stainless steel tubing and necessary compression fittings are provided Tube fittings are to be installed downstream of the afterfilter at the incident monitor differential pressure indicator DPI port T fitting on the afterfilter outlet nozzle Remove the hexagonal plug from the DPI T fitting Insert 1 8 in tubing into compression fitting and tighten Run the tubing back to the hygrometer housing Cut to necessary length and connect to the upper connection fitting Tubing is semi flexible so care must be taken when bending to ensure the tubing does not kink If the sample port is installed at a distance longer than the tubing supplied contact your Zander distributor for assistance 12 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 3 EQUIPMENT OPERATION 3 1 GENERAL OPERATING PRINCIPLES This dryer model has two parallel adsorption chambers filled with desiccant While the medium is being dried flowing top down in one chamber regeneration takes place from the bottom up in the other chamber The chan
34. ect the adsorption dryer from overloading The adsorption dryer can become overloaded if e The volume of the medium to be dried increases e The temperature of the air at entry and correspondingly its humidity increases e The minimum operating pressure decreases e The prefiltration and separation of impurities are not sufficient or the filter drain fails e Introduction of oil into the air stream 1 6 TRANSPORT Immediately upon delivery of the adsorption dryer it must be checked for any damage that may have occurred during transport If necessary the damage must be recorded on the shipping waybill receipt Liability for such damage usually rests with the shipper Contact Zander to arrange for any required service or replacement parts Attention For transport within your company site only the skids of the adsorption dryer may be used Lifting at any other points on the equipment will void the warranty and damage the equipment 1 7 STORAGE If the adsorption dryer is to be stored for a long period of time its place of storage must be dry and free of dust The ambient temperature cannot go below 33 F 1 C 1 8 USE OF A PREFILTER AND AFTERFILTER In order to prevent droplets of condensate oil and dirt from getting into the desiccant a Zander prefilter must be installed upstream of the adsorption dryer Otherwise an oil film on the desiccant would reduce the drying capacity In order to prevent breakdown in downstream con
35. een 400 F and 425 Verify pressure switch operation Inspect pilot air filter element If element seems clogged dirty or damaged replace it 25 USER MANUAL gt Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 4 1 4 ANNUAL CHECK e Disassemble clean and inspect the inlet switching purge exhaust and depressurizaton valves actuators Replace all worn or damaged parts Disassemble clean and inspect the outlet and purge check valves Replace all worn or damage parts e Inspect the desiccant through the chamber fill port Replace desiccant if degraded or if oil is present see paragraph 4 3 Replace prefilter afterfilter and pilot air filter elements at least once a year e Contact Zander to recalibrate the dewpoint sensor humidity probe NOTE Should the need for spare parts or service arise during work on the adsorption dryer the dryer model and serial number must be conveyed to Zander This information is given on the nameplate mounted on the control cabinet Telephone Zander to arrange for maintenance support 4 2 CHANGING THE FILTER ELEMENT e The filter element within the filter housing must be replaced when the incident monitor reads in the red or after one year of operation Depressurize the dryer and switch DRYER OFF Change filter elements only when the housing is fully depressurized e Separate the lower part of the housing from the upper part Loosen and remove t
36. for service 3 4 SHORT TERM SHUTDOWN Follow this sequence when switching off the adsorption dryer e First close all the isolation valves up and downstream of dryer Then immediately switch DRYER OFF 23 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 A Dryer will remain pressurized 3 5 SHUTDOWN IN CASE OF A FAULT OR FOR MAINTENANCE Follow this sequence when switching off the adsorption dryer e First switch DRYER OFF Make certain dryer is not in heating or cooling mode The dryer electrical panel will still have power The dryer disconnect must be turned off before opening electrical panel e Close all the isolation valves upstream and downstream of the adsorption dryer Depressurize the dryer by using the manual vent valve at the bottom of the desiccant chamber Depressurize the filters by opening vent valves at the bottom of each filter vessel Danger Before any kind of maintenance or repair work is done the dryer must be depressurized and disconnected from the power source 3 6 RESTARTING e Close the manual vent valve mounted at the bottom of the afterfilter and at the bottom of each desiccant chamber Slowly open the inlet isolation valve and pressurize the dryer up to the regular operating pressure by keeping the isolation valve mounted behind the afterfilter closed e Switch DRYER ON NOTE If the dryer is restarted after a long stands
37. geover from one chamber to the other is controlled by programmable logic control PLC and the Dewpoint Dependent Switching system that monitors desiccant performance by measuring the outlet air dew point The dryer operates continuously and is fully automatic The standard dryer with EC has a cycle time of eight hours Half the cycle time is dedicated to air drying and the other half to desiccant regeneration with one chamber working to dry the air while the other regenerates The dryer is configured at the factory Wet air enters the working desiccant chamber it can be either the left or right at the inlet switching valves top and is dried as it flows downward through the desiccant bed Dry air exits the dryer through the outlet check valve The regeneration of the off line chamber begins with a heating cycle After having depressurized the off line chamber the purge orifice allows a portion of the dry outlet air to flow across the regeneration heater The heated regeneration air then passes upward through the desiccant bed where it picks up previously adsorbed moisture from the desiccant and is then evacuated to atmosphere through the purge exhaust valve At the completion of the regeneration heating cycle the cooling cycle begins The regeneration heater is de energized The purge orifice allows a portion of the dry outlet air to flow through the off line tower It is then evacuated to atmosphere through the purge exhaust valve When the
38. he element by hand Install the new filter element and replace the O ring gasket making sure that the element seats perfectly e Refit the filter housing NOTE Zander filter elements cannot be cleaned or reused Attention AN Filters elements may contain pollutants as appropriate to their function Dispose of used filter elements in accordance with your local state and federal regulations 26 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 4 3 REPLACEMENT OF THE DESICCANT Desiccant life is determined by the care with which it is handled the quality of filtered inlet air provided and by its time in use Be careful to not abrade i e wear down the desiccant when installing it Proper filtering of inlet air and constant pressure and temperature will also extend its life In order to ensure trouble free operation we recommend replacing the desiccant every 10 000 operating hours or every 3 years The following considerations determine the life expectancy of desiccant e Care in installation e Quality of input gas e g air e Constancy of flow and temperature e Whether full service cycling or low demand usage e Time in service The following clues will suggest that you examine the desiccant and consider its replacement e Discolorization of desiccant e g oil residue other contaminants a brown or yellow tinge indicates that the adsorbancy capacity of the desicca
39. in use e Check the flow direction of each filter to ensure the prefilter is connected to the inlet pipe of the dryer and afterfilter is connected to the outlet pipe of the dryer e Connect the filter skid piping and dryer skid piping using materials and fabrication procedures that are suitable for compressed air pressure piping All flanges are ANSI B16 5 Class 150 raised face flanges 2 4 ELECTRICAL CONNECTION Warning high voltage Be sure that power is removed from the line feed before making connection between the site drop and the equipment e Connect the dryer to a correctly sized power supply Refer to the dryer nameplate or the electrical drawing see section 7 for the supply voltage and amperage requirement to properly size the electrical service Only one electrical connection is required All internal wiring was done at the factory NOTE A disconnect switch is not provided with the dryer and must be supplied by the customer in accordance with the local electrical codes 11 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 27103522 Rev 06 28 February 2007 2 5 Ground the frame of the dryer in accordance with the local electrical codes It is recommended that the common alarm relay located in the dryer control panel be connected to the control room or operator station so that an immediate response to a dryer alarm may be given when required Before energizing the electrical circuit the electrical h
40. ined technicians in a regularly scheduled site dedicated program This will ensure the safety of personnel the integrity of equipment and the surety of warranty coverage gt ZANDER 1 800 543 0851 5900 B Northwoods Parkway Charlotte North Carolina 28269 USA USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 TABLE OF CONTENTS 1 INTRODUCTION sre 1 1 41 GENERAL 1 L2 5 lt THERE TA Ee ee SEE 1 12 1 Pressure Vessel Regulations eet te kawsas qaspqqasasaqawasassppisyaksaqpaycaqawaqassqaysasapapukasaqss 2 1 2 2 TII nu 2 1 3 SAFETY INSTRUCTIONS seirce netro neee teret te setae 2 1 3 1 Identification of Signs and Symbols in this 2 1 3 2 General Safety Tips for Assembly Inspection and 2 14 TECHNICAL SHEET t eee ees eh eene 4 1 4 1 Models 400 to ZEH8S20 4 1 4 2 Models ZEH1000 to ZEH1 D 1 4 3 Models ZEH2100 to ZEH3500
41. is signal in order to press F2 for making the dryer step ahead in its cycle DRYER IN MANUAL MODE 3 2 4 HEATER SHEATH INFORMATION The F6 button accesses heater sheath information On this screen the actual sheath temperature in degrees Fahrenheit is displayed and so is the temperature setpoint for the sheath over temperature alarm The setpoint cannot be changed from the panel MESSAGE IDENTIFICATION MESSAGE DESCRIPTION Displays temperature of the heater sheath XXXX and also at which temperature the dryer will turn in alarm YYYY Both temperatures are in degrees Fahrenheit HEATER SHEATH XXXX F ALARM SETPOINT YYYY F USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 3 2 5 HEATER OUTLET INFORMATION The F7 button accesses the heater outlet information this screen the actual temperature in degrees Fahrenheit is displayed and so is the temperature setpoint for the heater outlet over temperature and heating failure alarm The setpoint cannot be changed at the panel MESSAGE IDENTIFICATION MESSAGE DESCRIPTION Displays the heater outlet temperature HEATER OUTLET XXXX F XXXX and the regulation temperature HEAT CONTROL YYYY F setting YYYY of the heater Both temperatures are in degrees F Displays the actual heater outlet temperature HEATER OUTLET XXXX and the heating failure alarm HEAT FAIL AT 4442 temperature setting 2727
42. n of the pressure Pressure switch malfunction switches Replace if needed Inlet or purge exhaust valves leaking 37 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 38 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 7 DRAWINGS 39 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 40 p A ZANDER 1 800 543 0851 5900 B Northwoods Parkway Charlotte North Carolina 28269 USA
43. nel not possess the necessary knowledge then they must be instructed If need be this training may be carried out by the manufacturer supplier at the request of the purchaser Further the purchaser is to ensure that all personnel completely understand and follow the content of this manual Attention e Never make structural changes to the adsorption dryer e Only use recommended spare parts as listed in section 5 e Never weld on a pressure vessel or change it in any way e Carry out maintenance only when the adsorption dryer is OFF depressurized and disconnected from the electric power supply Danger e Review the Material Safety Data Sheet MSDS provided with the desiccant when installing or disposing of it e Wear protective clothing and goggles when working with the desiccant e f desiccant comes into contact with the eyes rinse eyes immediately with a lot of clear water e If the desiccant is spilled clean up without causing swirls of dust e case of fire there is no restriction on the use of fire extinguishing material on the desiccant the reaction with water and foam is defined as strong e mask must be worn whenever handling desiccant p A USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 1 4 TECHNICAL DATA SHEET 1 4 1 MopELs ZEH400 To ZEH820 Model ZEH400 ZEH500 ZEH650 ZEH820
44. nt has been diminished e Frequent afterfilter replacement due to desiccant dust accumulation e Performance dew point rises Refer to paragraph 1 4 to determine the desiccant quantity required for your model of dryer e Close dryer inlet outlet isolation valves Depressurize and switch DRYER OFF Danger AN e Wear protective equipment and clothing when handling desiccant e For each chamber remove the desiccant drain port plug and empty the old desiccant into a container 27 USER MANUAL Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 4 3 REPLACEMENT OF THE DESICCANT CONTINUED Danger AN Desiccant may contain pollutants Desiccant is to be disposed of in accordance with local state and federal regulations Screw the plug back in and fill with new desiccant from above one half total quantity in each of the two chambers Start up the adsorption dryer in accordance with paragraph 3 3 for initial start up 28 7 USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 5 PARTS LIST 5 1 PARTS FOR ZEH400 to ZEH650 Description ZEH400 ZEH500 ZEH650 Part Qty Part Qty Part Qty Consumables Prefilter Element Only 2050XP 1 3050XP 1 3050XP 1 Afterfilter Element Only 2050ZP 1 3050ZP 1 3050ZP 1
45. ph 3 1 1 and the wiring schematic see section 7 before operating the dryer NOTE The hygrometer will signal an open circuit the ALARM light will illuminate until probe cable is connected to hygrometer probe This connection is described in paragraph 3 3 4 leave it as is for now While dryer is in purge mode for either chamber the regeneration pressure setting should be checked Warning AN Failure to correctly set the purge pressure can lead to improper regeneration of the desiccant bed resulting in a dewpoint failure when the chamber is returned to service 3 3 3 PRESSURE SWITCH ADJUSTMENT On the ZEH dryer there are four pressure switches PSH 1 PSL 1 PSH 2 and PSL 2 21 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 The PSH pressure switches are set at 30 psig below the operating pressure of the dryer and use the normally open contact When the adjustment is done the contact between C and NC should close when increasing to the desired pressure The PSL switches are set at 10 psig regardless of the operating pressure and use the normally closed contact When the adjustment is done the contact between C and NC should close when decreasing to the desired pressure To increase the pressure screw the knob toward the pressure switch diaphragm see figure 3 To decrease the pressure turn away from the pressure switch diaphram ADJUSTMENT KNOB FIGURE 3 P
46. ressed air to the system When full system operating pressure has been reached all connections should be soap bubble tested for leaks Any leaks should be repaired and retested prior to placing the equipment in service If some gas other than the process air will be used for leak testing consult Zander for its compatibility with system components before proceeding Fully open the inlet isolation valve When the system is filled with process air and leak tight slowly open the system outlet valve to pressurize the downstream piping During this procedure ensure that the dryer System pressure does not fall beyond 9590 of its reading prior to opening the system outlet valve This will protect the equipment internal components i e filler elements desiccant from gas velocities above design conditions When pressurizing is complete then fully open the system outlet valve to place the equipment in service Verify that the system inlet pressure and temperature are at the design operating levels see paragraph 1 4 Ensure that the pilot pressure regulator is set between 80 and 100 psig 3 3 2 ENERGIZING DRYER CONTROLS Turn 3 position switch to the DRYER ON position The operator monitor controls the dryer cycle This should be used as a reference guide to ensure dryer is cycling A manual mode is included in the dryer program to allow for fast cycling to verify to operation of the dryer Review the operational program of the dryer paragra
47. s ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 2 2500 ZEH3000 ZEH3500 Bypass Valve V012 131 3 V012 132 3 V012 132 3 EC Digital Panel Meter J006 071 1 006 071 1 J006 071 1 Probe 006 052 1 006 052 1 006 052 1 Parts Pressure Gauge B002 025 3 B002 025 3 B002 025 3 PLC C020 019 1 C020 019 1 C020 019 1 Power Supply C020 008 1 C020 008 C020 008 Text Display C020 010 1 C020 010 1 C020 010 1 Thermocouple C020 017 1 C020 017 1 C020 017 1 Relief Valve V006 012 2 V006 012 2 V006 012 2 Temperature Indicator B001 009 2 B001 009 2 B001 009 2 Heater H001 138 1 001 122 1 001 122 1 Pressure Regulator B007 027 1 H001 165 1 H001 165 1 Pressure Switch C002 011 5 C002 011 5 C002 011 5 Light Bulb E004 058 24 2 E004 058 24 2 E004 058 24 2 Transformer Primary Fuse E009 058 2 E009 058 2 E009 058 2 aa E009 136 1 009 136 1 009 136 1 Heater Fuses E009 126 3 E009 069 3 E009 069 3 Control Fuses E009 051 1 E009 051 1 E009 051 1 Control Relay E009 320RO 1 E009 320RO 1 E009 320RO 1 Heater Contactor E002 144 1 E002 146 1 E002 146 1 33 USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER Z103522 Rev 06 28 February 2007 34 USER MANUAL Models ZEH400 to ZEH3500 with EC Z103522 Rev 06 28 February 2007 6 FAULTS AND TROUBLESHOOTING 6 1 DEWPOINT HAS DE
48. s at the installation site the adsorption dryer skid frame must be placed onto vibration dampers to avoid desiccant abrasion and degradation 2 2 MECHANICAL ASSEMBLY e The equipment should be located in an area with adequate clearances for service An overhead clearance of not less than two feet above each desiccant tower is required for loading of the desiccant e Remove all protective shipping crates flange covers etc e Using the mounting holes provided on the skid anchor the dryer to a solid level foundation designed to support the equipment Do not hydrostatically test the pressure vessels All ZEH dryer pressure vessels and welded piping are hydrostatically tested at 1 5 times the design pressure after fabrication and before assembly e Desiccant for models ZEH820 and up is shipped loose and must be installed on site Refer now to paragraph 4 3 for instructions on installing the desiccant e f the equipment is installed in a high traffic area protective barriers may be required to prevent possible damage of equipment and to prevent contact with hot surfaces e Due to vibration during shipping some tube fittings may have loosened Therefore inspect all connections and tighten if required e Ensure that the inlet and outlet connections to and from the dryer are made using the correctly rated fittings and piping to meet the design conditions USER MANUAL p _ Models ZEH400 to ZEH3500 with EC ZANDER 7103522 Rev 06 28
49. sumers caused by material that has been abraded from the desiccant bed a Zander afterfilter must be mounted downstream of the adsorption dryer Since no condensate should accumulate in the afterfilter no automatic drain is required Both filters are equipped with an incident monitor i e differential pressure indicator to advise of blockage in the filter elements USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 27103522 Rev 06 28 February 2007 2 INSTALLATION 2 1 GENERAL Ensure that the installation site is free of dust dirt and litter The site floor must be level and strong enough to support the equipment The site itself must be an heated environment minimum 50 F to ensure proper operation and warranty protection Ensure that the Zander adsorption dryer is carried only by its skid base frame The adsorption dryer must be positioned so that the side from which it is to be operated is easily accessible The upstream piping is to be connected at a slightly downward slope toward the prefilter Install isolation valves on the inlet to the prefilter and outlet of the afterfilter Also bypass pipe with an additional isolation valve should be mounted around the adsorption dryer to allow for an uninterrupted supply of compressed air when the adsorption dryer requires maintenance or repair The bypass assembly may not be provided see paragraph 1 2 it is optionally available or can be customer furnished If vibration occur
50. till proceed as for an initial start up see paragraph 3 3 24 USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 27103522 Rev 06 28 February 2007 4 1 4 MAINTENANCE CHECKLIST These checks are to be carried out by the operator during the routine operations cycle 4 1 1 DAILY CHECK Operate prefilter drain ball valve as required to prevent excess accumulation This may require frequent exercise depending on line moisture content If the drain is automatic check for functionality and blow down daily to remove accumulated fluids Check the filter DPl incident monitors A reading in the red indicates a dirty filter element and it should be replaced Filter elements should last between 6 to 12 months under normal use The must be replaced annually regardless of the incident monitor reading Check correct purge pressure Ensure dryer is cycling without alarms 4 1 2 WEEKLY CHECK Check all mufflers for backpressure at the pressure gauge on a regenerating chamber It should not exceed 1 psig Replace muffler if clogged or dirty Verify heater operation 4 1 3 QUARTERLY CHECK EVERY THREE MONTHS Check operating conditions purge rate line pressure inlet flow Check dryer operating cycle for proper operation of valve operators solenoid valves dump valves heaters pressure switches and temperature controller Check the outlet dewpoint Blow down relief valves Check heater outlet temperature is betw
51. y be necessary for increasing safety or efficiency or in the interests of further product development 1 2 PRODUCT INFORMATION The adsorption dryer is used for the purpose of drying compressed air and other gases according to its contracted design Depending on certain conditions at the inlet and with pre and afterfilters properly installed it provides pure dry and oil free compressed air or gases The standard model of adsorption dryer is equipped with two desiccant vessels This specific model of dryer includes the Ecotronic Control EC energy management system to provide automatic monitoring and control of the dry regenerate cycle to optimize equipment efficiency This manual includes references to optionally available Low Dew Point LDP and 3 valve bypass 3V systems assemblies which may or may not be provided Selected options included with this dryer are indicated on the cover page by an X printed in the box USER MANUAL p Models ZEH400 to ZEH3500 with EC ZANDER 2103522 Rev 06 28 February 2007 1 2 1 PRESSURE VESSEL REGULATIONS The pressure vessels are designed and built to meet the American Society of Mechanical Engineers ASME standards They fulfill the test of the certifying procedure and carry the ASME symbols U or UM RANGE OF APPLICATION Design Pressure Max 150 psig 500 F 260 C Design Temperature Min 20 F 29 C 1 2 2 LEAK TEST Each Zander adsorption dryer is subjected to
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