Parker 20-606 User manual

Installation, Operation
and Maintenance Manual
Electronic
Condensate Drain
20-606
20-613
20-623
CELL:ASSY
TI-20600
Parker Hannifin Corporation
Industrial Gas Filtration and
Generation Division
4087 Walden Avenue
Lancaster, NY 14086
Tel: [phone] Fax: [phone]

Manufacturer's Declaration
Parker Hannifin Corp., Filtration and Separation Division,
242 Neck Road
Haverhill, MA 01835
herewith declares that the products
electronic condensate drain models 20-606, 20-613, 20-623
are ETL listed
conform to ANSI/UL STD 508
are certified to CAN/CSA STD C22.2 NO.14
ETL LISTED
CONFORMS TO
ANSI/UL STD 508
CERTIFIED TO
CAN/CSA STD C22.2
NO.14
3104761
FCC Compliance
The condensate drain series ZLD-006 to ZLD-330 is, according to the
manufacturer/applicant, primarily intended for use in industrial plants as "digital
devices" and "unintentional radiators". Therefore the drain series falls under the
category of exempted devices, according to FCC, CFR 47, 915.103 b).
Only the general requirement that a device must not emit electromagnetic
disturbances are to be fulfilled, and fulfilment is confirmed through an EMC report
according to the European EMC requirements for the CE mark.
2

General Information
About this operating manual
Signs and symbols
►Procedures that must be completed in the indicated sequence are numbered.
Items in lists are highlighted with grey boxes.
Note:
Always comply with these instructions to ensure safe and efficient
operation of the machines and devices.
Caution!
These safety notes help prevent damage to property and must always be
adhered to.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these operating instructions
This operating manual is intended for all persons who work with the condensate
drain. We assume that these persons have technical qualifications, e.g. as pipe-
fitters or electricians.
About your safety
Please observe the following general safety instructions:
Caution!
All maintenance work must be completed by suitably qualified and
authorized specialist personnel.
Risk of injury from escaping compressed air!
Never remove any parts of the condensate drain or perform any
maintenance as long as the unit is pressurized! Rapidly escaping
compressed air can cause serious injuries.
Prior to any work, depressurize the unit, and verify that it has been
depressurized.
Warning! Risk of injury from electrical voltage
All work on electrical components must be carried out by suitably
qualified specialist personnel!
3

Proper use of the condensate drain
The condensate drain must only be used for the removal of standard
condensates (condensed water and liquid oil) from compressed air systems. Any
other use is deemed improper.
4

Technical Description
Overview
Power connection
Top condensate inlet, or vent
(revolving)
Lid with test button and signal LED
Optional connection: potential-free
contact*
Bottom condensate inlet*
(not visible in diagram)
Condensate outlet
* not available in model 20-606 and 20-613
Function
The condensate enters the unit through the inlet (1 or 2) and collects in the
collecting chamber (3). When the collecting chamber is completely filled with
condensate (4), the condensate is drained through the outlet (5) until the
chamber is emptied. An integrated flow regulator (6) prevents rapid
depressurization when the valve is opened, ensuring smooth and quiet drainage
of the condensate.
The different condensate drain statuses are indicated by an LED in green,
orange and red. A green LED indicates normal and trouble-free operation. An
orange LED indicates that no condensate has been drained for a period of 15
hours. After condensate has been drained off, the LED changes to green.
5

The LED flashes slowly in red if the condensate cannot be drained off within the
set time and an internal cleaning program has been started. After successful
cleaning the drain returns to normal operating mode. If the cleaning program
cannot be completed successfully, an emergency program is started and an
alarm signal is issued (LED flashing rapidly in red).
Installation
All work at the pipelines and on the electrical components must be carried
out by authorized and suitably qualified technical personnel.
Requirements for installation
For proper installation of the condensate drain, the operator must provide the
following:
Proper connections and lines for the condensate inlet and outlet. For a list of
connection sizes, please refer to the technical data on page 17.
All lines and connections must be adjusted to the actual operating pressure.
Use only ball valves as shut-off valves.
Ensure that the condensate drain is connected to the correct electrical
voltage.
Basic requirements for installation
When installing the condensate drain, observe the following general instructions:
Avoid plumbing multiple
condensate lines into one
drain!
If condensate needs to be
drained at several locations,
separate condensate drains
should be used. Otherwise,
undesired flow will occur.
incorrect correct
6

Observe downward slope
into the condensate drain!
Ensure that the condensate
line entering the drain is
properly sloped in a
downward manner.
Otherwise, an air bubble
might prevent condensate
from entering the drain.
incorrect correct
Install vent line!
If the bottom condensate
inlet is used, install a vent
line. Otherwise, air bubbles
trapped in the condensate
inlet piping might prevent
condensate from entering
the chamber.
incorrect correct
Observe levels!
The switching level of the
condensate drain must be
lower than the vessel.
Otherwise, condensate
might be backed up in the
vessel.
incorrect correct
Prevent carry-over of
condensate!
Straight pipelines might
lead to carrying over of
condensate. Install suitable
condensate traps (driplegs).
incorrect correct
7

Connection of condensate inlet
20-606 and 20-613 are equipped with a top condensate inlet only, while model
20-623 has a revolving top inlet and a bottom inlet for condensate.
Note:
For installation, we recommend using the appropriate Parker
installation kit consisting of a ball valve with fittings.
Use open-ended spanner!
Never turn the condensate
drain to install it into the
pipeline! Always use an
open-ended spanner to
install the condensate drain.
wrong right
Installation of 20-606
►Under certain circumstances, the 20-606 can be mounted directly onto the
filter bowl. Ensure that the drain is in vertical position (maximum permissible
deviation from perpendicular: +/- 5 %).
The integrated vent ensures proper condensate inlet to the collection chamber.
Installation of 20-613 and 20-623
►Turn the upper inlet piece to the desired position:
—Pull pin.
—Turn inlet piece.
—Push back pin.
►Select the condensate inlet connection to be used.
►Ensure that the drain is in vertical position (maximum permissible deviation
from perpendicular: +/- 5 %).
►Connect condensate inlet connection to feed line. Install vent line, if required.
►Check connections for leakage.
8

9
Connection of condensate outlet
The condensate drain delivery includes a 0.3-0.4 in hose tail.
Note:
The water column in the condensate outlet should not exceed 6.5 ft.
The condensate outlet lines should not be pressurized but open.
►Connect the condensate outlet to the condensate drain line.
Connection to power supply/potential-free contact
Warning! Risk of injury from electrical voltage
All work on electrical components must be carried out by suitably
qualified technical personnel!
Model 20-623 is equipped with a potential-free contact, in addition to the main
power connection (not available for 20-606 and 20-613). Model 20-623 therefore
features two connections with matching adapters:
Adapter for supply voltage: magnetic valve connector "type B plug" industrial
standard (0.43 in) 2 + PE (see figure, item 1)
Adapter for potential-free contact: magnetic valve connector "type C plug"
industrial standard (0.37 in) 3 + PE (see figure, item 2)
Connection to supply voltage
Beware of electric shock in case of a fault!
The drain features a ground connection. Its purpose is to provide a safety
cut-out of the condensate drain in case of an error, provided that the drain
is plugged into a ground fault circuit interrupter has been installed in the
electrical line.
Otherwise there is the risk of an electric shock in case of moisture
penetration.
We absolutely recommend that you install a ground fault circuit
interrupter in the power supply line prior to connecting the condensate
drain.
►Attach type B plug to the cable. Observe pin assignment (see figure).

10
Supply voltage
Supply voltage
1
2
Earth ground
Type B plug supply voltage
►o the power adapter of the drain and screw it tight.
at
ort circuits by means of fuses or circuit breakers.
Connecti
e potential-free contact is protected by a cover.
see figure to the right).
Push plug with seal int
►Install a ground fault circuit interrupter, and plug the drain into the ground
fault circuit interruptor.
►In all phases the condensate drain must be connected to electrical lines th
are protected against sh
on of potential-free contact
The connecting socket of th
►Remove the cover (1) (
►Attach type C plug to the cable. Observe pin
assignment (see figure below).
1 NO (normally open)
NC (normally closed)2
3 Common
Earth ground (24 V only)
Type C plug: potential-free contact
Push plug with seal into the adapter of the potential-free contact and screw tight.
24 V connect
ransformer to generate the low voltage for the 24 V
ion
►Use a UL listed class 2 t
power supply.
This will exempt the unit from a safety inspection in line with ANSI/UL or
CAN/CSA.

Startup of the Condensate Drain
►Apply power to the drain.
The system initialization program is started. During this period, the LED flashes at
short intervals. When the process is completed (after approx. 3 seconds) the
green LED is constantly on.
►Pressurize the drain.
►Ensure that condensate enters the drain.
►Inspect connections for leakage.
►Press the test button to open the valve. If you can hear a low flowing noise,
your drain is working properly.
The condensate drain is now ready for operation.
If the potential-free contact is used:
complete function test
The potential-free contact is a standard integrated feature of the condensate
drain (not in model 20-606 and 20-613). To complete a function check at the
contact, proceed as follows:
►Disconnect the unit from the power supply.
If there is an alarm signal, the potential-free contact is working properly.
►Reconnect the unit to the power supply.
Note:
The internal relay of the potential-free contact is normally activated
when power is applied, and inactivated in alarm mode.
11

Monitoring of the Operation
Danger of slipping!
Water will condense on the drain’s outside when the condensate in the
drain is colder than the environment.
A puddle may form underneath the condensate drain if the condensed
water drops to the ground. Use an appropriate collecting device to reduce
the danger of slipping.
Note:
The unit is not equipped with an ON/OFF switch and it must be
constantly connected to the power supply at all times (including
weekends). Disconnection is only permitted for maintenance
purposes. When the power supply is interrupted, the condensate
drain issues an alarm signal.
The condensate drain is a fully automated device. Its operation and statuses can
be monitored by observing the LED, so that disruptions and malfunctions are
immediately detected. The LED signals and their significance are listed in the
table below.
LED
colour LED signal Description
flashing at long intervals Valve active, condensate is being
drained
green
permanently on Drain ready for operation
orange permanently on Warning signal (not an alarm signal):
No condensate has been drained for
15 hours
flashing at long intervals Cleaning program activated
flashing at short intervals Emergency program activated (alarm)
red
permanently on System error (alarm), drain defective
12

Test button
The test button is used to
open the valve manually;
release the pressure from the condensate drain.
The table below provides an overview of the test button functions:
Interval and action Response
Press and release test button Valve opens and closes
Press and hold test button for max. 3 seconds Valve opens and closes
Press and hold test button for more than 3
seconds
Valve opens and closes
automatically after 3 seconds
Press and hold test button for 5 seconds
(alarm reset)
Valve remains closed; LED
flashes fast in green: all
alarms are reset.
Malfunction of the condensate drain
Malfunctions or failure of the drain are indicated by
red LED, flashing at long intervals
red LED, flashing at short intervals
red LED, permanently on
If the condensate drain does not work properly, it is automatically cleaned. During
the cleaning process, the red LED is flashing at long intervals, indicating that the
program tries to remove contamination and unblock the lines by pumping. After
successful cleaning, the drain is emptied and is then automatically reset to
normal operation. If cleaning is not succcessful, the drain is switched to the
emergency program, which is indicated by the red LED flashing at short intervals
(alarm). If the red LED is permanently on, there is a system error. The
condensate drain is defective and must be replaced.
13

Maintenance
Caution!
Maintenance work may only be carried out by authorized and suitably
qualified technical staff. Prior to any maintenance work, depressurize the
drain, verify that it has been depressurized, and remove the voltage
source.
Cleaning of dirt screen (only necessary with highly contaminated
condensate)
If condensate that is contaminated more than usual is drained, regularly clean the
dirt screen.
►For this purpose, close the compressed air vent line and the condensate
inlet.
►Repeatedly press the test button until no flow noise is audible (depressurizing
the drain).
►Disconnect the power supply (remove the plug from the adapter).
►Dismantle condensate outlet by loosening nut (1) and pulling off the hose tail.
►Disconnect the drain:
—20-606:
remove the condenate drain with complete filter base. The condensate
inlet can be turned.
—20-613 and 20-623:
Loosen optional screw connections and remove the drain.
►Loosen the screw of the dirt screen (2)
and pull it out of the unit.
►Clean dirt screen.
►Rinse drain through the top
condensate inlet (3) to remove any
other dirt
In this way, all dirt can be removed without
having to completely dismantle the entire
condensate drain.
►Insert and secure dirt screen.
►Reinstall condensate drain in the
system.
Sectional drawing of condensate drain
►Reconnect condensate outlet and power supply. Open the compressed air
vent line and the condensate inlet.
►Restart the drain.
14

Annual maintenance
Every 8,000 operating hours or once every 12 months (whichever occurs first), a
number of parts in the condensate drain must be replaced as a precaution
(normal preventive maintainance). For this purpose, Parker has assembled the
ZLD-SK service kit containing these replacement parts (seals, springs,etc.).
When replacing these parts, strictly follow the instructions in the maintenance
manual included in the service kit.
Technical Data
Model
20-606 20-613 20-623
Flow rate1
Compressor aftercooler (SCFM) — 141 247
Refrigeration dryer (SCFM) — 282 494
Filter2(SCFM) 424 1410 2470
Nominal flow rate (ft3/h) 0.035 0.074 0.13
Operating pressure range 3–232 psig
Temperature range 35–140 °F
Electric data
Supply voltage3(selectable) 115 V/50–60 Hz (UL version)
24 Vac/50–60 Hz
24 V DC (available on request)
Potential-free contact4— 110 V DC, 250 V AC
1 A
30 W DC, 250 VA AC
Power consumption: Standby
Valve operation
1 VA
6 VA
1.8 VA
6.8 VA
Protection class IP 65
1at 14.5 psi and 68 °F, operating pressure 100 psi, suction: compressor 77 °F at 60 % rel. humidity,
compressed air outlet temperature at aftercooler 95 °F; refrigeration dryer dewpoint 37.4 °F
2Main condensate alreadly drained from aftercooler or refrigeration dryer; only for resdidual oil or low condensate
volumes arising from condensation.
3Magnetic valve connector type B industrial standard (0.43 in) 2+PE
4Magnetic valve connector type C industrial standard (0.37 in) 3+PE
For dimensions and connection sizes, see dimensional drawings.
15

Dimension Drawings
20-606
20-613
16

20-623
Model
20-606 20-613 20-623
Dimensions (in)
A1 4.33 3.97 4.80
A2 4.21 4.37 4.84
A3 0.47 0.47 0.47
A4 — 2.87 3.66
A5 — — 1.94
B1 2.63 2.63 2.63
B2 1.96 — —
C1 5.74 5.47 6.45
C2 5.03 4.76 —
C3 4.17 4.21 4.88
C4 1.73 2.63 —
Weight (lbs.) 1.10 1.32 2.20
NPT connections at condensate inlet
top inlet 3/8” 1/2”
vent integrated in connection 1/8”
bottom vent — — 1/2”
Connection at condensate outlet
3/8” BSP or 0.3–0.4 in hose tail
17

18

19

Parker Hannifin Corporation
Industrial Gas Filtration and
Generation Division
4087 Walden Avenue
Lancaster, NY 14086
Tel: [phone] Fax: [phone]
www.parker.com/igfg