ZEKS CFX NC Series User manual

TABLE OF CONTENTSPAGE
1.INTRODUCTION1
2.ABBREVIATED WARRANTY1
3.REFRIGERATED DRYER NOMENCLATURE2
4.RECEIVING AND INSPECTION3
5.SAFETY AND OPERATION PRECAUTIONS4
6.PRINCIPLES OF OPERATION7
7.INSTALLATION AND INITIAL START-UP16
8.SCHEDULED MAINTENANCE19
9.TECHNICAIN MODE22
10.TROUBLESHOOTING25
11.WIRING DIAGRAMS27
12.GENERAL ARRANGEMENT 31
13.PARTS IDENTIFICATION32
14.ENGINEERING SPECIFICATIONS35
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, Pennsylvania 19380
610-692-9100 800-888-2323
FAX [phone]
WWW.ZEKS.COM
NCTM500-800NCE-DPC V2/04
NC SERIES NON-CYCLING
NCE MODELS 500 - 800
COMPRESSED AIR SOLUTIONS
TM
PATENT # 6,186,223

1
1.INTRODUCTION
ZEKS’ Non-Cycling refrigerated air dryer removes moisture, oil vapor, and other contami-
nants from compressed air. These contaminants are detrimental to pneumatically
operated equipment, 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 36° and 40°F (2° and 4°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.
2.ABBREVIATED WARRANTY
ZEKS refrigerated dryers are warranted to be free from defects in material and workman-
ship 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.
ZEKSliability 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 AirSolutions. In addition, the usual maintenance and
replacement type products are not covered by this warranty.
HEAT EXCHANGERS
Dryers that utilize CFX heat exchanger technology (HSF, HSG, NCE, NCF & NCG) are
covered for a total of 10 years from the original date of shipment from the factory.
Following the standard warranty terms the available warranty is as stated below. The
exchanger warranty applies to the replacement exchanger only and does not cover any
labor expenses.
Prorated coverage of prices from date of shipment from the factory:
18 to 48 months100%
49 to 60 months70%
61 to 72 months50%
73 to 84 months30%
85 to 96 months20%
97 to 120 months10%
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.

2
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 months70%
25 to 36 months50%
37 to 48 months30%
49 to 60 months 10%
Freight and labor coverage varies internationally. Refer to Distributor Warranty Guidelines
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 implied, except as stated herein.
There are no
implied warranties of merchantability or fitness for a particular purpose, which are specifi
-
callydisclaimed.
3.REFRIGERATED DRYER NOMENCLATURE
NOMINAL*
FLOWDESIGNCONDENSER
SCFM TYPESERIESTYPE VOLTAGE OPTIONS
500, 600 NC= Non-CycleEA = Air Cooled1 = 115-1-60
700, 800W =Water Cooled2 = 230-1-60
3 = 220-1-50
4 = 460-3-60
5 = 230-3-60
6 = 575-3-60
7 = 380-3-50
8 = 220-3-50
9 = 500-3-50
O = STANDARDO = STANDARD
G = GAUGE PACKAGEF = COLD COALESCER
H = NEMA 4/12P = Z-Trol™ Plus Controller
K = H + GZ = NON-STANDARD
L = W + G8 = DPC™- Plus Controller
W = WEATHERPROOF
* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature
and 100 psig compressed air pressure.

3
4.RECEIVING AND INSPECTION
4.1 INSPECTION
Upon receiving your ZEKS air dryer, please inspect the unit closely. If rough
handling has been detected, please note it on your delivery receipt, especially if the
dryer will not be uncrated immediately. Obtaining the delivery person’s signed
agreement to any noted damages will facilitate any insurance claims.
4.2 UNPACKING AND HANDLING
Under no circumstances should any person attempt 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 during shipment, all dryer packages have been mounted on a
base that provides for forklifting between two base channels. Forks should extend all
the way through forklift channels to reduce unnecessary forces to the dryer during
moving. Slings can be used to lift the crates, but spreader bars must be used to
prevent the slings from exerting a force against the sides of the crates or the dryer.

4
5.SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in
operation or maintenance could be hazardous to personnel. In addition to obvious safety
rules that should be followed with this type of machinery, safety precautions as listed
below must be observed:
OSHA
Heading Descriptions
1.Only qualified personnel shall be permitted to adjust,
perform maintenance or repair this air dryer.
2.Read all instructions completely before operating unit.
3.Pull main electrical disconnect switch and disconnect
any separate control lines, if used, before attempting to
work or perform maintenance on the unit.
4.Do not attempt to service any part while machine is in
an operational mode.
5.Do not attempt to remove any parts without first relieving
the entire air system of pressure.
6.Do not attempt to remove any part of the refrigeration
system without removing and containing refrigerant in
accordance with the EPA and local regulations.
7.Do not operate the dryer at pressures in 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.
The user of any air dryer manufactured by ZEKS Compressed Air Solutions, is hereby
warned that failure to follow the above Safety and Operation Precautions may result in
personal injury or equipment damage. However, ZEKS Compressed Air Solutions
does not state as fact, nor does it mean to imply, that the preceding list of Safety and
Operating Precautions is all inclusive, and further, that the observance of this list will
prevent all personal injury or equipment damage.
“Warning” is used to indicate a
hazardous situation which has
some probability of death or
severe injury. Warning should
not be considered for property
damage accidents unless
personal injury risk is present.
“Notice” is used to indicate a
statement of company policy
as the message relates directly
or indirectly to the safety of
personnel or protection of
property. Notice should not be
associated directly with a
hazard or hazardous situation
and must not be used in place
of “Danger,” “Warning,” or
“Caution.”
“Caution” is used to indicate a
hazardous situation which may
result in minor or moderate
injury.
CAUTION
NOTICE
NOTICE

5
Air Under Pressure Will Cause
Injury, Death Or Property Damage.
• Do Not Exceed Pressure Rating.
• Relieve Press. Before Servicing.
• Do Not Modify/Repair/Rework
ASME Coded Pressure Vessels
As Insurance Rating Affected.
! READ INSTRUCTION MANUAL !
HIGH VOLTAGE Can Cause Severe
Injury Or Death.
• Some circuits may be energized
when switch is off.
• Disconnect and lockout ALL
power sources before servicing.
! READ INSTRUCTION MANUAL !
Air Under Pressure Will Cause
Injury, Death Or Property Damage
•
Relieve Press. Before Servicing.
•
Condensate Drain Discharges
Under Pressure.
•
Drain Requires Periodic
Cleaning (Service).
! READ INSTRUCTION MANUAL !
L'air sous pression causera
des blessures graves, des
dégats matériels et peut
même entrainer la mort
Ne pas excéder le taux de
pression
Relâcher la pression avant
la mise en service de
l'appareil
Ne pas modifier/réparer ou
retravailler
Le taux de pression des
vaisseaux est conforme
aux recommendations de l'
ASME ( American Society
of Mechanical Engineers)
et peut être vérifié lors d'un
controle.
LIRE LE MANUEL
D'INSTRUCTIONS!
La haute tension peut
entrainer des blessures
graves ou même la mort
· Certains circuits peuvent
être chargés lorsque l'inter-
rupteur est en position
"fermé" (off)
· Déconnecter et vérouiller
TOUTES les sources d'élec-
tricité avant la mise en
service de l'appareil
LIRE LE MANUEL
D'INSTRUCTIONS!
L'air sous pression
causera des
blessures graves,
des dégats matériels
ou même la mort
Relâcher la pression
avant la mise en
service de l'appareil
Condenser les
tuyaux de décharges
sous pression
Les tuyaux doivent
être nettoyés
régulièrement
(service)
LIRE LE MANUEL
D'INSTRUCTIONS

6
Removing fuses will not
disconnect power from
dryer. Always disconnect
power from ALL sources
before performing service.
! READ INSTRUCTION MANUAL !
WARNING
ELECTRICAL CONNECTION BOX
CONTAINS HIGH VOLTAGE
•Turn Off Power And Lock Out At ALL Sources Before Opening
To Perform Service.
•Remote Alarm Contact Wiring Has Control Power From Separate
Source.
! READ INSTRUCTION MANUAL !
ELECTRICAL CONNECTION BOX
•All Customer Connections To Be Made At This Location.
•See Attached Terminal Connection Diagram.
•Be Certain To Follow All NEC, State, Local and Other Applicable
Codes During Installation.
Label Group 2, Page 1 of 2
File: ZEKSLABELGROUP2-1
LA BOÎTE DE CONNEXION
ÉLECTRIQUE CONTIENT DE LA
HAUTE TENSION
· Éteindre et vérouiller Toutes les
sources d'électricité avant la mise en
marche de l'appareil
· Une alarme à distance sera
déclenchée lors de la mise en service
de l'appareil
LIRE LE MANUEL D'INSTRUCTIONS!
ATTENTION !
Retirer les fusibles ne déconnectera pas
l'électricité de l'appareil
TOUJOURS déconnecter toutes les sources
d'électricité avant la mise en marche de
l'appareil
LIRE LE MANUEL D'INSTRUCTIONS!

7
6.PRINCIPLES OF OPERATION
6.1 INTRODUCTION
ZEKS Non-Cycling dryers remove moisture from compressed air by cooling the air
temperature to 36° (2.2°C). This causes vapors to condense into liquid droplets
which can then be easily removed from the air. The major systems of the dryer which
contribute to its operation are the Air System, the Moisture Removal System, the
Refrigeration System and the Controls. The following paragraphs describe each of
the systems in greater detail.
6.2 AIR SYSTEM
The Air System consists of the dryer components which are in contact with the
compressed air. Referring to Figure 1 and following the bold “AIRFLOW,” hot saturated
air from the compressor enters the precooler/reheater where the air temperature is
reduced prior to entering the chiller 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 desired dew point by a
thermal mass fluid. The temperature of the thermal mass fluid is maintained by the
refrigeration circuit and controls. The air continues to the separator where moisture is
removed, thereby, allowing the cool, dry air to return to the precooler/reheater to be
heated by the incoming moist hot air. The air exiting the “reheater” portion of the
dryer should be approximately 15°- 20°F lower than the inlet air temperature based
on standard conditions at full rated flow.
FIGURE 1
FLOW DIAGRAM

8
6.3 MOISTURE REMOVAL SYSTEM
Liquid droplets are removed from the air stream in the separator. As the air and
liquid mixture passes through the separator it spins, slows down and then changes
direction. This causes the condensate to fall out of the air stream and collect in the
bottom of the separator. The collected liquid is removed from the separator by a
solenoid valve. The solenoid valve is controlled by the microprocessor controller as
described in Section 6.For adjustment please note the following:
• To obtain the optimum time values for operation of the solenoid drain valve, set
the off-time to five minutes and the on-time five seconds via the controller. Refer to
Section6 for details.
•
After running the unit under full rated flow for approximately 30 minutes, verify that
when the solenoid drain opens, all of the accumulated liquid is discharged and then
a small 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 there is all liquid and no air has been
discharged, increase the on-time setting or decrease the off-time setting.
•
The on/off time settings will vary according to seasonal operating conditions. During
the summer when more moisture is present in the air system a shorter on-time,
increasing the valve opening frequency, is required. A longer valve off-time may be
used during the winter months when moisture levels are lower.
6.4 REFRIGERATION SYSTEM
The Refrigeration System consists of all the components which handle refrigerant
R404A. This is a hermetically sealed closed-loop system. Referring to Figure 1 and
following the dot-dash “REFRIGERANTFLOW,” refrigerant is shown leaving the chiller
evaporator section, which in the process of removing heat is changed from a low
pressure liquid to a low pressure gas. This gas enters the suction side of the
compressor where it is compressed into a high pressure gas. The high pressure gas
is cooled in the air or water cooled condenser section becoming a high pressure
liquid. It then goes through a permanent filter-dryer that ensures the refrigerant
system is free of contaminants. A thermostatic expansion valve meters the refrig-
erant into the chiller’s evaporator. The pressure is reduced upon entering the chiller
evaporator where it removes heat from the air system. When there are low loads
(low air flow rate or inlet temperature), a hot gas valve by-passes the condenser and
throttling device (capillary tube). This valve maintains a minimum evaporator
pressure of 76 psig, which corresponds to a chiller temperature of 34°F, thus
preventing freeze-up.
6.5 CONTROLS
ZEKS’ 500-800NCE Refrigerated Compressed Air Dryers are equipped with the
Digital Performance Controller (DPC™). This advanced microprocessor-based
controller has been engineered by ZEKS exclusively for use with ZEKS’ Compressed
Air Dryers.

9
For NonCycling dryers, the DPC™ diplays the temperature of the air at the coldest
point in the air stream, providing an indication of the outlet pressure dew point of the
dryer. In addition, the DPC™ permits monitoring of dryer parameters and enuncia-
tion of alarm conditions.
The list below summarize the features the DPC™:
• 1 X 16 Character Backlit LCD Display - Easy-to-read display provides continuous
indication of dryer default parameter. Standard backlight permits viewing of critical
information in low light environments.
• Electronic Drain with On/Off Time Adjustment: Included with DPC™-equipped
HeatSink™ and NonCycle dryers is a solenoid drain valve. Control of the open and
close time of the valve is set via the DPC™ Controller.
• Remote Start / Stop: DPC™-equipped dryers offer a unique remote start / stop
feature. This feature allows the dryer to be operated via a remote user-supplied
switch.
• Remote Alarm Contact: DPC™-equipped dryers include a remote alarm contact to
provide indication of any of the dryers alarms described later in this manual.
Contact rated for 2A / 120V max.
The DPC™ Controller features three levels of access. The default level CUSTOMER
MODE permits adjustment of dryer parameters to address seasonal variations for
drain timing. A protected TECHNICIAN MODE permits access to and manipulation of
additional parameters to address the initial machine set up. A password protected
FACTORY MODE is also included for use by ZEKSService Personnel for
troubleshooting the dryer.
All ZEKS Non-Cycling dryers include a Hot Gas By-Pass (HGBP) Valve to maintain
suction pressure and temperature. This valve is necessary during low load applications
to prevent freeze-up in the chiller section. The normal suction pressure for no load
conditions should never drop below 76 psig. *This setting may need adjustment to
match the load/ambient conditions encountered.
*This adjustment is not a procedure covered under warranty as it is typically required for applica-
tion specific conditions.
FIGURE 2 - HGBP VALVE
For HGBP Valve adjustment note the following:
•Turning the adjustment screw clockwise raises
suction pressure and exchanger temperature.
•Turning the adjustment screw counter-clockwise
reduces suction pressure and exchanger tempera-
ture.
•All adjustments should be made without air flow
(load) on the dryer.

10
Do not rotate Hot Gas By-Pass valve adjustment nut fully clockwise. Full clockwise
rotation may result in refrigerant compressor damage. Any suction pressure setting
above 90 psig is not recommended.
CAUTION
ZEKS air cooled models utilize a microprocessor-controlled fan contactor to control the
condensing temperature. This contactor controls the condensing temperature by
cycling the fan based on refrigerant discharge pressure. When the unit reaches 275
psig, the microprocessor energizes the fan contactor that will run the fan until the
discharge pressure is reduced to 195 psig. On 700NCE and 800NCE dryers, should
the discharge pressure continue to rise, a secondary fan will energize at 335 psig and
continue to operate until the discharge pressure has been reduced to 235 psig.
For water cooled models, a high pressure cut out switch is positioned near the water
regulating valve. The switch is designed to open at 320 psig and close at 270 psig.
The DPC™ controller includes a digital readout for monitoring the discharge
pressure of the refrigerant gas exiting the compressor. This reading will vary
depending upon condenser type as indicated below:
•
Air Cooled condensers with ambient temperatures between 80°F and 100°F, the
refrigerant discharge gauge should read between 275 - 350 psig.
• Water cooled condensers utilize a water regulating valve. The water regulating
valve comes pre-adjusted from the factory at 250 psig discharge pressure.
To compensate for water tempera-
ture variation, it may be necessary
to adjust the water regulating
valve to maintain a 250 psig
discharge pressure. Adjustment
can be done by rotating the
adjusting screw counterclockwise
for an increase in discharge
pressure. For conditions where low
water temperature and/or high
water pressure are expected it is
advisable to install a water pressure
regulator ahead of the condenser.
WEATHERPROOF PACKAGE (OPTIONAL)
Dryers equipped with the optional Weatherproof Package are designed to operate in
ambient conditions as low as 35 °F.
ADJUSTMENT SCREW
FIGURE 3
WATER REGULATING VALVE
Drawing 600562

11
6.5.1BASIC USER INTERFACE
The DPC™ display provides the user with the operating parameters and their
corresponding values. When power is supplied to the dryer, the DPC™ will illumi-
nate and default to the “Standby” mode, displaying the “Press ON” prompt.
The following illustration summarizes the keypad functions.
BUTTONS
• ON
Places the dryer "On Line"; Initiates drain timer; Energizes
refrigeration system.
• OFF
Places the dryer "Off Line"; Stops all automatic functions.
• SELECT DISPLAY
Allows the user to cycle through the available displays.
The last display selected will remain displayed as the
default display.
• + / -
Allows user to increase set point values. Set point values
cycle through a fixed range. Also allows entering negative
numbers in FACTORY MODE.
• TEST
Allows user to manually activate the drain solenoid valve.
• RESET
Pressing once clears the local alarm indication and de-
energizes the remote alarm contact. Should the alarm
condition persist, the alarm will return after the alarm
inhibit time has expired.
• SET
Permits the adjustment of parameters in TECHNICIAN
and FACTORY MODE. In CUSTOMERMODE, allows
user to scroll back through displays.
• ENTER
Used to accept changed parameters and set point
values.
• i
Restricted Level access for factory use only. Not used
for basic dryer functions. Not to be used by customer or
service technician.
CHLLR TEMP: 37

12
6.5.2 DISPLAY PARAMETERS
The DPC™ Controller is capable of displaying a number of system parameters.
The following summarizes the parameters that can be accessed by the user from
the DPC™ Controller depending on the DPC™ version:
•
Chiller Temperature (CHLLR TEMP): The Chiller Temperature is the temperature,
in degrees Fahrenheit, of the air at the coldest point in the air circuit.
• Compressor Status (CMPRSSR): Displays whether the refrigeration compressor
is “ON” or “OFF”.
•
Discharge Pressure (P disch): Displays the discharge pressure of the refrigeration
system.
• Suction Temperature (T suction): Displays the suction temperature, in deg.F, of
the refrigeration system. This value is useful in determining superheat of the
refrigerant. (DPC™-Plus Only)
• Suction Pressure (P suction): Displays the suction pressure, in psig, of the refrig
-
eration system. (DPC™-Plus Only)
• Inlet Air Pressure and Temperature (P AIR IN / T AIR IN): Displays the tempera-
ture, in °F and pressure, in psig, of the inlet compressed air.
(DPC™-Plus Only)
• Outlet Air Pressure and Temperature (P AIR OUT / T AIR OUT): Displays the
temperature, in °F and pressure, in psig, of the outlet compressed air.
(DPC™-Plus Only)
• Drain Interval (DRN INT): Displays the length of time, in minutes, between
operation of the solenoid drain.
• Drain On (DRN ON): Displays the length of time, in seconds, that the solenoid
drain is open.
•
Cumulative Dryer Hours (CUM DRYER HR): Displays the length of time, in hours,
that the dryer has been operational.
Depressing the SELECTDISPLAYbutton repeatedly scrolls through the above
non-adjustable displays. The Customer Set Points appear at the end of the list
and may be adjusted by the end user to match seasonal refrigeration and drain
operation. These settings are as follows:
• Drain Interval (DRN INT)
• Drain On (DRN ON)

13
SELECT
DISPLAYPressing SELECTDISPLAY will increment the display
through the available display parameters.
Depress “ + / -“ as required to change the DRNINT time
to 5 minutes.
Pressing “ENTER“ saves the set point.
6.5.4 ADJUSTING SET POINTS
Accessing and manipulating each of the set points in the CUSTOMER MODE is
accomplished as follows. The parameter is selected using the SELECTDISPLAY
button. After scrolling through the displays, the “Cust Set Points” screen is
displayed. The parameters after this screen may be adjusted by the user. Once
the desired parameter is displayed, depressing the “+/-” button changes the set
point. Once the new set point is displayed, depressing ENTER saves the set point.
Exiting the Customer Set Point routine is accomplished by depressing the SELECT
DISPLAY button until the ENDCUSTSETPTS screen is displayed. The following
example illustrates the keystrokes required to change the Drain Closed Time from
the default value of 3 Minutes to 5 Minutes:
6.5.3DRYER SET POINTS AND ALARMS
The DPC™ Controller has several user adjustable set points that are displayed at
the end of the display parameter list. These set points allow the user to configure
the dryer to operate according to site conditions. The controller is shipped from the
factory with each parameter having its own default value. The following chart
summarizes the parameters that may be adjusted by the user:
Display Parameter
SETPOINT
Description Range HeatSink NonCycle
Drain Interval Time DRN INT 3, 5, 10, 15, 20, 30, 60 min 3 MIN 3 MIN
Drain On Time DRN ON 3, 5, 7, 10, 12, 15 , 20, 30 sec. 10 SEC 10 SEC
Chiller Off Temperature CHLLR TEMP 32°F - 50°F; 1 °F increments 34°F INACTIVE
Factory Setpoint
ENTER
DRN INT: 5 min
SELECT
DISPLAYPress SELECTDISPLAY as necessary to display the End
Customer Set points Screen.
End Cust Set Pts
DRN INT: 5 min
+
-
CHLLR TEMP: 36
SELECT
DISPLAY
Continue pressing SELECTDISPLAY until the Customer
Set point screen is displayed. The parameters that follow
are the User Adjustable Parameters for the controller.
Cust Set Points
SELECT
DISPLAYPress SELECTDISPLAY until “DRNINT” is displayed.
DRN INT: 3 min
SELECT
DISPLAYPress SELECTDISPLAY as necessary to return the DPC to the desired display parameter.
CHLLR TEMP: 36

14
The alarm names and a brief description of each are described in detail below.
Note that some alarms will enunciate only after a prescribed alarm delay. Refer to
the TECHNICIANMODE sectionof this manual for factory default alarm delay
periods.
HIGH TEMPERATURE ALARM (HITEMP ALARM)
When the air temperature at the inlet to the separator reaches the factory alarm set
point, after an alarm delay, the alarm will be activated. This alarm condition that
may not necessarily damage the dryer when subjected to long-term exposure. It
may, however, have a significant impact on downstream processes and thus should
be investigated upon detection. Note that this alarm will not shut down the dryer.
This alarm will reset automatically once the alarm condition is rectified.
LOW TEMPERATURE SAFETY ALARM (LOWTEMPALARM)
If the dryer chiller temperature falls below the factory set point and remains below
this set point for the alarm delay time, the alarm routine will activate. This alarm
condition may cause damage to the dryer when subjected to continuous or long-
term exposure. Note that this alarm will shut down the dryer after a response time
delay. This alarm will reset automatically once the alarm condition is rectified.
HIGH PRESSURE CUTOUT ALARM (HI PRESS CO)
If the discharge pressure of the refrigerant is determined to be above the set point,
the alarm routine will activate. This alarm condition may cause damage to the
dryer when subjected to continuous or long-term exposure. Note that this alarm will
shut down the dryer after a response time delay. The operator must depress the
RESET button in order to clear the alarm and restart the refrigeration system.
Alarm Display Alarm Set Point
HIGH PRESSURE CUTOUT HI PRESS CO See Table 1
HIGH TEMPERATURE ALARM HITEMP ALRM 55 °F
LOW TEMPERATURE ALARMLOTEMP ALRM 30 °F
HIGH DRAIN LEVEL ALARM DRAIN LVL ALARM N/A
6.5.5ALARMS AND THEIR FUNCTIONS
There are several alarms detected by the DPC™ to alert the user of an out of
tolerance condition. Once each alarm is detected, a description of the alarm will
appear in the screen and the remote alarm contact will close. Note that during the
alarm condition, the SELECTDISPLAY button may be depressed to scroll through
the available parameters. After approximately 30 seconds, the alarm screen will
reappear, provided the alarm condition persists.

15
HIGH DRAIN LEVEL ALARM - OPTIONAL (DRAIN LVL ALARM)
On dryers equipped with the optional High Drain Level Alarm, should condensate
rise to a predetermined level in the separator, a liquid level switch will signal the
DPC and the High Drain Level Alarm will enunciate. In addition to indicating the
alarm on the LCD and closing the remote alarm contact, the High Drain Level
Alarm will open the solenoid drain in an attempt to correct the problem. The
condition must be addressed to reset the dryer.
6.6.6START MODES
ZEKS dryers are capable of starting in one of three start modes. Note that to
protect the refrigeration compressor from repeated rapid starts, the DPC™ is
equipped with an an anti-short cycle (ASC) delay. The ASC delay will countdown
from the factory set point (see TECHNICIANMODE). Only after the ASC delay
has timed out will the refrigeration system operate. Below are brief descriptions of
these various start modes.
6.6.6.1 Manual Mode
ZEKS dryers are shipped from the factory in the Manual Mode. After power is
supplied to the dryer, the user will be presented with the ASC delay, followed by
the “PRESSONBUTTON” display. After the ASCdelay has timed out, the dryer
will only start once the ONbutton is depressed. In this configuration, to restart the
dryer, the user must manually depress the ON button on the dryer’s control panel.
6.6.6.2Auto Restart Mode
After power is applied to the dryer, and once an anti-short cycle delay has timed
out, the dryer will start automatically. In addition, this mode of operation allows
manual control of the dryer via the ON & OFF pushbuttons. This is useful for
applications where automatic restarting of the dryer is desired after a power failure
has occurred.
6.6.6.3Remote Automatic Mode
This mode of operation allows the user to control the dryer remotely and requires
the installation of a customer-supplied contact. With power applied to the dryer
and once the anti-short cycle delay has timed out, the dryer will start automatically
once the switch is closed. In addition, this mode of operation allows manual control
of the dryer via the ON & OFF pushbuttons.
Parameter R-22 R-404A R-407C
FAN 1 ON 235 psig 275 psig 235 psig
FAN 1 OFF 195 psig 195 psig 195 psig
FAN 2 ON 265 psig 335 psig 265 psig
FAN 2 OFF 210 psig 235 psig 210 psig
HPCO (Air Cooled) 400 psig 450 psig 400 psig
HPCO (Water Cooled) 320 psig 320 psig 320 psig
TABLE - 1

16
Failure to comply to the above instructions may result in equipment malfunction
and will void warranty.
Always use a backup wrench when making any threaded connection to the dryer.
Failure to use a backup wrench may result in damaged tubing and components
internal to the cabinet.
7.2 PIPING AND VALVES
Install piping, fittings and accessories as required for specific site conditions and
requirements. Figure 3 indicates a typical piping arrangement for a refrigerated dryer,
including dryer and filter bypasses. This figure can be used as a guide for valve and
accessory placement in the system.
ZEKS 500 through 800 NCE models come factory installed with a drain isolation
valve (D). The isolation valve permits maintenance of the automatic drain without
isolating air flow to the dryer. To operate dryer, all valves shown in Figure 4 are to be
closed except valves (B), (C) and (D). Valve (A) is used for bypass purposes and
valve (E) is for test and manual drain purposes.
7.3 FILTRATION
To protect the air dryer from gross contamination associated with compressor oil and
debris and ensure maximum dryer performance, a prefilter is recommended.
Prefilters and afterfilters sized to your drying application can be provided by ZEKS
and are available factory installed. Call your local distributor to select the filter that
best suits your filtration requirements. In addition to air filtration, condensate
discharge oil/water separators are also available to address stringent EPA regula-
tions.
7.INSTALLATION AND INITIAL START-UP
7.1 LOCATION AND MOUNTING
The dryer should not be located in an area where ambient temperature is likely
to exceed 113°F (45°C) or be less than 50°F (10°C). The dryer must be located in
an area that provides sufficient clearance from walls and other adjoining equipment
to allow easy access for servicing and maintenance requirements. A minimum of
18 inches is required to allow free flow of air to the condenser inlet.
On installations with a relatively steady flow rate, the dryer is normally connected
after the air receiver. If loads fluctuate widely, the dryer should be positioned ahead
of the receiver and sufficient storage capacity 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, proper vibration isolation and pulsation
dampening devices should be added to protect the dryer.
NOTICE
NOTICE

17
FIGURE 4
TYPICAL PIPING ARRANGEMENT
AIR
DRYER
OIL
SEPARATOR
DRAIN
VALVE
CHECK
VALVE
CHECK
VALVE
CHECK
VALVE
DRAIN
VALVE
CHECK
VALVE
PREFILTER
B
A
CAIR OUT
AIR IN
UNIT AS DELIVERED
OPTIONAL ACCESSORY ITEMS
NOTE: DRAIN TUBE MUST NOT RISE OR BE CONNECTED TO
EXCESSIVELY LONG PIPE WHICH MAY CREATE BACK PRESSURE
A CONNECTION TO OPEN FLOOR DRAIN IS REQUIRED
DE
7.4 ELECTRICAL CONNECTION
Equipment is available in various electrical configurations. All customer connections
can be made at the terminal connections located in the customer electrical connec-
tion box on the rear of the dryer. (Refer to General Arrangement and appropriate
Wiring Diagrams.)
A suitable fused disconnect switch or circuit breaker, in accordance with national and
local code requirements, is recommended for all ZEKS equipment. Refer to the
Engineering Specifications Section for voltage requirements and load.
7.4.1ZEKS dryers can be configured for three variations of start modes: Manual Mode,
Automatic Mode and Remote Mode. The instructions below describe the methods
to configure the dryer for a particular Start Mode.
A) Manual Mode (Factory Default) - No modification required to operate dryer in
Manual Mode. Once power is applied, dryer can be started or stopped by
depressing the local ON / OFF pushbuttons located on the front panel.
Never wire directly or connect any additional wires to the compressor
junction box. This will cause severe system malfunction.
CAUTION

18
7.5 INITIAL START-UP
For water cooled models, the water valve must be manually opened
to ensure that the condenser is full of water prior to start-up.
7.5.1START- UP SEQUENCE
• Apply power to dryer. LCD Panel will illuminate. The Anti-Short Cycle delay will
commence counting down.
After installation or a prolonged shutdown, start the dryer with no air load (no air flow).
This enables the dryer to reach its proper operating temperature in the shortest time
possible (typically within 5 minutes for NonCycle™ dryers).
B) Auto Restart Mode - Auto Restart Mode permits the dryer to start after a brief
delay once power is applied to the dryer. In TECHNICIAN MODE, changing the
Auto Restart parameter from the default “N” to “Y” using the SET button enables
this mode of operation. Note that the dryer’s touch pad will still affect dryer
operation. Depressing the OFF button will de-energize the refrigeration
compressor and all other electrical components. After the OFF button has been
depressed, the user must depress the ON button to permit the dryer to operate.
C) Remote Mode - Remote Mode allows the dryer to be turned ON or OFF via a
remote switch supplied by the customer. This mode will work regardless of the
setting for Auto Restart. The dryer must be powered on for this feature to take
effect. To enable this feature:
•
Install N.O. remote switch as indicated on the appropriate wiring diagram.
•
Customer-supplied contact should be rated at 1A at 24V. To operate dryer,
close switch or contact and allow dryer to start after an initial delay. The
local On / OFF pushbuttons may also be used at any time after contact
closure.
NOTICE
NOTICE

19
8.0SCHEDULED MAINTENANCE
8.1 INTRODUCTION
ZEKS NonCycle refrigerated air dryers require little maintenance. These dryers
utilize hermetically sealed compressors which do not require any lubrication. Fan
motors require lubrication at both oil ports every six months. ZEKS recommends
component inspection and service at regular intervals to obtain maximum perfor-
mance from your dryer.
8.2 REFRIGERANT CONDENSER
ZEKS dryers are equipped with an ambient air filter designed to protect the
condenser from dirt and debris that can accumulate on the condenser. For proper
operation, it is imperative that this filter be inspected and cleaned on a regular basis.
Annual replacement of the filter is recommended. For applications where excessive
dirt, dust or debris is encountered, more frequent inspection and cleaning may be
required.
• Start Dryer, using one of the following methods, depending on Start Mode setting:
Manual Mode - Press the ON pushbutton.
Auto Restart Mode - No additional action required
Remote Automatic Mode - Close the remote contact.
• For NonCycle dryers, after the initial delay has timed out, the compressor is
energized. The suction pressure gauge will typically pull down between 76 and
85 psig. The Hot Gas By-Pass Valve may require adjustment on start-up. Refer
to dryer’s Technical Manual for details.
After 5 minutes, slowly introduce air flow to the dryer.
After the alarm delay, provided the Chiller Temperature is greater than the HIGH
TEMPERATUREALARM set point, the dryer will go into HIGHTEMPERATURE
ALARM. The LCD panel will indicate the alarm and the refrigeration system will
continue to operate. Pressing the SELECTDISPLAY button will permit viewing of
the available dryer parameters during this alarm condition. Note that the alarm
condition screen will reappear after approximately 30 seconds until the alarm
condition is cleared.
The CHILLERTEMPERATURE will gradually drop as indicated on the display.
Once the temperature falls below the HIGHTEMPERATUREALARM set point, the
alarm will reset and the LCD panel will return to its default display.
Drain settings should be checked as described earlier in this manual and the
dryer’s Technical Manual.