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MODELS
OS300 THRU OS2501
COMPRESSED AIR SOLUTIONS
TM
ZEKS Compressed Air Solutions
1302 Goshen Parkway
West Chester, Pennsylvania 19380
610-692-9100 800-888-2323
FAX 610-692-9192
WWW.ZEKS.COM
OS-0604a
TABLE OF CONTENTS PAGE
1. INTRODUCTION 1
2. ABBREVIATED WARRANTY 1
3. OIL/WATER SEPARATOR NOMENCLATURE 1
4. RECEIVING AND INSPECTION 1
5. SAFETY AND OPERATION PRECAUTIONS 2
6. PRINCIPLES OF OPERATION 3
7. INSTALLATION AND INITIAL START-UP 3
8. SCHEDULED MAINTENANCE 4
9. PARTS LIST 5
1. INTRODUCTION
The ZEKS OS Series Oil/Water Separators have been specially developed to separate oil from condensate
extracted from compressed air systems and is effective with all types and makes of compressors, oils and drain
valves. Lubricant carryover in the separated water is 10ppm or lower.
Polyglycol models, indicated by (PG), require a Polyglycol Absorption element for Tower #1. The Carbon
Finishing Element for Tower #2, and the Carbon Finishing Element for the OSEXT, do not change for Polyglycol
applications.
For applications greater than 1250 scfm, the OSEXT can be added to an OS1251 to increase condensate han-
dling capacity up to a 2,500 SCFM system. The OSEXT model can not be utilized as a stand alone oil/water
separator.
2. ABBREVIATED WARRANTY
ZEKS OS Series Oil/Water Separators are warranted to be free from defects in material and workmanship for a
period of 12 months from date of start-up but not to exceed 18 months from date of shipment from the factory.
This warranty covers replacement parts. Labor coverage does not apply. Normal maintenance such as drain
cleaning and consumable element replacement are not covered by this warranty.
3. OS OIL/WATER SEPARATOR NOMENCLATURE
Model Number Air Compressor Capacity Application
OS300 Up to 300 scfm Mineral, Synthetic, Semi-Synthetic Oils,
Stable Emulsions
OS300PG Up to 300 scfm Polyglycol
OS751 300-750 scfm Mineral, Synthetic, Semi-Synthetic Oils,
Stable Emulsions
OS751PG 300-750 scfm Polyglycol
OS1251 750-1250 scfm Mineral, Synthetic, Semi-Synthetic Oils,
Stable Emulsions
OS1251PG 750-1250 scfm Polyglycol
OS2501 1250-2500 scfm Mineral, Synthetic, Semi-Synthetic Oils,
Stable Emulsions
OS2501PG 1250-2500 scfm Polyglycol
OSEXT* Extends Absorption time
*OSEXT is added to an OS1251 and OS1251PG to increase the handling capacity up to 2500 scfm.
4. RECEIVING AND INSPECTION
Upon receiving your ZEKS Oil/Water Separator, please inspect the unit closely. If rough handling is detected,
please note it on your delivery receipt, especially if the separator will not be put in to service immediately.
Obtaining the delivery person’s signed agreement to any noted damages will facilitate any incurance claims.
1
5. SAFETY AND OPERATION PRECAUTIONS
Because components of the Oil Water Separator are connected to pressurized equipment, the same precau-
tions 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 equipment.
2. Read all instructions completely before operating unit.
3. Do not attempt to remove any parts without first relieving the entire
air system of pressure or isolating unit from
pressure source.
4. Do not attempt to service any part while machine is in an opera-
tional mode.
5. Do not operate the separator under conditions in excess of its rat-
ing.
6. It is a violation of the Clean Water Act to discharge com-
pressed air condensate into a storm sewer or into a
body of water. Treated compressed air condensate may be legally
discharged into a storm sewer system provided the ppm concentra
tion is within the legal limits of the governing body of that sewer dis
trict. Consult your local sewer authority to determine the maxi
mum acceptalbe ppm limit.
7. Inspect unit daily to observe and correct any unsafe operating con-
ditions.
8. User must comply with all applicable regulations when
disposing of lubricant-contaminated filters or equipment.
NOTICE
“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 per-
sonal injury risk is present.
NOTICE
“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 haz-
ard 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.
The user of any Oil Water Separator sold by ZEKS Compressed Air Solutions, is hereby warned that
failure to follow the above Safety and Operation Precautions may result in personal injury or equip-
ment or environmental 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.
2
CAUTION
6. PRINCIPLES OF OPERATION
Oil-lubricated compressors create lubricant aerosols that combine with the water vapor that is present in the
compressed air. Regulations require that the condensate be separated for safe discharge into surface water,
sanitary sewers and wastewater treatment plants.
ZEKS OS Series Oil/Water Separators collect discharged condensate from the compressed air system.
Condensate enters the unit through the inlet ports and flows through the depressurization chamber where any
air that accompanied the condensate is separated and released to atmosphere. Condensate enters the
Absorption Tower (Tower #1) where the oil is absorbed by the element. The remaining condensate enters the
Carbon Finishing Tower (Tower #2) where any remaining oil residue. Condensate is then released to the
drainage system.
7. INSTALLATION AND INITIAL START UP
7.1 UNPACKAGING AND LOCATION SELECTION
Open the packaging for the OS Series Oil/Water Separator and remove the lids from Tower #1 and Tower #2.
Using normal lifting precautions, remove the Absorption Element (large white element) from Tower #1 and the
Carbon Finishing Element from Tower #2. Place lids and elements aside. The OS Series Oil/Water Separators
are designed to easily fit against a wall or in a corner. Select a location where both the condensate drain lines
from the compressed air system and the OS Oil/Water Separator Drain outlet can be conveniently installed
without the possibility of becoming damaged or kinked. Position the unit with the TEST port to the front.
Connect the provided TEST Valve and outlet nipple to the appropriate ports as indicated on the OS
Series unit. Do not over-tighten connections.
7.2 CONNECTION AND ASSEMBLY
Connect the condensate lines to the 1/2” inlet(s) located on top of the unit. Screw plugs (not provided) should
be used to seal the inlet ports that are not going to be utilized.
Connect the 1/2” drain outlet connection to a suitable drain. The drain line needs to be installed without obstruc-
tion and in a manner that will allow for unpressurized condensate flow. Testing shows that lubricant carryover in
the separated drain water is less than 10ppm or lower. Check local codes for applicable drainage requirements.
Install the Carbon Finishing Element in to Tower #2. Push the element to the bottom of the vessel and confirm
that the outlet drain port is not obstructed.
Confirm that there is no harmful pressure in the condensate lines from the compressed air system.
WARNING
3
If time permits, the Carbon Finishing Element should be allowed to soak in water for a period of 24
hours prior to installation. Though not necessary, soaking of the Carbon Finishing Element will pre-
vent carbon dusting from occurring within Tower #2 of the unit. Carbon dusting is completely harm-
less to the OS Series Oil/Water Separator and drainage systems.
NOTICE
Normal lifting precautions need to be observed when servicing the ZEKS OS Series Oil/Water
Separators. Failure to observe lifting precautions may result in personal injury. Elements will be sat-
urated with oil and condensate and therefore will be heavy. Protective clothing and gloves should
always be worn when servicing the units.
WARNING
Remove the foam depressurization pad from from the top of the unit. Pour clean water in to the depressuriza-
tion chamber until it flows from the outlet drain port of Tower #2. Confirm that there are not any obstructions
with the drain line and the unit is draining properly. During initial filling, dust may rise from the carbon elements;
this is only displaced air and is entirely harmless. ZEKS recommends that carbon elements should be pre-
soaked for 24 hrs. Any carbon dust in the outlet water is harmless. Replace the foam depressurization pad.
Using normal lifting precautions, replace the white Absorption Element in to Tower #1. Push the element com-
pletely to the bottom of the tower. Replace the lid to Tower #1.
7.3 INITIAL START-UP AND MONITORING
ZEKS recommends a daily check on the quality of the discharged condensate from the oil/water separator for
the first week of operation. Using the Test bottle provided with the unit, take a sample of condensate from the
TEST port on Tower #2. Fill the bottle as much as possible. The condensate collected should be clear when
viewed through the container. Particulate concentration less than 20ppm is not visible with the human eye.
Therefore, if the condensate appears cloudy, the oil carryover is greater than 20ppm. Within a week of opera-
tion, the quality of the condensate should improve. Clean the collection bottle and return it to the holder located
on top of the OS Oil/Water Separator.
8. SCHEDULED MAINTENANCE
8.1 REPLACEMENT OF ELEMENTS:
Under normal operating conditions, ZEKS recommends that the Absorption Element and the Carbon Finishing
Element(s) be replaced simultaneously on a yearly basis. Excessive oil by-pass from the compressed air sys-
tem will result in shortened element life. Test the quality of the condensate discharge to determine element
effectiveness (Reference Section 7.3).
ABSORPTION ELEMENT (TOWER #1)
Lift the saturated element from Tower #1 using standard heavy lifting precautions. Use caution when lifting
the saturated element from the tower as element will be heavy from retained oil. Allow the element to drain
off excess condensate prior to completely lifting from the tower. Place the saturated element in to a plastic
bag or bucket to allow element to safely continue to drain. Place the new Absorption Element in Tower #1
and push the element completely to the bottom of the tower. Replace the lid to Tower #1. Pour collect con-
densate from the Absorption Element in to Tower #1. This will ensure that the separation process of the col-
lected condensate is completed prior to disposal.
REPLACEMENT OF CARBON FINISHING ELEMENT
(TOWER #2) AND (TOWER #3 - OS2501 MODEL ONLY)
To prevent dusting, clean water can be poured over the Carbon Finishing Element. Carbon dusting is com-
pletely normal with a new element and is completely harmless.
Remove lid from Tower #2. Carefully lift the saturated Carbon Finishing Element from Tower #2 using stan-
dard heavy lifting precautions. Allowing the element to drain off excess condensate prior to completely lift-
ing from the tower. Place the saturated element in to a plastic bag or bucket to allow element to safely con-
tinue to drain. Place the new Carbon Finishing Element in Tower #2 and push the element completely to
the bottom of the tower. Ensure that the top of the element is below the drain outlet hole. Clean water can
be
Replace lid to Tower #2. Pour collected condensate from Carbon Finishing Element in to Tower #1. This
will ensure that the separation process of the collected condensate is completed prior to the condensate
exiting the unit.
4
All used elements must be properly disposed of in accordance with current regulations
for the disposal of hazardous waste in your area.
WARNING
5
Model Number Part Number Description Element Application
683535 Absorption (TWR 1) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683536 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683749 Absorption (TWR 1) Polyglycol
683536 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
684130 Absorption (TWR 1) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
684132 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
684131 Absorption (TWR 1) Polyglycol
684132 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683750 Absorption (TWR 1) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683751 Absorption (TWR 1) Polyglycol
683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683750 Absorption (TWR 1) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683753 Carbon Finishing (TWR 3) Extends Carbon Finshing Time
683751 Absorption (TWR 1) Polyglycol
683752 Carbon Finishing (TWR 2) Mineral Oil, Synthetic Oil, Semi-Syntheic Oil
683753 Carbon Finishing (TWR 3) Extends Carbon Finshing Time
OS300
OS300PG
OS751
OS751PG
OS1251
OS1251PG
OS2501
OS2501PG
9. PARTS LIST
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