Great Lakes Air Products EDR series User manual

Great Lakes Air Products
1515 S. Newburgh Road
Westland, MI 48186
PH: 734-326-7080
www.glair.com
COMPRESSED AIR DRYER
INSTRUCTION MANUAL
EDR-SERIES
REFRIGERATION TYPE
HIGH INLET
TEMPERATURE
Contents
Introduction
Page 2
General Safety & Warnings
Page 2
Proper Use of the Dryer
Page 3
Receiving Equipment
Page 3
Installation, Location and Piping
Page 3
Electrical Connection
Page 3
Recommended System Design
Page 4
Condensate Drain
Page 5
Start-up Procedure
Page 5
Shut-down Procedure
Page 5
Troubleshooting
Page 6
Required Maintenance
Page 7
Engineering Data
Page 7
Warranty
Page 8

Page 2
INTRODUCTION
Before attempting any installation or maintenance on the dryer, please
carefully read this entire manual.
Great Lakes Air Products genuine parts, manufactured to design tolerances, are developed for optimum
dependability –specifically for Great Lakes Air Products dryer systems. Design and material innovations
are the result of years of experience with hundreds of different compressor and dryer applications.
Reliability in materials and quality assurance are incorporated in our genuine replacement parts.
Your authorized Great Lakes Air Products distributor offers all the backup and reassurance you’ll
need. Our network of authorized distributors provides the finest product support in the air compressor
industry.
Your authorized distributor can support your Great Lakes Air Products Dryer with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Repair and maintenance kits designed with the necessary parts to simplify servicing
your dryer.
3. Authorized distributor service technicians are factory trained and skilled in compressor and dryer
maintenance and repair. They are ready to respond and assist you by providing fast, expert
maintenance and repair services.
To Contact Great Lakes Air Products or locate your local distributor:
Visit: www.glair.com or
Call: [phone]
Failure to install the compressed air dryer per this manual or any change to the dryer not previously
authorized by the manufacture will void the warranty.
The information and specifications in this manual are in accordance with the information in effect at the
time of printing. The manufacturer reserves the right to make changes without notice or incurring
obligation.
GENERAL SAFETY INFORMATION
General Warning
The associated text outlines conditions, which could indicate a hazardous situation that
has some probability of death or severe injury.
Electrical Hazard
The associated text outlines conditions, which could indicate a hazardous situation that
has some probability of death or severe injury.
Only qualified personnel can use and service electrically powered devices. Be sure that
the voltage is disconnected before any work is performed.
Danger Hazard
A compressed air dryer has two separate pressurized systems each with the potential
to be pressurized independently. First is the sealed refrigeration system which should
never be opened except by a licensed technician. Second is the actual compressed air
circuit. Depressurize the compressed system prior to performing any work or
maintenance on that system. Compressed air is a highly hazardous energy source.
Never work on equipment with parts under pressure.
Breathing Air
Air treated by this equipment may not be suitable for breathing without further
purification. Refer to applicable standards and specifications for the requirements of
breathing quality air.

Page 3
PROPER USE OF DRYER
This dryer has been designed, manufactured and tested to separate humidity normally contained in
compressed air only. Any other unauthorized use will be considered improper. The manufacturer will void
the warranty and not be held responsible for any problem arising from improper use. The correct use
requires adherence to installation conditions specified in this manual.
This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to
the plant in compliance with the instructions given in the following chapters.
RECEIVING EQUIPMENT
Immediately upon receipt of equipment, remove all crating and packaging around equipment. Examine
machinery for any damages either external or internal that may have occurred in transit.
If there is any physical damage or a refrigerant leak, (suction/analyzer gauge reads zero) please note
all damages on bill of lading during delivery. If damage is detected after the equipment delivery; contact
the local terminal to report all damages and file a claim immediately with the transportation company. The
carrier is legally responsible for any damages, since the unit is shipped F.O.B.
INSTALLATION LOCATION PIPING & CONNECTION
Particular care is required in selecting the installation site, as an unsuitable location could
jeopardize the proper operation of the dryer. This unit is not suitable to be used in an
explosive atmosphere, or where the risk of fire could be present.
The unit should be installed in an area that is clean and dry, allowing sufficient space on all sides for
routine maintenance and service. It should be located on a level floor or shelf free from vibrations and
sufficient to support the total weight of the machinery. Although the dryer package is a freestanding unit,
it may be secured by bolting the base to the floor but is not required. This standard dryer is designed
for indoor installation. Contact distributor if installing unit outdoors.
Installations at altitudes above 4000 feet (1219 meters) will experience a loss of capacity and may require
field adjustments of pressure settings. The unit has been factory adjusted to operate up to 4000 feet
(1219 meters), and if installation is above this altitude, contact your local distributor for correct refrigerant
settings.
Allow (2’) two feet, minimum clearance around the dryer for maintenance access and adequate free
circulation of cooling air to the dryer. The ambient temperature around the dryer must not exceed 110°F
(37.7°C) or be less than 50°F (10°C).
Ambient temperatures below 40°F (10°C) require optional equipment specified below. Sufficient
ventilation must be provided to maintain acceptable ambient for efficient operation. Consider heat
rejection when locating dryer.
ELECTRICAL CONNECTION
The Nameplate/Data plate located on each unit identifies the power supply requirements and
maximum fuse specification. Units supplied with cord and plug requires the installation of a
receptacle rated for 15 amps. Units supplied with electrical junctions, require a suitable fused
disconnect in compliance with the National and Local Electrical Code requirements.
The wiring of all functional electrical components has been completed and tested at the factory in
accordance with the electrical wiring schematic provided with this manual.

Page 4
RECOMMENDED SYSTEM DESIGN
A healthy, long-term, and trouble free compressed air supply design should be approached as a complete
system, not individual components. The air compressor Intake location is vital to system health; it should
supply clean fresh air that is free from possible contaminant (e.g. ammonia, chlorine or methane). Any
contaminant entering the compressor intake will be concentrated by a factor of 8 due to the compression
process in a typical compressed air system.
As inlet and ambient temperatures deviate from the design conditions, the moisture holding capacity of
compressed air can change dramatically. The following table represents the correction to load and dryer
capacity at alternate inlet and ambient temperatures. Design Inlet temperature 180°F (82.2°C), Design
Ambient Temperature 100°F (43.3°C)
Capacity Correction
Inlet Temperature
125°F
(37.7°C)
150°F
(40.5°C)
180°F
(43.3°C)
200°F
(46.1°C)
Ambient
Temperatures
100°F (37.7°C)
1.18
1.10
1.00
0.90
105°F (40.5°C)
1.07
1.00
0.91
0.82
110°F (43.3°C)
0.97
0.90
0.82
0.73
Inlet air pressure also has an impact on dryer capacity the following table will correct capacity for
operating pressures other than the designed 100 PSIG.
Inlet Pressure (PSIG)
80
100
150
200
Capacity Correction
0.80
1.0
1.15
1.20
The pipe connection to the dryer should match the standard connection ports provided. The chart below
is provided as a basic guide to size branch and header piping. It is recommended that shut-off valves with
unions be installed at each port, with a valve bypass to permit isolation of the unit for servicing without
interruption of plant air supply.
Maximum Recommended Compressed Air Flow Schedule 40 pipe @ 95 to 115 PSIG
Pipe Size
½”
¾”
1”
1¼”
1½”
2”
2½
3”
4”
6”
Flow (SCFM)
40
100
150
200
350
650
900
1500
2500
5000

Page 5
CONDENSATE DRAINS
The condensate system is at line pressure and can cause personal injury or equipment
damage when discharging. Securely anchor the drain pipes or tubes prior to dryer
operation.
Prior to any maintenance isolate and depressurize condensate drain valves.
This refrigerated dryer comes standard with two condensate drains. The first is an automatic float that
removes condensate after the inlet precooler. The second is an electronic solenoid drain that removes
condensation generated by the refrigeration system. The drain timer is factory preset to 4 seconds of “on
time” and 10 minutes of “off time”. This factory setting is applicable for virtually all-industrial applications. If
adjustment is required contact your local distributor for alternate settings and procedures.
Precooler Automatic Float Drain
Electronic Solenoid Drain
When maintaining float drains
depressurize the dryer & drain prior
to work initiation.
Drain line and “Drain Connector”
must be removed prior to bowl and
float drain removal.
Drain Timer Factory Preset
4 seconds
on time
10 minutes
off time
The factory setting is applicable for virtually all
industrial applications. If adjustment is required
contact your local distributor for alternate settings
and procedures.
Condensate discharged from the dryer may contain oil/lubricants.
Verify and follow local regulations regarding disposal.
STARTUP PROCEDURE
Energize the refrigeration compressor by placing the “on/off” dryer switch with indicating light to the “on (I)”
position. The refrigerant compressor and fan motor(s) will begin to operate. The suction/analyzer gauge
will fall to a range of 28-35 PSIG. If the suction/analyzer gauge is not in the specified range, contact your
local distributor.
SHUT DOWN PROCEDURE
When the dryer is to be shut down for service, maintence, or other reasons switch the dryer off by placing
the “on/off” dryer switch with indicating light to the “OFF (0)” position. If service or maintenance is
required disconnect and lockout the main power supply, isolate and depressurize the internal compressed
air pressure to atmosphere prior to commencement of any work.

Page 6
TROUBLESHOOTING
Sec
Symptom
Possible Cause(s)
Corrective Action
A
Water downstream of
dryer.
1.
Residual free moisture
remaining in downstream
piping
Drain low spots in system and purge with
dry air
2.
Air By-pass system is open
Verify valve positions and correct valve
positions
3.
Ambient temperature
surrounding downstream
piping is below the dryer’s
dew point.
Insulate and/or heat trace piping exposed
to low ambient temperatures or dry air to a
lower dew point.
4.
Free water (liquid) is entering
the dryer
Dryers are designed to handle saturated
air not condensed liquid. Install a separator
and coalescing filter upstream of dryer.
5.
Condensate is not being
drained
See section B
6.
Dryer is overloaded resulting
in high dew point
See capacity charts to determine correct
load
7.
Refrigeration system is not
functioning.
See section E
8.
Suction pressure not in
operating range
Contact your local distributor to perform
adjustments.
9.
Precooler Fan not functioning
or cooler is clogged
Clean cooler coils and/or replace fan motor
B
Drain system failure
with no condensate
discharge on test
initiation or continuous
air discharge.
1.
Drain strainer is clogged
Depressurize dryer and replace or clean
drain strainer.
2.
Solenoid valve or electronic
timer failure
Replace drain solenoid and or timer
assembly
3.
Solenoid valve diaphragm
rupture or orifice path blocked
open
Clean or replace internal diaphragm
assembly. Clean or replace auto float
drain.
4.
Precooler float drain failure
Replace float drain.
C
High pressure drop
across dryer
1.
Inlet flow exceeds
maximum capacity
Check inlet flow vs. rated capacity
2.
Freezing of moisture in
evaporator is restricting inlet
air flow
If refrigerant suction pressure is out of
standard operating range, contact your
local distributor to perform adjustments.
E
Refrigeration System Fault
E1
Power on indicator
does not illuminate
1.
Power failure, Line fuses
blown, or disconnect open.
Have an electrician check electrical feed
and connection integrity.
2.
Power switch failure
Replace switch
E2
Refrigeration
compressor cycles on
and off
1.
Ambient Conditions are
above or below minimum or
maximum ranges.
Verify range and rectify ambient
conditions.
1.
Condenser fan failure
Replace condenser fan
3.
Compressor thermal
overload failure
Replace thermal overload and
investigate cause of failure.
3.
Air-Cooled Units,
Dirty condenser
Clean condenser as per required
maintenance.
4.
Water-Cooled Units,
High fluid temperature or low
fluid flow.
Check fluid temperature, bring in range
and check for free fluid flow through
condenser. If problem persists contact
your local distributor to perform
adjustments.

Page 7
REQUIRED MAINTENANCE
INSPECTION
Frequency
Verify operation of the solenoid and auto float drain system.
Weekly or
as required.
Verify refrigeration analyzer gauge is in the correct range.
Verify operation of both cooling fans.
Disconnect and lockout dryer power as well as compressed air supply and
depressurize prior to performing the following maintenance items.
GENERAL MAINTENANCE
Frequency
Clean refrigeration condenser coil by blowing dust and dirt from the inside of the
cabinet out. (Opposite from normal fan air flow)
Monthly
Clean Precooler coil by blowing dust and dirt from the inside of the cabinet up and
out. (Opposite from normal fan air flow)
Monthly
Isolate the valve prior to the Solenoid drain system and remove and clean the
strainer screen.
Monthly
Model series B & C have 5-micron separation elements located in the separator
after the precooler, replace the element as required.
6 Months or
high differential
Replace auto float drain on internal separator and filter element of inline filters.
6 Months or
high differential
DRAIN SERVICE
Frequency
If the drain system is not discharging condensate and the strainer is clean, try
cleaning debris from diaphragm, or replacing the solenoid or timer.
As required
If the drain system is continually discharging condensate and air from the drain
tube, try replacing the solenoid valve diaphragm, or the complete drain valve.
As required
ENGINEERING DATA
Model EDR
A1
A2
B1
B2
C1
C2
SCFM @ 50°F PDP & 120 PSIG
28
36
50
80
102
155
SCFM @ 50°F PDP & 100 PSIG
24
30
43
67
86
132
SCFM @ 39°F PDP &120 PSIG
23
30
42
66
85
129
SCFM @ 39°F PDP &100 PSIG
20
25
36
56
72
110
Min. / Max. Inlet Pressure
30 PSIG (2.1 kgf/cm²) / 230 PSIG (16.2 kgf/cm²)
Max. Inlet Temperature
200°F (48.8°C)
Min. / Max. Ambient Temperature
50°F (10°C) / 110°F (43.3°C)
Inlet / Outlet Connections (NPT)
3/4”
3/4”
3/4”
3/4”
1”
1-1/2”
Delta Pressure / P (PSID)
@ Std. Rated Conditions
1.7
1.7
1.7
1.9
2.7
3.0
Shipping Weight (Lbs.)
127
130
165
185
297
300
Refrigeration Compressor Type
Non Cycling, Hermetic Type
Refrigeration Compressor HP
1/5
1/4
1/3
1/2
5/8
3/4
Ref. Compressor BTU/H @
35°F Evaporator & 100°F Ambient
1780
2160
2780
4430
5400
6120
Watts @ 35°F Evap. & 100°F Amb.
385
465
600
815
1080
1180
Refrigerant Suction Pressure
28-34 PSIG
Refrigerant Type
R-134a
Refrigerant Charge
8oZ
10oz
12oz
13 oz.
3 Lbs.
4 Lbs.
Nominal Voltage
(Min-Max Range)
115-1-60
(103-126)
115-1-60
(103-126)
230/208-1-60
(187-253)
115-1-60
(103-126)
230/208-1-60
(187-253)
115-1-60
(103-126)
230/208-1-60
(187-253)
Min. Circuit Ampacity
5.0
6.6
7.67
12.46
6.38
15.53
7.83
17.65
9.45
Maximum Fuse Size (Amps)
15
15
15
15
15
20
15
20
15
(Comp) RLA: Run Load Amps
3.7
4.9
5.8
9.5
4.8
11.0
5.7
13.0
7.0
(Comp) LRA: Locked Rotor Amps
29.0
27.5
32.0
48.0
23.0
58.8
27.4
69.0
41.8
Condenser Fan Motor (Watts/FLA)
N/A
N/A
6 / 0.4
9 / 0.6
9 / 0.3
35 / 1.4
35 / 0.7
35 / 1.4
35 / 0.7
Precooler Fan Motor (Watts/FLA)
9 / 0.6
9 / 0.6
9 / 0.6
9 / 0.6
9 / 0.3
34 /1.6
34 / 0.8
34 /1.6
34 / 0.8
Overload
External “Klixon” Thermal and Current (Auto Reset)

WARRANTY
Any standard EDR Series Refrigerated Air Dryer manufactured by Great Lakes Air Products is
warranted free from defects in material and workmanship under normal use for a period of 2-Years.
The warranty applies to original purchaser effective at date of shipment from manufacturer’s
warehouse. Said warranty consists of 1-Year job site labor and 2-Years covering OEM replacement
parts. The company’s obligation under this warranty is limited to repairing or, at its sole option,
replacing, during normal working hours at an authorized service facility of the company, any part
which in its judgment proved to be not was warranted within the applicable warranty period.
This warranty covers the standard catalog EDR series air dryers including options, excluding
customer maintained components such as separator float assembly, drain solenoid, drain
strainer screen, fan motor lubrication, condenser cleaning, and filter element replacement.
This warranty applies to equipment installed, operated and maintained in accordance with the
procedures and recommendations as outlined in the owner’s manual by Great Lakes Air Products.
Great Lakes Air Products will not be responsible for the following items: Freon, insulation, torch
charge, reclaiming charge, truck charges, freight damages, or any parts not original to the EDR
series dryer.
In all cases, seller must be given a reasonable opportunity to investigate and inspect any assumed
defects. At seller’s option, buyer must return any defective materials to seller’s plant or authorized
depot at buyer’s expense. Freight charges for returned or replacement machines or parts are not
the responsibility of Great Lakes Air Products. Seller’s liability whether on warranty contract or
otherwise shall be limited to repair or replacement of material found within such period to be
defective. In no event shall the seller be liable for consequential or special damages.
Great Lakes Air Products shall not be responsible for any incidental or consequential damages or
other costs resulting from the following; labor charges, delays, vandalism, negligence, fouling
caused by foreign material, damage from adverse air conditions, chemicals, or any circumstances
over which Great Lakes Air Products has no control.
The liability of Great Lakes Air Products for all loss or damage resulting from non-conforming goods
or tender, including breach of any and all warranties, shall be limited to refund of the purchase price
of the particular goods with respect to which the loss or damage occurred.
This warranty is in lieu of all other warranties oral or written, expressed or implied, including
warranties of merchantability or fitness for a specific purpose are hereby excluded and disclaimed.
This warranty shall not apply to any equipment, which has been subjected to misuse,
shipping damage, nonpayment, neglect or accident, nor shall it apply to any equipment that
has been repaired or altered by persons not authorized for each incident with a Great Lakes
Air Products Authorization number.