ERF Manual 060116
ERF Manual 060116
ERF-SERIES
REFRIGERATION TYPE
NON CYCLING
STANDARD
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
Recommended System Design Page 4
Electrical Connection Page 4
Condensate Drain Page 5
Start-up Procedure Page 6
Shut-down Procedure Page 6
Required Maintenance Page 7
Troubleshooting Page 8
Engineering Data Page 9
Warranty Page 10
060116
INTRODUCTION
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.
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.
Page 2 of 10
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.
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.
Air-Cooled Units
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 40°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.
Page 3 of 10
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.
A properly sized and maintained compressed air aftercooler is vital to maintaining an acceptable system
temperature range. ERF Series refrigerated air dryers are designed to operate at rated flow with a
maximum inlet temperature of 100°F (37.7°C). Units can be oversized to accommodate higher inlet
temperatures up to 120°F (48.8°C). As dryer inlet temperatures rise above the design 100°F (37.7°C),
the moisture holding capacity of the air rises dramatically. The following table represents the additional
moisture load at elevated temperatures.
Inlet Temperatures 100°F (37.7°C) 105°F (40.5°C) 110°F (43.3°C) 115°F (46.1°C) 120°F (48.8°C)
Additional Load 0% 15% 32% 51% 75%
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.
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.
Three phase versions of the ERF air dryer are NOT sensitive to phase alignment. Rotation of motors is
universal.
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 of 10
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.
Drain line and “Drain Connector” The factory setting is applicable for virtually all
must be removed prior to bowl and industrial applications. If adjustment is required
float drain removal. 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.
Page 5 of 10
STARTUP PROCEDURE
If the shutdown resulted in loss of main power interruption, repeat start up procedure so crank
case heater has time to raise the crank case temperature.
Page 6 of 10
REQUIRED MAINTENANCE
INSPECTION Frequency
Verify operation of the solenoid and auto float drain system.
Weekly or
Verify refrigeration analyzer gauge is in the correct range.
as required.
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.
90 1.35 1.24 1.06 1.00 0.91 0.78 0.74 0.68 0.58 0.56 0.51 0.44
100 1.48 1.36 1.15 1.09 1.00 0.85 0.81 0.75 0.63 0.61 0.56 0.48
110 1.61 1.47 1.25 1.18 1.09 0.92 0.88 0.81 0.69 0.66 0.61 0.52
120 1.73 1.59 1.35 1.29 1.17 0.99 0.95 0.87 0.74 0.72 0.66 0.56
130 1.86 1.70 1.45 1.37 1.26 1.07 1.02 0.94 0.80 0.77 0.71 0.60
140 1.98 1.82 1.55 1.46 1.34 1.14 1.09 1.00 0.85 0.82 0.75 0.64
150 2.11 1.93 1.64 1.55 1.42 1.21 1.16 1.06 0.90 0.87 0.80 0.68
To obtain flow capacities at conditions other that standard (SCFM @ 100 PSIG, 100°F Inlet & 100°F
Ambient), locate the multiplier at the interception of actual operating conditions. Multiply the rated
capacity of the selected dryer by the selected multiplier. The result is the corrected flow capacity. Flow
rates in excess of specified due to capacity correction can result in increasing pressure drop.
Page 7 of 10
TROUBLESHOOTING
Sec Symptom Possible Cause(s) Corrective Action
A Water downstream of 1. Residual free moisture Drain low spots in system and purge with dry
dryer. remaining in downstream air
piping
2. Verify valve positions and correct valve
Air By-pass system is open
positions
3. Ambient temperature Insulate and/or heat trace piping exposed to
surrounding downstream low ambient temperatures or dry air to a lower
piping is below the dryer’s dewpoint.
dewpoint.
4. Free water (liquid) is Dryers are designed to handle saturated air
entering the dryer not condensed liquid. Install a separator and
coalescing filter upstream of dryer.
5. Condensate is not being See section B
drained
6. Dryer is overloaded See capacity charts to determine correct load
resulting in high dewpoint
7. Refrigeration system is not See section E
functioning.
8. Suction pressure not in Contact your local distributor to perform
operating range adjustments.
B Drain System Failure 1. Drain strainer is clogged Depressurize dryer and replace or clean drain
with no condensate strainer.
discharge on test 2. Solenoid valve or Replace drain solenoid and or timer assembly
initiation. electronic timer failure
C Drain System Failure 1. Solenoid valve diaphragm Clean or replace internal diaphragm
with continuous rupture or orifice path assembly.
condensate or air blocked open
discharge.
D High pressure drop 1. Inlet flow exceeds Check inlet flow vs. rated capacity
across dryer maximum capacity
2. Freezing of moisture in If refrigerant suction pressure is out of
evaporator is restricting standard operating range, contact your local
inlet air flow distributor to perform adjustments.
E Refrigeration System Fault
E1 Power on indicator 1. Power failure, Line fuses Have an electrician check electrical feed and
does not illuminate blown, or disconnect connection integrity.
open.
E2 Refrigeration 1. Ambient Conditions are Verify range and rectify ambient
compressor cycles on above or below minimum conditions.
and off or maximum ranges.
2. Air-Cooled Units, Clean condenser as per required
Dirty condenser maintenance.
3. Water-Cooled Units, Check fluid temperature, bring in
High fluid temperature or range and check for free fluid flow
low fluid flow. through condenser. If problem
persists contact your local distributor
to perform adjustments.
Page 8 of 10
ENGINEERING DATA
Model ERF 10 20 25 40 50 75 100 125 150 200 250 300
Capacity in SCFM @
10 20 25 40 50 75 100 125 150 200 250 300
100 PSIG, 100°F Inlet & 100°F Ambient
Min. / Max. Inlet Pressure 30 PSIG (2.1 kgf/cm²) / 220 PSIG (16.2 kgf/cm²)
Max. Inlet Temperature 120°F (48.8°C)
Min. / Max. Ambient Temperature 50°F (10°C) / 110°F (43.3°C)
Inlet / Outlet Connections (NPT) 3/8 OD 1/2” 1/2” 1/2” 3/4” 3/4” 1” 1” 1-1/4” 1-1/4” 1-1/2” 2”
Delta Pressure / P (PSID)
2.0 1.5 1.7 1.7 1.9 2.7 3.0 3.5 2.4 3.4 3.4 3.9
@ Std. Rated Conditions
Product Weight 105 118 123 165 170 249 258 265 267 315 321
Refrigeration Compressor Type Non Cycling, Hermetic Type
Refrigeration Compressor Horsepower 1/7 1/7 1/5 1/4 1/3 1/2 5/8 3/4 3/4 1 1-1/2 1-1/2
Ref. Compressor BTU/H @
969 969 1880 2250 2250 4142 5400 6120 6120 9550 12084 12084
35°F Evaporator & 100°F Ambient
Watts @ 35°F Evap. & 100°F Amb. 210 210 330 410 570 850 1080 1180 1180 1450 2270 2270
Refrigerant Suction Pressure 28-34 PSIG 69-81 PSIG
Refrigerant Type R134a R404A
Refrigerant Charge 4 oz. 4 oz. 8 oz. 10 oz. 13 oz. 13 oz. 3 Lbs. 4 Lbs. 4 Lbs. 5 Lbs. 7 Lbs. 7 Lbs.
Nominal Voltage (Min-Max Range) 115-1-60 (103-126)
Min. Circuit Ampacity 2.8 5.0 6.6 7.7 12.4 15 17 17 Not Available
Maximum Fuse Size (Amps) 15 15 15 15 15 20 20 20 Not Available
RLA: Rated Load Amps 1.9 3.7 4.9 5.8 9.5 11.3 14.4 14.4 Not Available
LRA: Locked Rotor Amps 14.4 29 27.5 32 48.0 58.8 69.0 69.0 Not Available
Nominal Voltage (Min-Max Range) 230/208-1-60 (187-253)
Min. Circuit Ampacity Not Available 6.3 7.8 9 9 10.4 11.7 11.7
Maximum Fuse Size (Amps) Not Available 15 15 15 15 20 20 20
RLA: Rated Load Amps Not Available 4.8 5.9 7.7 7.7 8.1 9.5 9.5
LRA: Locked Rotor Amps Not Available 23 27.4 41.8 41.8 41 51 51
Overload External “Klixon” Thermal and Current (Auto Reset)
Model ERF 250 300 400 500 650 800 1000 1200 1500 1750 2000 2250
Capacity in SCFM @
250 300 400 500 650 800 1000 1200 1500 1750 2000 2250
100 PSIG, 100°F Inlet & 100°F Ambient
Min. / Max. Inlet Pressure 30 PSIG (2.1 kgf/cm²) / 220 PSIG 30 PSIG (2.1 kgf/cm²) / 150 PSIG (10.6 kgf/cm²)
Max. Inlet Temperature 120°F (48.8°C)
Min. / Max. Ambient Temperature 50°F (10°C) / 110°F (43.3°C)
Inlet / Outlet Connections (NPT) 1-1/2” 2” 2” 2” 2” 3” 3” 3” 4” Flg 4” Flg 4” Flg 4” Flg
Delta Pressure / P (PSID)
3.4 3.0 3.7 3.8 3.9 3.7 3.9 4.2 3.9 4.0 4.2 4.4
@ Std. Rated Conditions
Shipping Weight 315 321 350 549 555 920 1009 1200 1600 1611 1980 2115
Refrigeration Compressor Type Non Cycling, Hermetic Type
Refrigeration Compressor Horsepower 1-1/2 1-1/2 2 3 3 4 5 7 9 9 10 10
Ref. Compressor BTU/H @ 8798
12084 12084 14544 26832 26832 36624 47904 60540 74868 74868 87984
35°F Evaporator & 100°F Ambient 4
1521
Watts @ 35°F Evap. & 100°F Amb. 2270 2270 2743 5169 5169 5710 7544 10070 11760 11760 15210
0
Refrigerant Suction Pressure 69-81 PSIG
Refrigerant Type R404a
Refrigerant Charge 7 Lbs. 7 Lbs. 7 Lbs. 7 Lbs. 7 Lbs. 18 Lbs. 22 Lbs. 24 Lbs. 40 Lbs. 40 Lbs. 40 Lbs. 40 Lbs.
Condenser Fan Switch Primary = Cut In: 265 / Cut Out: 215
Primary = Cut In: 300 / Cut Out: 250
Pressure Settings Secondary = Cut In: 300 / Cut Out: 250
Overload Internal Thermal and Current (Auto Reset)
Nominal Voltage (Min- Max Range) 230/200-3-60 (180-253)
Min. Circuit Ampacity 9.2 9.2 10 19.4 19.4 19.6 26.6 35.4 38.2 38.2 47.1 47.1
Maximum Fuse Size (Amps) 15 15 20 30 30 35 45 70 70 70 90 90
RLA: Rated Load Amps 7.6 7.6 8.2 15.9 15.9 17.1 23.4 30.5 35.1 35.1 42.2 42.2
LRA: Locked Rotor Amps 38 38 38 98 98 117 128 155 157 157 210 210
Nominal Voltage (Min- Max Range) 460-3-60 (414-506)
Min. Circuit Ampacity 4.6 4.6 5.4 9.1 9.1 10.2 13.1 15.5 19.5 19.5 23.1 23.1
Maximum Fuse Size (Amps) 10 10 10 15 15 20 25 30 35 35 40 40
RLA: Rated Load Amps 3.8 3.8 4.4 7.5 7.5 8.9 11.8 13.7 17.9 17.9 21.1 21.1
LRA: Locked Rotor Amps 16 16 16 38 38 42 67 80 90 90 105 105
Nominal Voltage (Min- Max Range) 575-3-60 (546-603)
Min. Circuit Ampacity 4.1 4.1 4.8 9.1 9.1 9.5 11.66 13.8 17.37 17.37 20.9 20.9
Maximum Fuse Size (Amps) 15 15 15 15 15 20 30 30 50 50 50 50
Total Amperage 3.04 3.04 3.52 6 6 7.12 9.44 10.96 14.32 14.32 16.88 16.88
LRA: Locked Rotor Amps 16 16 16 38 38 42 67 80 90 90 105 105
Page 9 of 10
WARRANTY
Any standard ERF 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 5-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 5-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 ERF 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.
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 ERF
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.
Page 10 of 10