GREAT LAKES AIR

LE DE R NDA STA 5R YEA I RON CT

WA

T RAN R I WPO E

E ALV NV SIO AN EXP SS N RAI D NIC O CTR LE DE R T NDA TA OIN S P DEW E SUR S PRE F E -39 35 ALV V N ION RAI S D PAN NIC O EX SS CTR LE Y DE ANT DAR RR TAN WA AR -YE 5

35-

E F PR 39

E SUR S

GTX Series Thermal Xchange Cycling Refrigeration Dryers

Why Dry Compressed Air?

Compressed air is a clean, convenient and versatile energy source ideal for many commercial, or industrial applications. Air compressors draw in ambient air where the gas volume is reduced to increase pressure and store energy. Any solids, vapors or aerosols drawn into the compressor is concentrated in direct proportion to the ratio of compression. This process produces saturated compressed air with particulate contaminants and excess liquid at the compressor discharge. Filtration can remove the liquids and solid contamination but the moisture in a gaseous state (humidity) needs to be removed with a compressed air dryer. The dryer chills the compressed air condensing the humidity into a liquid. This enables a separation device to remove it from the system. Removing the moisture from a compressed air system optimizes reliability, efficiency, and productivity by avoiding costly equipment failure, product contamination, and distribution system breakdown.

How A Cycling Dryer Works

Rising energy costs have forced equipment efficiency and operating costs to become a significant factor in the purchase of new equipment. A basic non-cycling refrigerated dryer is specified by matching the capacity of the dryer, with the maximum capacity requirement of the compressed air system. This design is very efficient when the loads are balanced. Unfortunately in many applications, compressed air systems experience wide fluctuations that range from 0 to 100% of full load. If the compressed air load falls, the refrigeration system of a non cycling dryer must dump or waste energy to balance the system. The GTX cycling refrigerated air dryer uses a fully loaded refrigeration system to store energy in the TRANS-TEMP energy cell during low load periods. By operating the refrigeration system fully loaded, you maximize the operating efficiency, reducing energy costs. When the ENERGY CELL reaches maximum charge, the refrigeration compressor CYCLES OFF, allowing the energy cell to continue providing the required energy for cooling and drying the compressed air system.

Sequence of Operation
Saturated compressed air enters the dryer and is initially cooled in the Air to Air heat exchanger by the cold outgoing air. The TRANS-TEMP Fluid from the energy storage cell further cools the compressed air in the Trans-Temp to Air heat exchanger. Liquid that has been condensed by the reduced air temperature is removed in the high efficiency separator. The cold air is then reheated as it pre-cools the inlet air via the Air to Air heat exchanger. The refrigeration system maintains the temperature in the energy cell with a microprocessor based controller and operates only as required. The energy cell is capable of maintaining dewpoint, allowing the refrigeration compressor to be cycled off, reducing the required energy of operation.

The Trans-Temp Energy Cell integrates a proprietary blend of non-hazardous, completely biodegradable fluids that attains an ideal balance of thermal storage and thermal conductivity. The energy cell is encased in a heavy duty non ferrous vessel that is insulated to maintain energy efficiency.

Energy Savings Calculation

Compressed air volume, temperature, & pressure along with ambient temperature are variable conditions that affect the energy load on a refrigeration dryer. The two most significant variables are inlet volume and temperature. Use the following sample calculation to determine annual energy savings of a GTX cycling dryer. Sample Calculation for GTX-500 Step #1 Determine an average compressed air consumption Hours of operation 1st 500 60 40 2nd 475 60 40 3rd 275 60 35 Weekend 150 60 16 Actual volume consumption (weekly) Shift SCFM Min System Volume FT3 1,200,000 1,200,000 577,500 144,000 3,121,500 Sample Calculation for GTX-500 Step #2 Temperature correction has a high variance due to multiple factors like region, season, and time of day. Select an average dryer inlet temperature taking into account cool evening temperatures. If an annual average is to general to get an accurate result. Average temperature by seasons and break the cost savings calculation into individual seasons. Temperature 60F 70F 75F 80F 15.5C 21.1C 23.8C 26.6C Multiplier 0.29 0.40 0.47 0.55 Temperature 85F 90F 100F 110F 29.4C 32.2C 37.7C 43.3C Multiplier 0.64 0.74 1.0 1.32

Determine the total possible load for the compressed air dryer by multiplying the rated capacity of: 500 x 10,080 = 5,745,600 (GTX-500) x (60 min x 168 Hrs a week) = 5,745,600 Divide actual volume consumption by Total possible load consumption 3,121,500 / 5,745,600 = 0.54 or 54% Actual Load

Sample Calculation for GTX-500 Step #3 In step #1 the average compressed air consumption calculated to 54% of full load conditions. Assuming a midwest average inlet temperature of 85F select the multiplier of .64 or 64%. Multiply the average consumption by the temperature correction factor to attain a total percentage of load. .54 x .64 = .345 or 35% Select the GTX-500 row and extrapolate 35% from the 30% and 40% columns. $2,326 + $2,714 / 2 = $2,520 Annual savings

Cost Savings at % of full load operating conditions Model GTX-100A GTX-125A GTX-180A GTX-225A GTX-300A GTX-400A GTX-500A GTX-600A GTX-800A GTX-1000A GTX-1350A GTX-1800A GTX-2000A GTX-2250A 80% $149.64 $180.46 $211.22 $371.42 $400.35 $606.33 $775.53 $862.65 $1,218.26 $1,587.78 $1,648.23 $2,311.62 $2,542.74 $2,971.17 70% $224.45 $270.68 $316.83 $557.14 $600.52 $909.50 $1,163.30 $1,293.98 $1,827.39 $2,381.66 $2,472.35 $3,467.42 $3,814.11 $4,456.76 60% $299.27 $360.91 $422.44 $742.85 $800.69 $1,212.66 $1,551.06 $1,725.31 $2,436.52 $3,175.55 $3,296.46 $4,623.23 $5,085.47 $5,942.35 50% $374.09 $451.14 $528.04 $928.56 $1,000.87 $1,515.83 $1,938.83 $2,156.63 $3,045.66 $3,969.44 $4,120.58 $5,779.04 $6,356.84 $7,427.94 40% $448.91 $541.37 $633.65 $1,114.27 $1,201.04 $1,818.99 $2,326.59 $2,587.96 $3,654.79 $4,763.33 $4,944.69 $6,934.85 $7,628.21 $8,913.52 30% $523.72 $631.60 $739.26 $1,299.98 $1,401.21 $2,122.16 $2,714.36 $3,019.29 $4,263.92 $5,557.22 $5,768.81 $8,090.66 $8,899.58 $10,399.11 20% $598.54 $721.82 $844.87 $1,485.70 $1,601.39 $2,425.32 $3,102.12 $3,450.61 $4,873.05 $6,351.11 $6,592.93 $9,246.47 $10,170.95 $11,884.70

Savings are calculated on a basis of $0.10 per kw/h

5-Year Product Warranty

The Great Lakes GTX series refrigerated air dryer is manufactured to the highest quality standards. Over 25 years ago in a decision to express this quality standard and distinguish our products from competitors, we standardized on an industry leading 5-Year Product Warranty. This unique warranty covers the entire dryer for 5-Years and excludes only maintenance items. Many competitive warranties cover only select components, and or prorates a charge for component replacement. With continuous improvement of quality standards, along with engineering improvements that are moving ahead of current technology, you can be assured that Great Lakes Air Products will provide you with a quality product for years of uninterrupted service. For detailed warranty coverage and requirements consult the GTX warranty publication.

Made With Pride in the U.S.A.

Great Lakes Air manufactures all of its compressed air dryers at one of its southeast, Michigan facilities. We offer our customers a steady stream of high quality industrial products with a proven history of performance. Replacement and maintenance components are readily available through the Great Lakes distribution system or are also available through several national networks of wholesale refrigeration supply houses. Purchase the quality and durability of an American made product.

Environmental Refrigerants
Great Lakes Air GTX series utilizes only non ozone depleting Hydro-fluorocarbons or HFC refrigerants approved by the EPA and Montreal protocol. Models with fractional HP refrigeration compressors utilize R134A refrigerant. The larger systems utilize R404A refrigerant which has no phase out program. Optional refrigerant types are available consult your representative for details.

Design Features & Benefits

GTX series compressed air dryers are designed for ultra low pressure drops that average 3.7 PSID. Pressure drop can substantially increase the operating cost of your dryer, each pound of pressure drop (PSID) raises the required compressor horsepower by 0.5%. If a facility is required to raise discharge pressure by 3 PSI to overcome component restriction (Pressure Drop), 1.5% additional compressor HP is required.

Low Pressure Drops

Adjustable Dewpoint
This feature allows the user to adjust the temperature of the Trans-Temp Energy Cell affecting the dryer dewpoint. Increasing dewpoint in applications that do not require optimum dewpoint suppression will further increase energy savings. The controller has a bright LED display, alarm text messaging, and a display that will read in F or C.

Component Level Reliable Design

SS thermostatic expansion valve with interchangeable SS orifices to matches system design to refrigeration load. This modulates refrigerant flow to match modulating system requirements caused by ambient temperatures and changing compressed air loads. Capillary tube systems used by other manufacturers will increase or decrease refrigerant flow on ambient conditions with no regard to system load. High ambient temperatures or slightly clogged condensers will increase refrigerant flow without a load to balance the system. Operation under these conditions can cause premature compressor failure. The addition of a suction accumulator further reduces the possibility of refrigerant liquid returning to the compressor causing premature failure. The addition of liquid receivers provide a stable feed to the refrigeration expansion valve. This provides pump down ability and additional refrigeration storage avoiding a critical charge system. Full service refrigeration valves are standard on both the suction and discharge systems. SS panel mounted gauges with brazed connections and coiled vibration eliminators removes the possibility of a refrigerant leak from a common leak point in competitive dryers. During refrigeration compressor off cycles the liquid line solenoid isolates the high side from the low side of the refrigeration system. This prevents refrigeration liquid from condensing in the TRANS-TEMP energy cell then slugging the compressor with that condensed refrigerant during restart. The the liquid line solenoid adds years of trouble free service to your refrigeration compressor and GTX series dryer. Great Lakes dryers utilize high quality diaphragm type solenoid valves as drains in addition to an isolation valve and strainer. Diaphragm valves isolate contaminants from the internal piston that would normally foul and restrict its movement causing failure. Diaphragm valves also have much larger orifices and flow paths that in conjunction with the strainer virtually eliminates the possibility of clogging a condensate drain valve.

Great Lakes Premium Diaphragm Valves

Industry Standard Direct Acting Valves

Non Standard Condition Capacity Correction

Inlet Temperature F Ambient Temperature F 70 psig 80 psig Inlet Air Pressure 90 psig 100 psig 110 psig 120 psig 130 psig 140 psig 150 psig 90 90 100 110 0.84 0.94 1.04 1.13 1.23 1.33 1.43 1.53 1.63 90 0.80 0.90 0.99 1.09 1.18 1.28 1.37 1.47 1.56 1.00 0.92 1.12 1.03 1.24 1.14 1.36 1.25 1.48 1.36 1.60 1.46 1.72 1.57 1.83 1.68 1.95 1.79 100 100 0.73 0.82 0.91 1 1.08 1.17 1.26 1.35 1.43 110 0.67 0.75 0.83 0.91 0.99 1.06 1.14 1.22 1.30 90 0.66 0.73 0.81 0.89 0.97 1.04 1.12 1.20 1.28 110 100 0.60 0.67 0.75 0.82 0.89 0.96 1.03 1.10 1.17 110 0.55 0.61 0.68 0.74 0.81 0.87 0.94 1.00 1.07 90 0.50 0.55 0.61 0.67 0.73 0.79 0.85 0.91 0.97 120 100 0.45 0.51 0.56 0.62 0.67 0.72 0.78 0.83 0.89 110 0.41 0.46 0.51 0.56 0.61 0.66 0.71 0.76 0.81

To obtain flow capacities at conditions other that standard (SCFM @ 100 PSIG, 100F Inlet & 100F 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 of the selected dryer under corrected operating conditions. Flow rates in excess of design due to capacity correction can result in increased pressure drop. Example: Model GTX-500 operating at 110F, & 100 PSIG inlet with a 100F ambient the corrected maximum dryer capacity would be: 500 x 0.82 = 410 SCFM if your volume requirements are 475 SCFM the GTX-500 is to small and the next larger unit must be selected.

Standard and Optional Features

Features
Power & Instrument

100/125 Optional Optional

180

225/600 Standard

800/2250

Refrigerant Suction Gauge Refrigerant Discharge Gauge Air Outlet Pressure Gauge Illuminated Power On Switch Compressor Relay/Contactor Compressor Overload Protection Compressor High Pressure Shutdown* Compressor Low Pressure Shutdown * Optional Optional Optional

Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Optional Standard Standard Optional

Refrigeration Drain

Compressor Crankcase Heater SS Thermostatic Expansion Valve Liquid Line Solenoid Suction Accumulator Liquid Receiver Air Cooled Condenser Water Cooled Condenser Condensate Strainer with Isolation Valve Diaphragm Timed Solenoid Drain Valve Zero Loss Drain Installed

* supplied with automatic reset manual reset is available as an option

Specifications & Dimensions

Model Number GTX-100A-t GTX-125A-t GTX-180A-t GTX-225A-t GTX-300A-t GTX-400A-t GTX-500A-t GTX-600A-t GTX-800A-t GTX-1000A-t GTX-1350A-t GTX-1800A-t GTX-2000A-t GTX-2250A-t
Notes:

35F PDP 100 125 180 225 300 400 500 600 800 1000 1350 1800 2000 2250

50F PDP 120 150 216 270 360 480 600 720 960 1200 1620 2160 2400 2700

Available Voltages 208/230-1-60 200-1-50

HP 5/8 3/4 1 1-1/2 2 2.8 3 4 5 7 9 10.5 12 13.5

Watts 954 1130 1319 2234 2399 3574 4647 5144 7199 9339 10059 13889 15208 17654

Freon 120V 134A 134A 134A 404A 404A 404A 404A N/A 404A 404A 404A 404A 404A 404A N/A 404A 1 N/A 1 1-1/2 208/230-3-60 ~ 440/480-3-60 200-3-50 ~ 575-3-60 1-1/2 2 2 2 3 3 4 Flg 4 Flg 4 Flg 3 1-1/2

H 34 34 46 46 46 46 46 46 60 60 65 75 75 75

W 26 26 33 33 33 33 33 33 35 35 42 57 57 57

D 33 33 30 30 45 45 45 45 56 56 67 74 74 74 320 350 500 525 750 880 920 950 1525 1780 3200 3800 4050 4375

1. Capacity reflects 100F & 100 PSIG inlet conditions and a 100F ambient. 2. The symbol "t represents a missing voltage designation see table for appropriate designation 3. Inlet/Outlet connections are NPT unless otherwise specified 4. Refrigeration watts specified is an average of all power components through a fully loaded operational cycle. 5. For full load amps and recommended max fuse see owners manual. 6. Dimensions are in inches, complete drawings available at www.glair.com 7. Shipping weight is in pounds 8. Dimensions, weights, and specifications are subject to change without notice

115/120-1-60 100-1-50

116 115

Voltage Designation Table 208/240-1-60 216 440/480-3-60 200-1-50 215 575-3-60 208/240-3-60 236 200-3-50 235

150 PSIG

230 PSIG

436 536

Dryer Heat Rejection & Cooling Requirements

Water-Cooled Units: 55.2 BTU/H per SCFM of dryer capacity to cooling fluid 4.8 BTU/H per SCFM of dryer capacity to ambient Fluid Requirements 0.0040 GPM per SCFM of dryer capacity @ 50F Fluid 0.0050 GPM per SCFM of dryer capacity @ 60F Fluid 0.0065 GPM per SCFM of dryer capacity @ 70F Fluid 0.0100 GPM per SCFM of dryer capacity @ 80F Fluid 0.0150 GPM per SCFM of dryer capacity @ 90F Fluid Air-Cooled Units: 60 BTU/H per rated SCFM of dryer capacity to ambient

Shipping Weight

In / Out Ports

Refrigeration System

Max. Inlet Pressure

Capacity in SCFM @100 PSIG &

Dimensions Inches

Other Products from Great Lakes Air Products

GRF Series Non Cycling Refrigerated Air Dryer

EDR Series High Inlet Temperature Air Dryer

Regenerative Type Desiccant Air Dryers

Compressed Air Filtration Distributed By:

Condensate Drain Systems

Great Lakes Air Products, Inc. 5861 Commerce Drive Westland, MI 48185-7689 USA Ph: 734-326-7080 Fx: 734-326-5910 www.glair.com