An air dryer is an essential component of compressed air systems, being responsible for removing the moisture from the compressed air. They are vital because any moisture in the air can result in corrosion, rusting, ice formation and blockages that can cause damage to the system and even result in failure.
However, like any other component, air dryers are also prone to wear and tear, and eventual failure. There could be several reasons why they may stop working.
Let’s look at some of the most common reasons air dryers may fail.
Common Causes of Air Dryer Failure
Clogged or Dirty Air Filters
One of the most common reasons why air dryers may fail is due to clogged or dirty air filters. The air filter is responsible for removing particles and debris from the compressed air before it enters the dryer. Over time, the filter can get blocked with debris, which can hamper air flow and make the dryer less effective.
When the air filter is clogged or dirty, it can cause the compressor to work harder to compensate for the restriction. It can lead to increased energy consumption and operating costs. In extreme cases, a clogged air filter can even cause the compressor to overheat and fail completely.
To prevent this from happening, it is important to replace the filter regularly. The frequency of filter replacement will depend on the operating conditions of the system, but most manufacturers recommend replacing the filter every 6 to 12 months.
Inadequate Maintenance
Another common reason why air dryers may fail is because maintenance is not carried out on time, or properly. Like any other piece of equipment, air dryers require regular maintenance to ensure that they keep operating at peak efficiency. If you neglect their maintenance, you’d be risking a number of issues that can cause damage to your applications.
Common maintenance tasks for air dryers include replacing filters elements, desiccant cartridges and inspecting and cleaning float drains, timer drains, checking and monitoring the dew point of the compressed air. Neglecting maintenance can cause problems like reduced efficiency, increased operating costs, and component failure.
The easiest way to prevent your air dryer from failing to dry the air properly because of this is to stay on top of your maintenance and be as regular about it as possible. Most manufacturers will provide a recommended maintenance schedule that you should follow. Carry out regular inspections and keep track of any maintenance tasks that have taken place to make sure you stay on top of your schedule.
Electrical Issues (Refrigerated Air Dryers)
Air dryers rely on electrical components to operate, and issues with these components can cause the dryer to fail. Common electrical issues include blown fuses, damaged wiring, and faulty control panels.
When electrical issues occur, the dryer can stop working completely or may end up operating intermittently. In some cases, electrical issues can cause the dryer to overheat or cause other components in the system to fail.
To prevent air dryer failure due to electrical issues, you should ensure that the electrical components are properly installed and maintained. Regular inspections and testing can help to identify potential issues before they cause a complete failure.
If you do notice your air dryer failing due to electrical issues, you can likely get it fixed by replacing some wiring within certain parts. Some parts may need total replacement.
Refrigerant Leaks (Refrigerated Air Dryers)
Refrigerant leaks are another common cause of air dryer failure. Air dryers that use refrigerant-based cooling systems rely on a constant supply of refrigerant to operate. When there is a leak in the system, the refrigerant level can drop, which can cause the dryer to stop working properly.
These leaks can be caused by a number of different issues. From corrosion or damage to the refrigerant lines, to issues with the compressor. When a refrigerant leak occurs, it can reduce the capacity at which the dryer operates, which can result in your operating costs rising rapidly, and your efficiency dropping.
To keep your air dryer safe from problems caused by refrigerant leaks, perform regular inspections of the refrigerant lines and compressor. Any leaks should be repaired as soon as possible, and the refrigerant level should be checked regularly to make sure that it is at the proper level.
Desiccant Material Degradation (Twin-Towers Air Dryers)
Desiccant material is a key component of many air dryers. It is what’s responsible for absorbing moisture from the compressed air and making sure that the air leaving the dryer is dry and free from moisture. Your air dryer is practically useless without the desiccant material since this is what gets rid of all the moisture to begin with.
However, over time, the desiccant material can become saturated and less effective, which can cause the dryer to fail.
Desiccant material degradation can be caused by a range of factors, including high temperatures, exposure to chemicals, and long periods of use. When the desiccant material becomes saturated, it can cause a drop in pressure and reduced efficiency of the dryer. In extreme cases, desiccant material degradation can cause the dryer to stop working altogether.
To prevent air dryer failure due to desiccant material degradation, you should stay on top of inspections of the desiccant material and replace it when necessary. Most manufacturers of twin-towers air dryers recommend replacing the desiccant material every 3 to 5 years, depending on the operating conditions of the system.
Air dryers are important components of any air compressing system, and their failure can cost you large amounts in terms of replacement and fixing. It’s always better to stay on top of maintenance and inspections to catch problems before they escalate into something more difficult to deal with.
Still, no matter how much care you take, there will eventually come a point where you have no choice but to replace your air dryer. If you’re looking for high-quality air dryers and compressed air filters Super Dry Systems has just what you need. Head over to our website and check out our products!