The initial purge and desiccant cartridge decompression lasts only a few seconds and is evidenced by an audible burst of air at the AD-9 ™ air dryer exhaust. Most refrigerated air driers also want a coalescing filter before the unit, and one after it as a sanity check isn't a bad idea either. Turned out to be the PPV because the governor wan't getting any air pressure to put the compressor into unloading AND send a signal to purge the dryer. That will start the next charge cycle. Turned out to be the PPV because the governor wan't getting any air pressure to put the compressor into unloading AND send a signal to purge the dryer. You must log in or register to reply here. Whoever sold the apple processor those original dryers clearly didn’t take a systems approach. A couple of other details:-The pressure in the tanks seem to stay steady at about 120psi. Actually ran it for about an hour while fanning the brakes. Here are some descriptions of a few recent troubleshooting calls I have personally made, where the systems approach worked well. Desiccant dryers all have a built-in regeneration cycle, which can be based upon time, dew point, bed moisture load or a combination of these. What we found here is the compressor room is a separate building, and the compressed air lines run outside before entering the apple sauce plant. Everything checked out. If it's building too much pressure it's probably not the dryer. Oil present at air dryer A. So to add to the saga of things that need to get addressed, I noticed the air dryer purging some oil. I get calls on every make and model imaginable. Get Rid of Troublesome Problems in your Air System with the help of Van Air Systems. lots and lots of looking unsuccessful. removed by air flowing from the purge volume through the desiccant drying bed to the open purge valve. This dryer operates on an 8 hour cycle(4 hours drying, 4 hours regenerating) so I had to wait for an hour or so to make sure the regenerating tower was coming up to the proper temperature. All of the pipe runs are stainless steel and indoors. It is not unheard of for the  governor to get moist and to freeze. This customer has a 5000 SCFM Van Air Systems, model HB-5000, externally heated blower purge dryer and a 5000 SCFM Van Air Systems, model HL-5000, heatless dryer as a backup. This leads to instant project rejection. D. If it is not seated it will allow pressure to bleed back out the purge valve in a constantly repetitive 10-30 sec cycle. Air dryer started purging every minute and a half or so. exhaust port of governor. Check solenoid valve. When I arrived on site, the customer told me that he could not maintain the specified -40 dew point with the blower purge dryer. It must be connected to an unloader port on the governor. All I'm familiar with are Bendix air dryers and have repaired many. See Causes, B, E, and G for Symptom #4. Here again, we checked all the condensate drains to make sure they were working. So I went back and traced all the piping between the compressors and the dryers. Heated purge air may also be supplied by a blower. Note that at the end of the purge cycle if the air dryer exhibits fl uttering, perform the unloader leakage test on the compressor, per the manufacturers guidelines, before continuing. The purge valve will not close until air brake system pressure is reduced and the governor signals the compressor to begin compressing air again. As the service reservoir air pressure drops to the “cut-in” setting of the governor, the governor returns the compressor back to building air and the air dryer to air drying mode. It may not display this or other websites correctly. The air dryer will then purge. The drops were from the bottom of the pipe header instead of the top. If it's not shutting off the compressors ability to build pressure then the system will over pressure. Within the air dryer system, there are three key components to monitor: the air dryer cartridge, the purge valve, and the delivery check valve. They replaced the desiccant, governor, valve, and dried out the lines. I had a Mack that would freeze up a compressor mounted governor. The end-user had dramatically restricted the flow of purge air. Clean or replace purge control line. Order Entry Fax: 814.774.3482, Pipeline Natural Gas Dryer used to prevent wellhead freeze-up for the TransCanada Pipeline. Failure to Shift (Dryer fails to pressurize.) After determining air reaches purge valve control port by installing a T-fitting with a pressure gauge into the governor unloader port, repair purge valve if necessary. The telltale sign of this problem is a drying tower that doesn’t hold full pressure. What’s the danger of having moisture in your natural gas pipeline? Even though I eventually solved the problem, I should have looked at the piping and valves sooner. This allows any condensation in this area to flow past a diaphragm in the top of the purge piston and out through a channel in the middle of the central bolt of the purge SEPARATOR assembly to be drained. The primary products produced at this facility are apple juice and apple sauce. Air system leaks, such as compressor discharge line, air dryer, reservoirs, brake or … Contact Us. Repair and replace if necessary. This is a small clear tube filled with color changing silica gel crystals. Started doing that I’m very cold weather. 2012 cascadia dd13 air dryer not purging. Compressor fails to unload (stop compressing air) and air dryer purge exhaust makes “sputtering” or “popping” sound Purge control line connected to reservoir or exhaust port of governor. In the winter months in northern Virginia temperatures can fall well below 35F. As soon as I stopped the needles began to rise, and continue on past 120, and headed for the top. Ken The same air signal is sent to the dryer to operate the purge valve. Upon further inspection I found the customer piped the purge exhaust from the dryer some 20 ft to an outside wall. exhaust piping must not restrict the passage of purge air near atmospheric pressure. The first application we looked at included a 75 horse power screw compressor, an after-cooler with a separator and automatic condensate drain, and a Hankison 300 SCFM heatless dryer with mounted pre- and post- filters. The customer strongly believed that our dryers were not performing. Over the years we have built a great reputation for helping customers solve issues with their compressed air systems regardless of what brand equipment has been installed. Remember always have a systems approach. if it is an ad-9 drier and it leaks through the purge valve after its initial main purge and doesn't stop till it is back on the build cycle check the check valve in the discharge port. Purge valve frozen open – malfunctioning heater and thermostat, wiring, blown fuse. After a short time, I noticed a strange noise coming from under the dash in the drivers area. Manufacturing Website Design. The purge air may also be heated, either within the dryer or externally, to reduce the amount of purge air required. 15.0 Compressor constantly cycles (compressor remains unloaded for a very short time.) 5) Air dryer does not purge or exhaust air. Blue crystals mean the dryer’s outlet air is dry. Also, we informed them the bottling plant application could have used a refrigerated dryer instead of a regenerative dryer because all of the compressed air lines are indoors in a climate controlled ambient and a -40F PDP is not necessary. to stop the compressor from building air and also causes the air dryer to purge. Compressed air dryers are special types of filter systems that are specifically designed to remove the water that is inherent in compressed air. When the air dryer builds to 120 nominal psi the piston in the governor shifts closing the unloader line and opening the purge line, springs on the unloader valves in the head of the air dryer are overcome with air pressure and are held open. Pink crystals indicate that wet air is exiting the dryer. Warming it up should return it to good service, but a replacement is pretty cheap. In this case, the moisture indicator on the dryer was blue. The truck will not build air due to air constantly pumping out the purge valve. The single check valve in the AD-9 end cover keeps air pressure in the brake system from blowing back into the air dryer during the purge cycle. Warming it up should return it to good service, but a replacement is pretty cheap. After determining air reaches purge valve control port by installing a T-fitting with a pressure gauge into the governor unloader port, repair purge valve if necessary. Turn off power to the dryer.In many makes and models, both towers will pressurize. Swapped the air dryer and new governor. The post filter should never have any water in it, but if you start getting moisture its a good hint that something is wrong with the drier. We also informed the customer they really need to install a regenerative dryer rather than a refrigerated for the apple sauce plant. 13.0 Reservoir safety valve releases air 14.0 Air dryer doesn’t purge. Wh … read more I first try find a solution over the phone, but sometimes it actually requires a on-site inspection of the customer’s plant air system. Air brake charging A. Failure to Shift (Dryer fails to pressurize.) The initial purge and desiccant cartridge decompression lasts only a few seconds and is evidenced by an audible burst of air at the AD-IPTM air dryer exhaust. We checked all the drains and the pressure and temperature conditions at the dryer inlet. Toll Free: 1.800.840.9906 If it is a Bendix, its probably an AD9 or an AD-IS. If the dryer is operating on a fixed cycle with no dew point control and the associated compressor turns off for some reason, which stops the flow of compressed air through the dryer, the purge will often continue to be fed from other system compressors. When the air pressure becomes greater than that of the preset “cut-out”, the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also causes the air dryer to purge. It either allows the air compressor to keep "making air" or allows the air to bypass back into the compressor and stop filling the tanks. Air-Cooled Aftercooler System a “must have” product for your Portable Diesel Air Compressors. Failure to Shift (Dryer fails to depressurize.) there are two air lines that go to the dryer, one is the unloader line, its stamed on the dryer. Everything checked out, the dryer was getting a 35F PDP according to the readout on the control panel. Next, I looked at the visual moisture indicating stick on the dryer’s gauge panel. (Never hear exhaust from air dryer.) This means looking at a complex range of problems and solutions, not just what you suspect the problem to be. One problem I observed here was the piping drop legs. Stopped and drained the tanks. Corporate Fax: 814.774.0778 JavaScript is disabled. Check valve – This keeps the air in the air tank from back-flowing into the air dryer. 3. The air dryer will then purge. Air tank – This is where the compressed air is stored. You need to develop a systems approach. I started by looking at the compressors to confirm operating pressures, temperatures, and flow rates to the dryers. It is not uncommon for the governor to freeze up. Faulty air dryer purge valve. It was a squeaky, rushing air noise that sounded like static on an AM radio. No loss in pressure. Built air to 150 psi and it blew off at the compressor. B. Rule of Thumb:  When piping purge exhaust to a remote location you must increase the pipe diameter by one full size every 10 feet. c. The process of compressing air raises its temperature and concentrates atmospheric contaminants, primarily water vapor. a. Yup it was moisture in the lines. I know I do not have any air leaks as I only lose about 5 PSI over 24 hours. Too much pressure in a regenerating tower of heatless dryer causes problems. Next, I checked the automatic condensate drains on the after-cooler separators and pre-filters. Faulty air dryer purge valve. The air governor could also be froze up not from cold/moisture, but from rust/corrosion. As a best practice in preventive maintenance, Bendix recommends replacing the purge valve assembly whenever the air dryer cartridge is replaced. Bendix AD9 air dryers have a large capacity desiccant cartridge that allows for longer maintenance intervals. Check to make sure air flows through purge control line when compressor is unloaded. My truck last winter did that. The air dryer cartrige was old, and it ruined the governor and a valve up front. I have an International 9900 with an AD-IP air dryer. This flow allows the purge cycle to continue uninterrupted, but once the desiccant has been regenerated an uncontrolled dryer will continue to consume purge air for no reason and waste significant amounts of compressed air … Here's the piece I think you should be looking for. Once I closed the by-pass valve and dried out the sample cell on the plant’s dew point meter, the dew point came back into specification. Because the heatless dryer was not working properly all of the moisture going downstream was pooling in the bottom of the pipe header and made its way to the bottling machines. I’m always glad to solve a problem, even when it involves a non-Van Air Systems dryer. The dryer is purging about every 30-45 seconds. Purge valve stuck in closed position. Everything looked good. Repair and replace if necessary. The customer insisted something was wrong with our dryers. b. It does this whether I am parked or driving. What is Dewpoint and How Low Should it be in my Compressed Air System? The air dryer remains in the purge mode until the air system pressure drops below the governor cut-in pressure, thereby placing both the compressor and the air dryer in the charge mode. We then took a look at the 700 scfm compressed air application in the apple sauce plant. After the purge reservoir pressure is depleted, the air dryer desiccant has been regenerated and is now ready for the next charge cycle. In this case the lack of dry air had nothing to do with the dryers. 3. Our representative in Virginia, PBE Inc., asked me to make a call with them to try and solve the customer’s compressed air problems. A. c. Faulty purge valve. I’m asked quite often to troubleshoot compressed air dryers. Heatless desiccant dryers do not contain a heated system in the regenerating tower; instead, they utilize “purge air” to expel moisture from the tower. If it is working properly then the dryer and the tanks can't possibly overpressure themselves because the compressor isn't still "working". Freeze-ups can happen anywhere. The compressed air supplied by this installation feeds the apple juice bottling line. Easy To Service Desiccant cartridge replacement is the only reason to ever completely disassemble the Bendix AD9 air dryer. ð Verify operation of air dryer. Purge valve stuck in closed position. This restriction caused the back pressure we were seeing on the regenerating tower. Even though all the drying and filtration equipment used by this customer was from a competitor, we were able to solve the customer’s problems and we will be involved in their future expansion plans. Regenerative desiccant compressed air dryers require purge air to strip moisture from the desiccant beds. We always do, hence the name, Van Air Systems. Is there a "best" fuel purchase program for diesel? Internal purge volume does not use system air for regeneration, maximizing available air for braking, suspension and transmission. Oil filter – This captures the oil from the desiccant that is purged at the purge valve. Be glad it didn't freeze up on the road and keep pressure from building. We later got a report that he’d completed the re-work and the problem had been solved. The governor is a rather in expensive item to buy and easy to change. For a better experience, please enable JavaScript in your browser before proceeding. It is not uncommon for the governor to freeze up. I have a 1997 cummins 8.3 with a holset compressor and AD-9 dryer. The regenerating tower on a heatless dryer must be at 0 psig in order to get a complete regeneration of the desiccant bed. In this case, the purge exhaust pipe size was actually smaller in diameter than the purge outlet on the dryer. This is a fairly common strategy for managing the noise of a heatless dryer. A systems approach finally led me to the source of the trouble. We also checked the inlet conditions to the dryer. Air dryer does not purge or exhaust air. Line between governor and dryer kinked, plugged, broken or frozen. That’s where I found the problem. Great idea. Repair or replace thermostat/heater. Check solenoid valve. Also, we informed them the bottling plant application could have used a refrigerated dryer instead of a regenerative dryer because all of the compressed air lines are indoors in a climate controlled ambient and a -40F PDP is not necessary. Consequently, the compressed air is generally at an elevated temperature and 100% relative humidity. It’s not just Van Air Systems dryers. Advice on Appropriate SUV To Tow 4k lb Camper, Back after our Texas winter storm (storms actually). But if one isn’t careful, this extra piping will put a lot of back pressure on the regenerating tower. Phone: 814.774.2631 When I arrived on site, the customer told me that he could not maintain the specified -40 dew point with the blower purge dryer. if it is an ad-9 drier and it leaks through the purge valve after its initial main purge and doesn't stop till it is back on the build cycle check the check valve in the discharge port. Problem: Wet air downstream of the dryer This customer has a 5000 SCFM Van Air Systems, model HB-5000, externally heated blower purge dryer and a 5000 SCFM Van Air Systems, model HL-5000, heatless dryer as a backup. Of course, this would be a stop gap measure until the root cause of the water could be addressed. Since the compressed air lines run outside between the buildings they are condensing water out when the ambient drops below 35F. Now, I watched the heatless dryer to make sure it was cycling properly. If it's building too much pressure it's probably not the dryer. No purging of air should occur after 30 seconds. Purge valve does not open. Applications:  Dry 300 scfm of compressed air to -40 FPDP, Dry 700 scfm of compressed air to +35FPDP, Problem:             Product rejections resulting from wet compressed air downstream of the dryers. Shut off the engine and push in the yellow button to … Check that repressurization circuit is sending control signal. I have installed a new purge valve, new governor, new desiccant ca … read more Donaldson coalescing air dryers are designed to meet the specific needs of your application by removing oil and water from the air brake system. See Causes, B, E, and G for Symptom #4. Build some heat in the engine block, shut her down for 15-20 min., let her heat soak and problem solved until the next cold damp day morning. The governor is mounted to the compressor and sends an air signal to the unloader when pressure is reached. The operator then put heatless dryer on line. Air compressors are designed to build air … Note 1: ® The AD-IS air dryer and reservoir system DESICCANT purge piston has a purge control channel drain. Too. Air brakes are their specialty. There's also a patch of oily grass under where the air dryer purges. Air Dryer Cartridge Maintenance – Easy as 1-2-3 Depending on vocation, Bendix recommends a one-, two-, or three-year air dryer cartridge replacement on vehicles equipped with a Bendix compressor. A refrigerated dryer cannot product air lines exposed to low ambient temperatures. Purge valve – This is opened and the air purges the water and oil. Next morning pressure gauges were reading MAX air pressure. It is not uncommon for the governor to freeze up. Heated Dryers. As I was crawling around to try to find the source, I noticed the air pressure on both gages were pegged at 150psi! Our contact said water was showing up in the apple sauce plant especially in the winter months. Check that repressurization circuit is sending control signal. need suggestions for 3/31 & 4/1 RV park for 40' DP st petersburg area. Next we visited the bottling plant. Air dryer not purging Purge (air exhaust) time insufficient due to excessive system leakage Excessive air usage, duty cycle too high Compressor malfunction - Passing oil Air bypasses desiccant cartridge assembly - If vehicle has a Holset compressor, inspect feedback check valve. Page 21 ™ AD-9 AIR DRYER TROUBLESHOOTING CHART (Continued) REMEDY SYMPTOMS CAUSE C. Purge control line C. Purge control line must be connected to connected to reservoir or unloader port of governor. It is not unheard of for the governor to get moist and to freeze. maintenance not (d) Air dryer malfunction. (due to the inaccuracy of the gauges) and stop. purge cycle. Typical dew points in heatless dryers range from -40°C to -73.3 °C (–40 to –100 °F). I'd run it at high idle for a period of time, depending on ambient temp. Our interim suggestions were to insulate the outside pipe run that feeds the apple sauce plant and to install a moisture separator in the main header immediately after it enters the apple sauce plant. The same air signal is sent to the dryer to operate the purge valve. I noticed that the off stream regenerating tower pressure gauge read 30 psig. Prevent pipeline freeze-ups, like what occurred in Texas with a Deliquescent Natural Gas Pipeline dryer. You are using an out of date browser. If the equivalent length of extended purge exhaust piping does not exceed 15 feet, use pipe one size larger than the dryer purge exhaust connection. The governor is mounted to the compressor and sends an air signal to the unloader when pressure is reached. Here are some steps you should take if this is happening. Still doing the same thing after new parts. So how was moisture appearing downstream of the dryer? Its not a puddle or anything, but the wet tank has a small leak from the drain valve and the tank is getting oily around it. Faulty purge valve: Check purge valve and its solenoid valve. What was causing this back pressure, I next asked. If you have any questions not covered in our FAQ, send us a message and we’ll get back to you shortly. I then asked the customer to bring the HB-5000 blower purge dryer on line. Built air to 150 psi and it blew off at the compressor. A. Take note: Wet Compressed air + Dry Compressed air = Wet Compressed Air. Sometimes the problem is where you least expect it to be. Check that the air dryer purge value is functioning correctly; if this gets stuck in the open position, it can leave your system very sluggish and slow to build pressure. I am not getting any air from the small air line to actuate the dryer. Since it would be quite costly to re-do all of these stainless steel pipe drops correctly, we recommended the customer install point of use filtration on all the bottling machine pipe drops. Had I been in his shoes, I’d have felt the same way. Faulty purge valve: Check purge valve and its solenoid valve. Air dryer safety valve ð ê ê Technician removes governor. As the atmospheric air is compressed, all the water 100-watt heater available for 12-volt or 24-volt applications I realized I had never heard the purge valve, and immediately started pumping the brake pedal to lower the pressure. The key to helping the customer is to take your time and properly analyze the installation. a. Sound like it time to put some ethanol in the air tank to De ice it, Also try to find a trucker forum. Whenever compressed air cools below its dew point, condensation will start to form. So I shut her down. We have a 2002 Newmar Dutch Star and today when I started it up everything seemed fine. My truck last winter did that. Usually the air lines going to the dryer comes from the governor, this one does not. Lake City, PA 16423 Truck is a '98 3116 with 16k miles. A common failure in older dryers is leaking or purging air from a tower that should not be venting any air. Air dryer does not purge or exhaust air. After this, I fast cycled the dryer to make sure it was sequencing properly. 2950 Mechanic Street Note that at the end of the purge cycle if the air dryer exhibits fl uttering, perform the unloader leakage test on the compressor, per the manufacturers guidelines, If it is not seated it will allow pressure to bleed back out the purge valve in a constantly repetitive 10-30 sec cycle. The governor is mounted to the compressor and sends an air signal to the unloader when pressure is reached. We then to a look at the dryer to make sure it was cycling properly. Purge valve does not open. The air governor is mounted right on the compressor prior to the compressed air going to the dryer. There was an open by-pass valve. Still wet air was somehow getting downstream. Faulty heater or thermostat. Everything checked out here as well. Internal governor to simplify plumbing, reduce overall installed cost, and has improved functionality and faster response timing. I needed to confirm that the each tower pressure gauge read zero during regeneration. Externally heated regenerative desiccant dryers use temperature swing adsorption (TSA). The puzzle was still not solved. A. b. The air governor is mounted right on the compressor prior to the compressed air going to the dryer. A refrigerated dryer cannot product air lines exposed to low ambient temperatures. Be glad it didn't freeze up on the road and keep pressure from building. A common failure in older dryers is leaking or purging air from a tower that should not be venting any air. Failure to Shift (Dryer fails to depressurize.) B. The customer was very appreciative we were able to help them solve their moisture problems which will eliminate the product rejection issues. Application:    Dry 5000 scfm of compressed air to -40F Pressure Dew Point (PDP), Problem:         Wet air downstream of the dryer. A. – Oil or lubricants can cover the desiccant material, which makes it useless if pre-filtering is not maintained – Purge air is typically required. For this troubleshooting call, I visited an apple processing plant in the Shenandoah Valley region of northern Virginia. Here slugs of water from the compressed air system were landing directly on product. The actual reactivation of the desiccant drying bed begins as dry air flows from the purge volume through the desiccant cartridge purge orifice and into the desiccant drying bed. The same air signal is sent to the dryer to operate the purge valve. Wet air upstream of the dryer was escaping past the dryer, mixing with the dried air. Air dryer rebuilds can be stretched to every 36 months when the AD-9 is installed on a typical over-the-road truck or tractor. This system has (3) 50 horse power screw compressors with after coolers, separators, a competitor’s refrigerated dryer with pre and post filters, and a dry air receiver tank. These dryers use a series of valves to control the flow of compressed air through the dryer. We told the customer he needed increase the pipe by 2 full pipe sizes. After all, he had wet air in his plant. Tried that. Be glad it didn't freeze up on the road and keep pressure from building. This will address several potential purge valve issues, including: Air leakage or lack of pressure building due to purge valve seal wear “Popping” of the purge valve due to intermittent sticking Now, I was on the defensive.
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