Possible causes: Acute overload due to extreme dust ingress, incorrect cleaning parameters, irreversible clogging (blinding) of the medium, or an excessive air volume flow that exceeds the system's capacity.
Solutions: Check cleaning (operating pressure in the pressure tank depending on the medium 4-6 bar, impulse time depending on the medium 0.1 – 0.35 s), if necessary switch to Delta P cleaning to promote filter cake build-up and prevent deep storage, change filter medium (for very fine, sticky dusts, a change to special coatings may be necessary, for pleated media, reduce the pleat depth if necessary), control volume flow (if the actual volume flow is far above the design, this leads to high filter surface load and wear of the filter media), if necessary, the filter surface must be enlarged or the volume flow reduced.
Possible causes: Mechanical defect in the filter medium (tear, hole), inadequately secured element on the perforated plate (bypass), check volume flow (if the actual volume flow is far below the design, this leads to very low filter surface loading and barely measurable differential pressure)
Solutions: Check filter paper for dust traces, visually inspect the perforated plate for correct seating of filter elements and seals, examine filter media for damage and replace defective elements, if necessary increase volume flow (reduce constrictions or install bypasses).
Possible causes: The internal valve membrane is torn, the upstream solenoid valve (pilot valve) is faulty or blocked by dirt particles in the compressed air and no longer closes.
Solutions: Depressurise the compressed air tank, open the affected valve, check the diaphragm and spring for breaks and clean them or install the repair kit (diaphragm kit), replace the solenoid valve if necessary.
Possible causes: Too frequent cleaning (continuous pulsing) causes deep penetration of particles into the filter medium, abrasive or oily/greasy dusts.,
Solutions: Extend cleaning intervals or switch to delta p-dependent control, for abrasive fine dusts use polypropylene filter media, for oil-/grease-containing dusts switch to oleophobic filter media.
Possible causes: The seal on the filter plate or filter cartridge is missing or damaged, incorrect installation of the filter element, fabric too coarse for the fine dust present (conditioning failure), too frequent cleaning (continuous pulsing) prevents the formation of a protective filter cake, fine particles pass through the medium instead of being trapped by the filter cake.
Solutions: check seals and correct installation of filter media, switch to filter media with a PTFE membrane or solid body (Sinbran) for fine dust, extend cleaning intervals, or switch to Delta p-dependent control.
Possible causes: Dropping below the dew point in the filter housing (condensation formation), wet or oily compressed air from the compressor network in combination with hygroscopic dusts.
Solutions: Insulate or heat the filter housing, check the compressed air system's water separator and refrigerant dryer, use media with a PTFE membrane or oleophobic treatment for sticky dusts.
Possible causes: Residual dust remaining in the housing cools down during downtime, attracts moisture and settles on the elements as a sticky film.
Solutions: Activate post-cleaning phase (after-cleaning cycle). After the main fan is switched off, the cleaning process must continue to run automatically for 10–15 minutes while stationary, in order to completely discharge the dust into the hopper.
Possible causes: The tank volume of the compressed air reservoir is too small, the air supply line to the pressure tank is undersized, so that air cannot flow in fast enough, the impulse time is set incorrectly (too long)
Solutions: Enlarge the cross-section of the compressed air supply line, install a larger pressure tank, correct the pulse time (pulse time 0.1 – 0.35s depending on the medium).
Possible causes: The operating pressure in the compressed air tank is too low, the valve opens too slowly due to a defect, or the blow pipe is misaligned and does not hit the element opening centrally.
Solutions: Set the pressure regulator to the set point (usually 4–6 bar), check the alignment of the blow pipe with the filter inlets, and check the diaphragm valve and solenoid valve.
Possible causes: The downstream discharge unit (rotary vane feeder, screw conveyor or flap) is blocked, defective or overloaded, material clumping in the hopper and not feeding down sufficiently.
Solution: Stop discharge components and remove mechanical blockages, retro-fit a fill-level sensor in the hopper to prevent overloading early on, retro-fit knockers or vibratory pads.
Possible causes: The flushing pressure is too low; the filter element is blocked.
Solutions: Check the cleaning pressure at the pressure tank (4–6 bar depending on the medium); check the filter elements.
Possible causes: Abrasive dust strikes the filter media directly at too high an inlet velocity, or the support baskets have sharp edges or are damaged
Solutions: Fit baffle plates or a deflector in the raw gas inlet of the filter to redirect the air flow; check the support baskets and replace them if damaged.
Possible causes: The internal support frames are incorrectly dimensioned or damaged.
Solution: Check correct fit of basket and filter medium, check support frame for damage.
Possible causes: Use of pleated elements with sticky, fibrous, or very wet dusts. The narrow pleat spacing leads to mechanical bridging.
Solutions: Conversion of the filter to media with a larger pleat spacing, possibly filter bags or sintered elements (Sinbran).
Possible causes: Chemical reactions in the dust cake due to incomplete drying or falling below the dew point.
Solution: Increase process temperature, add thermal insulation to the filter housing, and if necessary, electrically heat it.
Possible causes: No power supply to the filter control unit, fault on the circuit board, main compressed air supply to the system is shut off.
Solutions: Check power supply and fuses for the control system, measure output signals to the valves, check the main shut-off valve on the compressed air line.
Possible causes: Missing or faulty earthing of the filter elements.
Solutions: Use exclusively antistatic filter media with a woven-in guide, Ensure that the grounding strands have metallic contact with the earthed perforated plate.
Possible causes: The filter is operated with excessively high negative or positive pressure, exceeding the static design of the housing.
Solutions: Immediately stop the plant, install safety valves, rupture discs or pressure relief devices, and, if necessary, reduce the operating pressure.
Possible causes: Deformed slot plate, missing filter media fastenings, damaged filter media support.
Solution: Check mounting plate for deformation, check fasteners, replace damaged elements (Caution: overtightening filter fasteners can damage filter elements!)
Cause: The pickup speed at the extraction points is too low, the extraction pipes are blocked
Solution: Check lines on flaps/throttles and open if necessary, check piping system for deposits, reduce filter differential pressure (e.g. by cleaning or changing filter media) to increase volumetric flow.
