Filter Cleaning System Troubleshooting Matrix Version 1.

0 Release: 11/10

To use this troubleshooting matrix, please make the closest selections in (1), (2), and (3) meeting the description of your particular problem. Then examine each possible source listed in (4) which will narrow down the possible causes (5), and ultimately recommend an appropriate remedy (6).
Please note: This troubleshooting matrix is a guide only and should not be the only point of reference for resolving problems with filter cleaning systems or the dust collector itself. If your specific filter cleaning system problem is not described below or is more complex to resolve
please contact the Goyen or Mecair representative in your area, or your system supplier.

(1) Category (2) Main Symptom (3) Secondary symptom (4) Possible source of problem (5) Possible cause (6) Remedy
Pressure loss Cleaning system manifold pressure decays to Pressure does not recover completely Compressed air supply to manifold Restriction to compressed air feed pipe to manifold. For Ensure feed pipes provide adequate flow to the system.
below the desired value. between pulses instance; isolating ball valves not fully open.
Manifold feed pipe diameter is too small. Ensure feed pipes provide adequate flow to the system.
External load on compressed air supply, such as a new Ensure compressed air supply system is able to meet the compressed air
process using air from same compressor. demand.
Compressor not adequately sized, or running under capacity. Ensure compressed air supply system is able to meet the compressed air
demand.
Pulsing frequency Pulse rate of valves is faster than the recovery time for the Increase pause time between pulses. Or adjust compressor cycle settings.
manifold to reach set system pressure
Cleaning system manifold pressure continuously Pressure decay rate is slow. Leakage at diaphragm valve Leakage past the main diaphragm. (1) Replace using diaphragm repair kit, (2) clean internal valve seats, (3)
decays between pulses to zero pressure or well determine source of foreign matter and eliminate.
below specification. System cannot be
pressurised.
Leakage through the valve integral pilot exhaust port (1) Replace component using pilot repair kit, (2) clean internal valve seats,
(3) determine source of foreign matter and eliminate.
Leakage at pilot valve Leakage at pilot line fittings Ensure good seals at pilot line connections.
Leaks within the pilot lines Replace pilot lines.
Leakage at the pilot valve exhaust port (1) Replace component using pilot repair kit, (2) clean internal valve seats,
(3) determine source of foreign matter and eliminate.
Leakage at valve to manifold attachment Incompatible/out of tolerance stub pipe threads. Check threads, if out of specification correct them.
Poor use of thread sealant or sealing tape. (1) remove valve, (2) clean off sealant from valve and stub pipe, (3)
carefully re-apply according to sealant instructions.
Dresser nut seals damaged Replace dresser nut seals using dresser nut seal replacement kit.
Dresser nuts loose Tighten firmly by hand or with the use of chaingrips, or dresser-nut
spanner tool.
Valve to manifold O-ring seal damaged or missing (FS, MM, or Inspect and replace if necessary. Also ensure sealing surfaces are clean
Mecair 400/500 series) and undamaged.
Leakage at other fittings on the manifold Leaks through welds or fittings Identify leak locations and consult factory (if a TES supplied manifold) or
contact the manifold fabricator for repairs.
Leakage at the manifold itself Leaks through welds. Identify leak locations and consult factory (if a TES supplied manifold) or
contact the manifold fabricator for repairs.
Air leaking through solenoid pilot exhaust Damaged sealing tip on armature/plunger Age/wear Replace using pilot repair kit.

Foreign matter such as metal shavings and grit (1) Replace component using pilot repair kit, (2) clean internal valve seats,
(3) determine source of foreign matter and eliminate.
Heat aging Check that application temperature is within the operating range of the
product. Install an appropriate pilot repair kit.
Damaged pilot orifice seat Foreign matter such as metal shavings and grit (1) Replace valve (2) determine source of foreign matter and eliminate.

Air leaking through secondary diaphragm Damaged secondary diaphragm seat Age/wear Replace using diaphragm repair kit.
exhaust
Foreign matter such as metal shavings and grit (1) Replace diaphragm repair kit, (2) clean internal valve seats, (3)
determine source of foreign matter and eliminate.
Heat aging Check that application temperature is within the operating range of the
product. Install appropriate diaphragm repair kit

FILTER CLEANING SYSTEM TROUBLESHOOTING MATRIX Page 1 of 3

(1) Category (2) Main Symptom (3) Secondary symptom (4) Possible source of problem (5) Possible cause (6) Remedy
Pulse valve does Pulse valve does not open Air is exhausted from pilot exhaust port(s) - Pulse controller Pulse setting too short Increase pulse duration setting
remote or integral pilots - when pilot is
not open
actuated.
Weak signal and only partial lift of pilot armature (plunger). Check output voltage and amps meet solenoid requirements.

Main diaphragm bleed. Bleed pins are over size or missing Replace with correct pins.
Diaphragm bleed holes are torn or stretched (only for valves Replace diaphragm
with bleed holes in diaphragm).
Main diaphragm. Diaphragm is damaged (torn or has holes) Replace diaphragm
Weak air exhaust at remote pilot. Pneumatic remote pilot line and connections Pneumatic remote pilot line is partially blocked or kinked. inspect and replace/repair.

Pneumatic remote pilot line bore is smaller than 4mm Replace with appropriate size pneumatic tube
Pneumatic remote pilot line is longer than 2m (for single Relocate pilot valves closer to diaphragm valves and shorten pilot lines.
diaphragm valves).
Pneumatic remote pilot line is longer than 4m (for dual Relocate pilot valves closer to diaphragm valves and shorten pilot lines.
diaphragm valves).
Pneumatic pilot line fittings are restrictive (effective bore Inspect and replace fittings.
diameter smaller than 4mm)
Pneumatic pilot line fittings are partially blocked. Inspect and repair/replace fittings.
Air exhaust is either weak or not exhausted Solenoid The solenoid is not being energised. Check controller and connections. Also check solenoid continuity (i.e no
from integral pilot exhaust port(s) open or short circuits.

The solenoid has burned out Feel temperature of solenoid (should not be hot to touch), examine for
evidence that solenoid is heat affected (discoloration, warping etc).
Replace solenoid.
Plunger/armature Plunger is not lifting due to wear or deformation caused Check movement, should be smooth but not loose. If movement is rough,
through age. tight or loose, replace using pilot repair kit.
Pilot exhaust port blockage Exhaust port is blocked by foreign matter. Examine exhaust port and clear the foreign matter.
Silencers/noise attenuators The silencer is significantly restricting the pilot exhaust flow. (1) If dirty, replace the silencer with new ones. (2) Try different model
silencer. (3) Remove silencer alltogether.

Air is not exhausted from remote pilot Solenoid The solenoid is not being energised. Check controller and connections
exhaust port(s)
The solenoid has burned out Feel temperature of solenoid (should not be hot to touch), examine for
evidence that solenoid is heat affected (discoloration, warping etc).
Replace solenoid.
Plunger/armature Plunger is not lifting due to wear or deformation caused Remove pilot ferrule tube. Check movement of plunger inside tube,
through age. should be smooth but not loose. If movement is rough, tight or loose,
replace using pilot repair kit.
Pilot exhaust port blockage Exhaust port is blocked by foreign matter. Examine exhaust port and clear the foreign matter.
Silencers/noise attenuators The silencer is significantly restricting the pilot exhaust flow. (1) If dirty, replace the silencer with new ones. (2) Try different model
silencer. (3) Remove silencer alltogether.
Remote pilot line and connections Remote pilot line is blocked or kinked. Inspect and replace/repair.
Pneumatic pilot line fittings are blocked. Inspect and repair/replace fittings.

Pulse valve does Pulse valve remains open, draining manifold Air continues to be exhausted at pilot or Pilot armature/plunger Mechanically stuck in open position Inspect and replace with pilot repair kit.
pressure secondary diapragm exhaust ports.
not close
Residual magnetic field (1) Ensure that the installation is not affected by stray magnetic fields, (2)
replace solenoid.
Controller Controller output remains energised Check controller. Reprogram or replace.
Remote pilot connections Pilot line cut Replace pilot line.
Pilot line disconnected Reconnect.
No air being exhausted at pilot. Air may be Main diaphragm Severely damaged/fractured Inspect and replace with diaphragm repair kit.
exhausted at secondary dipahragm exhaust
ports.
Secondary diaphragm Severely damaged/fractured Inspect and replace with diaphragm repair kit.
Valve bleed Blocked (primary or secondary) Inspect and ensure bleed paths are clear.

FILTER CLEANING SYSTEM TROUBLESHOOTING MATRIX Page 2 of 3

(1) Category (2) Main Symptom (3) Secondary symptom (4) Possible source of problem (5) Possible cause (6) Remedy
Diaphragm spring Diaphragm springs fail rapidly usually damaging Diaphragm resonance, often accompanied Air supply starvation to the valve inlet. Very small manifolds, with pressure at end of pulse less than Replace manifold system with higher volume manifolds to ensure residual
the diaphragms. by deep resonating or fluttering sounds 70% of starting pressure. pressure is 70% of pre-pulse pressure, OR shorten pulse duration.
failures
during pulsing.
Long pipes connecting to valve inlets. Reduce pipe lengths or increase pipe diameters.
Partially blocked valve inlets (eg. Partly closed ball valves at Ensure any valves inline with the pulse valves are fully open or removed
valve inlet) entirely.
Air supply path through small manifolds connected in series Replace manifold system with higher volume manifolds to ensure residual
by small connecting pipes. pressure is 70% of pre-pulse pressure. Increase the diameter of
connecting pipes to minimum 1.5 x the nominal pulse valve outlet size.

Valve bleed paths Bleed paths partially blocked by foreign matter such as thread Clean manifold system, clear bleed paths.
sealing material, grit, etc.
Valve outlet restriction very low. Very large An/Ap ratio (>1.5), or no blowtube connections. Introduce a small restriction to the valve outlet, to assist in developing
This is particularly a problem if in combination with valve air some backpressure at the valve outlet.
supply starvation.
Where relevant, replace nitrile diaphragms with the Shockwave molded
diaphragm equivalent.

Insufficient filter Insufficient cleaning flow delivered to the filters Very low pressure drop in manifolds during Pulse jet valve Valve not opening Refer to relevant analysis in this document.
the pulse
cleaning
Blowtube and attachments Blowtube/nozzle orifices are too small or undrilled. Check required orifice sizes using GOCO. Confirm actual orifice sizes meet
the recommended sizes. If too small, drill the orifices to the correct size.

Residual pressure immediately after pulsing Manifold Very small manifold, holding insufficient air mass to support Check required manifold size using GOCO. If manifold is very much
is less than 70% of the starting pressure. good filter cleaning undersize, replace with correct size manifold.

Initial manifold pressure is low. Air supply pressure Supply pressure settings or supply flow rate to manifolds. Increase manifold system pressure.

High manifold pressures, but low flow Blowtube and attachments Blowtube/nozzle orifices are too small or undrilled. Check required orifice sizes using GOCO. Confirm actual orifice sizes meet
discharged from blowtube orifices. the recommended sizes. If too small, drill the orifices to the correct size.

Pulse jet valve/blowtube combination Pulse valve flow delivery is too small to meet reverse flow Check pulse system design using GOCO. Discuss with Goyen engineers for
requirements of the dust collector possible solutions. May require larger valves and blowtubes.

Obvious signs of pulse jet misalignment on Blowtube and attachments Ratio of total orifice area to blowtube cross-section area Check pulse system design using GOCO. Discuss with Goyen engineers for
plenum floor near filter openings and (An/Ap) exceeds 0.8 without use of Nozzles. This results in possible solutions. Likely to require implementation of GOCO nozzles,
possible filter failures near top of filter significant pulse jet misalignment and reduced cleaning flow with appropriately sized orifices.
elements. entering the filter elements.

Premature filter Filters develop tears or holes near filter opening. Failures occur consistently at same filter Blowtube and attachments Ratio of total orifice area to blowtube cross-section area Check pulse system design using GOCO. Discuss with Goyen engineers for
location and in the same place on the filter. (An/Ap) exceeds 0.8 without use of Nozzles. This results in possible solutions. Likely to require implementation of GOCO nozzles,
failure
significant pulse jet misalignment and reduced cleaning flow with appropriately sized orifices.
entering the filter elements.
Consistently very low dP accross filters. Pulse system design Excessive filter cleaning pressures. Check pulse system design using GOCO. Discuss with Goyen engineers for
possible solutions. May be as simple as a reduction in manifold pressures.

Filter over-cleaning Much lower than expected filter dP, with dust High dust emissions, although filters are Pulse system design Excessive filter cleaning pressures. Check pulse system design using GOCO. Discuss with Goyen engineers for
collector flowrates as expected. intact. Little obvious dust cake formation possible solutions. May be as simple as a reduction in manifold pressures.

FILTER CLEANING SYSTEM TROUBLESHOOTING MATRIX Page 3 of 3