Detailed Causes of Malfunctions in the Dust Cleaning System of Self-Cleaning Air Filters

The pulse backflushing dust cleaning system malfunctions mainly result from abnormal air supply,faulty executive components, blocked/abnormal pipelines and nozzles, 

control unit failures, unreasonable parameter settings, and improper installation and maintenance. The detailed concise causes are as follows:

1. Abnormal backflushing compressed air supply (most common)

Insufficient pressure (0.4~0.6Mpa is standard): Caused by air compressor failure, blocked pressure reducing valve, pipeline blockage/air leakage, insufficient air storage tank capacity, 

or excessive pipeline pressure loss. Air with water, oil and impurities: Untreated air source leads to scaling and blockage of pipelines/nozzles, and jamming/wear of solenoid valve internal parts.

Low-temperature freezing blockage: Water vapor in air condenses and freezes in pipelines/nozzles/tanks, cutting off air flow.

2. Pulse solenoid valve faults (core executive part)

Solenoid coil burnout: Due to unstable voltage, overload operation, moisture intrusion, or internal wire short circuit.

Spool jamming: Caused by impurities/oil sludge in air, or aging of internal lubricating oil from long-term inactivity.

Internal seal damage: Sealing rings/gaskets age/wear under high pressure and temperature changes, leading to air leakage and pressure drop.

Loose valve connections: Joint air leakage reduces actual backflushing pressure.

3. Backflushing pipeline and nozzle faults

Pipeline problems: Corrosion/perforation causes air leakage; deformation/inner scaling increases resistance and reduces air flow.

Nozzle malfunctions: Blockage by dust/oil sludge; misalignment/falling off from vibration fails to match Venturi tube; wear/cracking leads to air flow dispersion and pressure loss.

4. Control unit faults (system "brain")

Main control instrument/PLC failure: Internal component aging, program disorder/loss, or loose/short-circuited wiring cuts off control signals.

Sensing component abnormality: Stuck/calibrated incorrectly/dusty differential pressure transmitters/sensors, or damaged timers, make automatic dust cleaning invalid.

Wiring harness faults: Loose/aged/corroded wiring interrupts signal transmission, disabling solenoid valve control.

5. Unreasonable dust cleaning parameter settings

Too short pulse width (below 0.05~0.1s) leads to ineffective jet and incomplete dust removal.

Too long pulse interval causes excessive dust accumulation and hard-to-clean compact dust layers.

Wrong blowing sequence disperses air pressure due to simultaneous multi-nozzle jetting.

Too high differential pressure trigger value or too long timing interval results in delayed dust cleaning and heavy dust buildup.

6. Improper installation and daily maintenance

Improper installation: Loose pipeline fixation, misaligned nozzles, missing/blocked air tank drain valves, non-standard sealing parts causing air leakage.

Inadequate maintenance: No regular cleaning of tanks/pipelines/nozzles, no timely inspection/replacement of aging valves/seals/sensors,

 no regular air source drainage/oil removal, and delayed air source filter replacement, leading to system blockage and component failure.