First two minutes: Bypass Test while Cleaning

The FSX TrapBlaster is the machine used to pneumatically clean DPF filters. It is equipped with a unique patented diagnostic feature that finds damaged or defective filters in the first two minutes of operation. Automated bi-directional air knives scan across the filter individually testing every cell. Broken cells and cracks in the ceramic media are easily identified. Based upon the two-minute bypass test our technicians will decide if the cleaning process should continue or stop.

The bypass test, right up front, makes sure we don’t waste your time or money. If your DPF passes the two-minute test, there is a very high likelihood that the filter is in good physical condition and just plugged. If no visual bypass is observed, the cleaning process continues.

Next 20 minutes: Cell by Cell Automated Cleaning

If the DPF passes the two-minute bypass test, the FSX TrapBlaster automatically continues cleaning the filter.  High pressure, high volume air is applied using our patented, bi-directional air scanning mechanism. Each cell is individually cleaned multiple times, from both ends, removing a high percentage of the soot and ash. We find that 70% to 80% of the DPFs that complete the 22-minute average Stage 1 cleaning process reach Green Tag status.   Filters receiving a Green Tag, meaning ‘Good to Go’, can be placed back in service.

After the Stage One 22-minute cleaning the DPF goes through a series of quality tests to assure that the filter is clean.  FSX quality checks measure airflow, ash loading and find hidden defects.  At this point over 95% of the soot and soft ash have been removed. A decision will be made whether the filter is ready to go back to you, the customer, or needs to move on to Stage 2 to continue the cleaning process.

FSX continues the cleaning process unless an unrecoverable flaw is found, resulting in a “Red Tag” classification.

The FSX TrapBurner thermal re-generator heats the DPF to oxidize 100% of any remaining soot and loosens hardened ash after the Stage 1 pneumatic cleaning. The Stage Two is a 12-hour overnight process used when the DPF does not meet the Green Tag airflow range after the Stage 1 pneumatic cleaning.  After a Stage 2 thermal cleaning the filter goes through a second round of testing.  Typically, another 15% of DPFs will reach “Green Tag” status after a Stage 2 cleaning. At this point 100% of the soot will be gone but hardened ash could still remain.

If the filter meets the “Green Tag” specification, it will be returned to the customer. If hardened ash plugs are found in the second round of testing the filter will be moved on to Stage 3 Chemical Cleaning.

If the DPF still has hardened ash plugs in the filter cells, or poor airflow performance, it would increase engine back-pressure and reduce operating performance. To prevent that, FSX moves the filter into a chemical cleaning process. This process dissolves and flushes any remaining hardened ash plugging the cells and micro-pores. It also restores catalytic performance by stripping off contaminants masking the precious metals.

The chemical process includes immersion in an ultrasonic tank with chemicals that do not damage the wash coat. Water alone is inadequate. FSX’s proprietary cleaning chemicals have been approved and used by major OEMs. After the ash is dissolved the filter is flushed with water and air to remove any remaining residue.