Directional or other valve open due to dirt or failed pilot circuit, locate damaged part and clean or replace. Pneumatic conveying building on the information presented in his first three series of columns, paul e. Introduction to pneumatics and pneumatic circuit problems for. Jan 21, 2010 pneumatic directional control valves that use electrical solenoids to operate the valve spool are often equipped with manual overrides fig. Chapter 2 the general design of a pneumatic system and its. Heres a good troubleshooting procedure from jerry condiff, the instructor. In a pneumatic system, energy is stored in a potential state under the form of compressed air. Pressure in a pneumatic system must be controlled at two points after the compressor and after the air receiver tank.
Infrared cameras are the most effective tool to use when trying to locate where the heat is being generated. The fault can now be attributed to an inlet or outlet valve as indicated in the following table. Fluid power system maintenance and troubleshooting. These lists are intended as a starting point for troubleshooting since it is impossible to include all possibilities. Mostia also explores test equipment, programmable electronic systems, communication circuits, transient problems, and. We will introduce many aspects of troubleshooting hydraulic systems and will share information that will help you to better understand and enhance the operation of your hydraulic equipment. The following troubleshooting charts cover common problems with pneumatic equipment including actuators, filters, regulators, lubricators, air valves, directional control valves and air cylinders. Certified valves support engineers in designing safer systems without wasting time in components validation versus the applicable safety standards.
As with most things we encounter in our work, problems with pneumatic zoning systems can be electrical or mechanical, or can be related to the air pressure and vacuum that is used to open and close the systems dampers. Pneumatic systems use air as the medium which is abundantly available and can be exhausted into the. Troubleshooting pneumatic systems course objectives. It teaches the fundamentals of fluid power and provides details on the design and operation of hydraulic and pneumatic components, circuits, and systems. Advanced manufacturing agritech aviation maintenance biotech industry learning systems certified production technician cnc machine operator construction technology correctionsbased training diesel mechanics engineering technology green energy technology hvac ignite. Even with all the great new technology in hvac controls, there are still many pneumatic buildings out there. This course allows the participant to extend their knowledge of complex pneumatic systems and improve their troubleshooting and maintenance skills. The chapters that follow describe troubleshooting for all the major components of a typical pneumatic system. Pdf troubleshooting in dry fly ash conveying systems. This course is designed specifically for millwrights, electricians, reliability technicians, supervisors and engineers who are responsible for maintaining and controlling pneumatic systems.
Hydraulic tools for troubleshooting any hydraulic system. The person maintaining air systems in todays modern plant must know the following. Develop an organized and methodical system of troubleshooting. Every pneumatic circuit has a logical sequence of operation that can involve timing logic, pressure sensing, position sensing, and speed regulation. Pneumatic systems lecture 1 pneumatic system nptel. The infrared camera has many uses in the hydraulic field and should be used when troubleshooting any hydraulic problem. These troubles are usually caused by sticking pneumatic valves, due to internal corrosiondirt particles in the control air systemdefective seals, etc. Normal operating temperature for the majority of hydraulic systems is between 100120 degrees f. Troubleshooting and preventive maintenance of hydraulic. The word troubleshooting in the minds of production managers, plant managers, and maintenance personnel means hours of lost production and downtime. Extensive coverage is provided for both hydraulic and pneumatic systems. Troubleshooting and preventive maintenance of hydraulic systems. Chapter 14 fluid power system maintenance and troubleshooting plugin pressure gauges can be used to trace pressure levels through a pneumatic system.
These industrial components will be used to study troubleshooting topics for air preparation, pneumatic actuators, vacuum systems, pneumatic systems, and more all within an innovative, portable solution that doesnt sacrifice the comprehensive knowledge and skill building for which amatrol is known. If you happen to be someone who has to work on pneumatic controls, you know it can be frustrating when you have a problem with the system. Solt a private consultant with more than 40 years experience installing and troubleshooting pneumatic conveying systems presents a fourth series of columns on troubleshooting pneumatic conveying systems. Workbook basic level tp101 advanced level tp102 optional courseware. Many companies invest in pneumatics because they know they will not have a lot of breakdowns and that the equipment will last for a long time. The most used pneumatic actuation systems are electrically controlled systems. Pdf hydraulics and pneumatics download ebook for free. Introduction a pneumatic control system is more sophisticated and complex than many electrical control systems. Identify the main components of the pneumatic work station tp 101. An itemized equipment operation checklist can help an equipment operator provide information that can reduce the amount of time needed for the troubleshooting process. Troubleshooting residential pneumatic zoning systems is usually a simple matter of using the process of elimination. Troubleshooting is initiated when the circuit does not operate properly, and certain general diagnostic and testing steps can. These systems are called electropneumatic actuation systems 2.
Practical exercises on training equipment for setup, commissioning, troubleshooting and repairfault elimination facilitate the transfer of knowledge to daytoday work. Troubleshooting variable air volume modular assembly vma. H19141 pneumatic troubleshooting student reference. Pressure systems make a mess vacuum is hard to diagnose and find. High quality compressed air is by definition 100% oil free class 0. For many, troubleshooting pneumatic systems have been considered as a science or an art. Troubleshooting tips for hydraulic systems womack machine. Field report pneumatic troubleshooting charts valmet. Electropneumatic control system is a combination of electrical unit and pneumatic control unit both in one unit.
It also includes numerous examples of troubleshooting problems in mechanical systems, process connections, pneumatic systems, electrical systems, electronic systems, and valves. Pn121 maintenance and troubleshooting of pneumatic systems. Pneumatic controls preventive maintenance and troubleshooting johnson controls, inc. How to adjust the system control devices such as pressure switches, regulators, lubricators and dew points for dryers.
Pneumatic conveying systems for bulk materials by k. Troubleshooting tips for hydraulic systems download data sheet this data sheet describes a stepbystep checkout procedure for hydraulic systems which have previously been working satisfactorily but which have developed trouble, usually over a 24hour working period, which renders them inoperative. Mostia also explores test equipment, programmable electronic systems, communication circuits, transient problems, and software. Working energy kinetic energy and pressure results in a pneumatic system when the compressed air is allowed to expand. Hydraulics and pneumatics is a teaching package aimed at students pursuing a technicianlevel career path. During the op eration of th e pneumatic systems the blocka ge of th e pipel ine i s recog nized a s the major issue. Introduction to pneumatics module objectives after the completion of this module, the student will be able to. Pneumatic systems are very reliable and can keep working for a long time. Issue related to components of system that is like. Pneumatic control systems can be designed in the form of pneumatic circuits. Amatrol portable pneumatics troubleshooting learning system. Magnum systems has manufactured pneumatic conveying systems for more than 50 years. Troubleshooting vma1400 series controllers technical bulletin 3 troubleshooting vma1400 series controllers introduction although the variable air volume modular assembly vma has been designed to provide years of reliable service, problems can develop in the related building and heating, ventilating, and air conditioning hvac systems.
Troubleshooting control equipment problems powder and bulk. Economical if we compare pneumatic systems to other systems, we find that they are cheaper to run. In the last year, functional safety in hydraulic systems has become more and more important and is no longer optional. The process vessel, piping, control valve, controller, and level transmitter are all brandnew. Pneumatic troubleshooting textbook schoolcraft publishing. Technological studies pneumatic systems 3 pneumatic systems 1 pneumatic systems a pneumatic system is a system that uses compressed air to transmit and control energy. The installation, modification and troubleshooting of a pneumatic system require an understanding of pneumatic circuit drawings. For example, a tank is charged to 100 psia with compressed air. In the minds of maintenance personnel, production managers, and plant managers, the word troubleshooting conjures up images of hours of downtime and lost production. Troubleshooting a pneumatic system should be a stepbystep procedure. Maintenancetroubleshooting of pneumatic systems in recent years, an increased number of maneuvering troubles reported which may result in costly accidents and delays.
Steps to troubleshooting pneumatic valves or systems. Pneumatic system troubleshooting maintenance technician. Certified valves support engineers in designing safer systems without wasting time in components validation versus the. A company that molds nonmetallic airplane propellers loads both halves of a mold in a vertical press. It shifts an air valve that retracts 4clamp down cylinders to hold the bottom half of the mold to the base plate and attach the top half to a large hydraulic ram that opens and closes the top of the mold. However, when reduced to its basic elements, troubleshooting a pneumatic system is a stepbystep procedure. Air lines the central tire inflation system uses a dedicated pneumatic system plumbed from the vehicles exiting supply tank.
A pneumatic circuit is formed by various pneumatic components, such as cylinders, directional control valves, flow control valves, etc. Our experienced team members are happy to help trouble shoot your system issues and help provide a solution to keep your line moving. P121 maintenance and troubleshooting for pneumatic and electropneumatic systems pop tracking down waste economic use of pneumatics pneu pneumatics refresher and update iwpep repair and maintenance in the field of control technology pneumatic and electropneumatic systems pal pneumatics for further education. Some cti systems make use of either a userselectable load setting or can respond automatically to a load signal or message which can be used to adjust the pressure targets based on the load of the vehicle. To properly maintain and service a pneumatic control, it is important for the service technician to be familiar. Plant engineering 12 steps to troubleshooting pneumatic systems. You will be provided with the most uptodate information and best practice in dealing with the subject.
Pneumatic directional control valves that use electrical solenoids to operate the valve spool are often equipped with manual overrides fig. Mar 10, 2004 12 steps to troubleshooting pneumatic systems troubleshooting a pneumatic system has been considered an art, a science, or just hitormiss luck. Economical if we compare pneumatic systems to other systems, we. Troubleshooting pneumatic zoning systems contracting business. The general design of a pneumatic system and its components page 4 hafnerpneumatik kramer kg, stammheimerstra. Mastering manufacturing industrial maintenance industry 4. But when it comes to troubleshooting pneumatic valves or systems, its a necessary step by step procedure that corrects. Trailer systems troubleshooting guide how to use this chart the purpose of the chart is to help you solve a specific problem in the pneumatic portion of a trailer air brake system with the assumption the foundation brake components and tractor pneumatics are in good repair. Due to the range of available pneumatic equipment and systems in industry, the practical tasks you will need to undertake to meet the outcomes for this competency will be determined by your assessor. Introduction to pneumatics and pneumatic circuit problems. Pneumatic systems are used in controlling train doors, automatic production lines, mechanical clamps, etc fig. On the job, you are sent to troubleshoot a brandnew control system, consisting of a pneumatic liquid level transmitter connected to a pneumatic controller, which in turn drives a pneumatic control valve.