Pn121 maintenance and troubleshooting of pneumatic systems. Troubleshooting residential pneumatic zoning systems is usually a simple matter of using the process of elimination. Amatrol portable pneumatics troubleshooting learning system. Pdf troubleshooting in dry fly ash conveying systems. 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. Pneumatic controls preventive maintenance and troubleshooting johnson controls, inc. However, when reduced to its basic elements, troubleshooting a pneumatic system is a stepbystep procedure. But when it comes to troubleshooting pneumatic valves or systems, its a necessary step by step procedure that corrects. High quality compressed air is by definition 100% oil free class 0. This course is designed specifically for millwrights, electricians, reliability technicians, supervisors and engineers who are responsible for maintaining and controlling pneumatic systems. Troubleshooting is initiated when the circuit does not operate properly, and certain general diagnostic and testing steps can. The general design of a pneumatic system and its components page 4 hafnerpneumatik kramer kg, stammheimerstra.
Troubleshooting control equipment problems powder and bulk. Extensive coverage is provided for both hydraulic and pneumatic systems. Introduction to pneumatics and pneumatic circuit problems. 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. Steps to troubleshooting pneumatic valves or systems. H19141 pneumatic troubleshooting student reference. Electropneumatic control system is a combination of electrical unit and pneumatic control unit both in one unit. Pdf hydraulics and pneumatics download ebook for free. 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. Issue related to components of system that is like. 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. Hydraulics and pneumatics is a teaching package aimed at students pursuing a technicianlevel career path.
Troubleshooting variable air volume modular assembly vma. Pneumatic conveying systems for bulk materials by k. A company that molds nonmetallic airplane propellers loads both halves of a mold in a vertical press. How to adjust the system control devices such as pressure switches, regulators, lubricators and dew points for dryers. The installation, modification and troubleshooting of a pneumatic system require an understanding of pneumatic circuit drawings. Develop an organized and methodical system of troubleshooting. Troubleshooting and preventive maintenance of hydraulic. Chapter 14 fluid power system maintenance and troubleshooting plugin pressure gauges can be used to trace pressure levels through a pneumatic system. Pneumatic systems lecture 1 pneumatic system nptel. In the minds of maintenance personnel, production managers, and plant managers, the word troubleshooting conjures up images of hours of downtime and lost production.
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. It also includes numerous examples of troubleshooting problems in mechanical systems, process connections, pneumatic systems, electrical systems, electronic systems, and valves. 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. For many, troubleshooting pneumatic systems have been considered as a science or an art. A pneumatic circuit is formed by various pneumatic components, such as cylinders, directional control valves, flow control valves, etc. Troubleshooting pneumatic systems course objectives.
The person maintaining air systems in todays modern plant must know the following. 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. Maintenancetroubleshooting of pneumatic systems in recent years, an increased number of maneuvering troubles reported which may result in costly accidents and delays. Pressure systems make a mess vacuum is hard to diagnose and find.
Normal operating temperature for the majority of hydraulic systems is between 100120 degrees f. The infrared camera has many uses in the hydraulic field and should be used when troubleshooting any hydraulic problem. To properly maintain and service a pneumatic control, it is important for the service technician to be familiar. Pneumatic conveying building on the information presented in his first three series of columns, paul e.
The chapters that follow describe troubleshooting for all the major components of a typical pneumatic system. Every pneumatic circuit has a logical sequence of operation that can involve timing logic, pressure sensing, position sensing, and speed regulation. Chapter 2 the general design of a pneumatic system and its. 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. Plant engineering 12 steps to troubleshooting pneumatic systems. Fluid power system maintenance and troubleshooting. The most used pneumatic actuation systems are electrically controlled systems.
Certified valves support engineers in designing safer systems without wasting time in components validation versus the. Workbook basic level tp101 advanced level tp102 optional courseware. Mostia also explores test equipment, programmable electronic systems, communication circuits, transient problems, and. The fault can now be attributed to an inlet or outlet valve as indicated in the following table. Air lines the central tire inflation system uses a dedicated pneumatic system plumbed from the vehicles exiting supply tank. 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. 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. These troubles are usually caused by sticking pneumatic valves, due to internal corrosiondirt particles in the control air systemdefective seals, etc. Pneumatic troubleshooting textbook schoolcraft publishing. Pneumatic control systems can be designed in the form of pneumatic circuits. It teaches the fundamentals of fluid power and provides details on the design and operation of hydraulic and pneumatic components, circuits, and systems. Introduction to pneumatics module objectives after the completion of this module, the student will be able to. Mostia also explores test equipment, programmable electronic systems, communication circuits, transient problems, and software. Mastering manufacturing industrial maintenance industry 4.
Field report pneumatic troubleshooting charts valmet. Working energy kinetic energy and pressure results in a pneumatic system when the compressed air is allowed to expand. 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. Pneumatic systems use air as the medium which is abundantly available and can be exhausted into the. The word troubleshooting in the minds of production managers, plant managers, and maintenance personnel means hours of lost production and downtime. Directional or other valve open due to dirt or failed pilot circuit, locate damaged part and clean or replace. 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. Troubleshooting tips for hydraulic systems womack machine. Magnum systems has manufactured pneumatic conveying systems for more than 50 years. Troubleshooting a pneumatic system should be a stepbystep procedure.
Pneumatic systems are very reliable and can keep working for a long time. The process vessel, piping, control valve, controller, and level transmitter are all brandnew. Practical exercises on training equipment for setup, commissioning, troubleshooting and repairfault elimination facilitate the transfer of knowledge to daytoday work. Economical if we compare pneumatic systems to other systems, we find that they are cheaper to run. In a pneumatic system, energy is stored in a potential state under the form of compressed air. Infrared cameras are the most effective tool to use when trying to locate where the heat is being generated. Jan 21, 2010 pneumatic directional control valves that use electrical solenoids to operate the valve spool are often equipped with manual overrides fig. 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. 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. Pneumatic directional control valves that use electrical solenoids to operate the valve spool are often equipped with manual overrides fig. Even with all the great new technology in hvac controls, there are still many pneumatic buildings out there. 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. This course allows the participant to extend their knowledge of complex pneumatic systems and improve their troubleshooting and maintenance skills.
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. Identify the main components of the pneumatic work station tp 101. Troubleshooting pneumatic zoning systems contracting business. To control the injection and release of compressed air. The following troubleshooting charts cover common problems with pneumatic equipment including actuators, filters, regulators, lubricators, air valves, directional control valves and air cylinders. Hydraulic tools for troubleshooting any hydraulic system. Heres a good troubleshooting procedure from jerry condiff, the instructor. Introduction a pneumatic control system is more sophisticated and complex than many electrical control systems. Pneumatic systems are used in controlling train doors, automatic production lines, mechanical clamps, etc fig. For example, a tank is charged to 100 psia with compressed air. An itemized equipment operation checklist can help an equipment operator provide information that can reduce the amount of time needed for the troubleshooting process. 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. Economical if we compare pneumatic systems to other systems, we.
Introduction to pneumatics and pneumatic circuit problems for. You will be provided with the most uptodate information and best practice in dealing with the subject. Practical exercises on training equipment for setup, commissioning, troubleshooting and repairfault elimination. Mar 10, 2004 12 steps to troubleshooting pneumatic systems troubleshooting a pneumatic system has been considered an art, a science, or just hitormiss luck. These systems are called electropneumatic actuation systems 2.
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