Chapter 7

Module 7: Safety, Troubleshooting and Maintenance

Table of Contents
Pneumatics Automation System Maintenance Tips .............................................................................. 7-2
 Preventive Maintenance Schedule ................................................................................................. 7-3
 Dos & Don’ts............................................................................................................................................ 7-3
Common Symptoms of a Fault ....................................................................................................................... 7-4
Troubleshooting of Pneumatic System ...................................................................................................... 7-4
 Safety in Troubleshooting ................................................................................................................ 7-4
 Actuator Failure .................................................................................................................................... 7-6
 Valve failure ............................................................................................................................................ 7-6
 Solenoid valves Fault ........................................................................................................................... 7-7
 Service Units Failure............................................................................................................................ 7-8
 Tubing Failure ........................................................................................................................................ 7-8
Piston actuator fault........................................................................................................................................... 7-8
Reference................................................................................................................................................................... 7-

Table of Figure

What you will cover

Module 7: Safety, Troubleshooting and Maintenance
Pneumatic Automation System Maintenance Tips
Common Symptoms of a Fault
Troubleshooting of Pneumatic System
Safety in Troubleshooting
Common faults and solutions

Learning Outcome
At the end of this module participants will be able to:
Understand Pneumatic Automation System Maintenance Tips
Identify Common Symptoms of a Fault
Understand how to troubleshooting of Pneumatic System
Identify common Pneumatic System faults and solutions

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 Module 7: Safety, Troubleshooting and Maintenance

Pneumatic Automation System Maintenance Tips

The documentation of a pneumatic/electro-pneumatic system is very important for proper

management or maintenance and comprises of the following:
 Machine diagram
 Circuit/Termination diagram
 Data sheets
 Operating instructions
When the system is modified, the documentation and the machine history should be
updated to reflect any changes, in order to facilitate maintenance and trouble-shooting and
elimination of faults.

Indications of poor compressed air preparation

 Rapid wear of moving parts in cylinders and valves.
 Water drops form in the pipeline.
 Water accumulation in lubricator.
 Dirty filter bowls.
 Slow speed of working elements
 Silencers on the valves become dirty.
 Working elements operate at different speeds.

For pneumatic systems the following regular maintenance routines are

recommended:
 Check the filter & service units – drain water regularly from traps.
 Discuss with the operators of the system any noted differences in performance or
unusual events.
 Check for air leaks, crimped air lines or physical damage.
 Check signal generators for wear or dirt.
 Check cylinder bearings and mountings.

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 Module 7: Safety, Troubleshooting and Maintenance

Preventive Maintenance Schedule

Daily:
 Check whether auto drain fitted on large reservoirs are draining in time.
 Drain condensate from the air filter / service units.
 Check the oil level in the air lubricator & the setting of oil drop metering.
 Check the pressure gauge of the pressure regulators.
 Check whether the lubrication is functioning correctly.

Weekly:
 Check the seals of the connectors for leaks. If necessary, re-tighten.
 Check the exhaust ports of the valves for leaks.
 Clean filter cartridges with water (do not use solvents) and blow them out with
compressed air in the reverse of the normal flow direction.

Monthly:
 Check the rod bearings in cylinders for wear and replace if necessary, also replace the
scraper and sealing rings.

Note: that these schedule can vary, depending on the harshness of the operating
environment.

Dos & Don’ts:

Service Units
 Service Units must be mounted vertically.
 Position the service unit in a safe position to avoid mishandling and any accidental
damage
 Pressure regulators without (relief port) should not be used with a direct control
valve and cylinder especially for high back pressure & frequency switching cycles.
 Pre-filter and moisture separation is necessary after compressor to safe guard the
pneumatic components in the machine.
 Is advisable to install Automatic drain filter.
 Lubricating Oil must be as per ISO VG32 specifications ( Kinetic viscosity =32)
 Min / max level for lubricator to be maintained
 Service Unit must be mounted within 5 Meters from the last drive or cylinder,
because by longer distance the Lubrication effect in the drive will not be effective.

Fittings & Tubing's

• Always keep tube connections as short as possible.
• Do not kink tubes, use the right fitting and size.
• Observe the push-in fit procedure always during connections
• Fittings with plastic sealing rings should not be over-tightened.
• Fittings with tapered threads: Teflon coated threads should not be tightened fully; 2-
3 threads can be left outside. If the Teflon coating is damaged use Teflon tape.

Valves
 Directional control valves should be preferably mounted vertically (reduces uneven
wear and tear of seals).
 Connector size must match the valve type as the thread length of the connector
should match the depth of the port.
 If plunger tube assembly is dismantled, while re-assembling the spring should be
placed back properly.

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 Module 7: Safety, Troubleshooting and Maintenance

 The spring washer between the coil and round nut is a must for a secured fittings of
coil to plunger tube assembly.
 Individual Valve Non repairable type should not be opened.
 In stores the valves should be placed in moisture tight cabinets & safe position to
protect the plunger tube assembly against external forces.
 Manual override should be always on position zero.

Flow Control Valves

 Meter-out type used usually to control speed of double acting cylinder
 (exhaust control)
 Meter-in type used usually to control speed of single acting cylinder
 (in-line control)
 Inline flow control valve (arrow indicates the direction of flow control)
 Adjustable knurled nut should not be over tightened after
 Locknut is fastened.

Actuators
• Ensure proper load sizing and working tool coupling
• Ensure proper mounting to avoid side loads & rubbing surfaces.
• Protect the barrel of the cylinder from any impact, avoid other particles falling on the
piston to safeguard the slide rings (seals) and barrel surface
• Steel band should be protected against corrosion

Common Symptoms of a Fault

 In a typical pneumatic or electro-pneumatic machine a fault will first be apparent due

to one or more of the following:
 Poor/slow performance
 Faulty product, inaccurate
 Machine stops
 Thus a troubleshooting process and correction procedure must be put into action

Troubleshooting of Pneumatic System

• Methodic approach is required in Troubleshooting of Pneumatic Control Systems

• Keep ready machine manual, Pneumatic circuitry, complete tool kit, electrical testing
equipment, blank labels for making the cables/pneumatic piping, torch, notepad,
writing/marking materials, some quantity of tubing, connectors used on the machine
before starting your work, so that no time will be wasted to procure them separately.
• Label all the electrical/pneumatic connections removed during the troubleshooting.
• If you do not know the complete operations of the machine ask help of someone who
knows them thoroughly or study operational the manual.
• Advance comprehensively, cautiously and systematically.

Safety in Troubleshooting
 In any fault tracing exercise personal safety and the safety of others is paramount
 Watch out for danger signs:
 Sudden exhausts to the face:
 noise can injure the ears

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 Module 7: Safety, Troubleshooting and Maintenance

 ejected particles can injure the eyes

 Electric shock
 Moving mechanical parts
 Work should be carried out using approved practices and observing relevant
legislation

Troubleshooting must start with:

“What you can see and what you can hear”
• Initial Checks:
• Check whether compressed air is connected?
• Check whether required pressure is built up?
• Check whether electrical supply is given check for voltage?
• Check whether you hear any blowing sound/ leaking sound?
• - If leaking, look for those spots and tighten the connectors
• Check whether the tubing are bent or twisted. If found remove these defects.

Monitoring indicators are very useful source of information during troubleshooting:

 Pressure gauges show the presence and level of pressure
 Pressure indicators show the presence of pressure
 Lamps show the presence of electrical power
 LEDs show that a solenoid is receiving power or that a reed switch or sensor is
turned ON
 Ideally all electrical and pneumatic power will be isolated, pressure exhausted and
moving parts mechanically locked
 In practice it may be necessary to have the machine or device partly or fully powered
up to locate a fault
 To gain access to test a suspect device, it may also be necessary to remove and
override the guards.
 This clearly presents many dangers and great caution and awareness is required by
the fault finding team
 Fault finders must keep well clear of the path of all actuators, mechanisms and other
hazardous moving parts
 Electrical equipment should be checked using only the proper test instruments
 Notes: While removing electrical connections label them carefully. While replacing
the components please take care of the polarity.
 DANGER! Jammed actuator
 The actuator should be pre-exhausted
 Clearing the jam will cause the actuator to impact to the end of its stroke
 This will be faster than you can react to remove your hand
 Ensure the actuator is de-pressurised and use a tool to clear the jam
 DANGER! Live trip valves and limit switches
 Accidentally touching or leaning on a limit valve or switch while testing a machine
can generate a signal
 This can cause an actuator or sequence of actuators to operate unexpectedly

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 Module 7: Safety, Troubleshooting and Maintenance

Common faults and solutions

Symptom: The machine is working but is falling off in performance due to slower
operation
 Possible Causes
 Upstream flow restriction or air starvation
 Downstream flow restriction
 Lack of lubrication
 Possible Solutions
 If weak supply pressure:
 Fit larger pipe
 Install local receiver
 Install larger compressor
 If strong supply pressure
 Check for kinked tube downstream and renew
 Lubricate mechanisms
 Fit airline lubricator
Symptom: One actuator is falling off in performance due to slower operation
Possible Causes
 Flow regulators set too low
 Tube kinked
 Lack of lubrication
 Out of alignment
 Objects in actuator path
 Piston rod bent
 Barrel dented
Possible Solutions
 Readjust flow regulators
 Renew tube
 Fit airline lubricator
 Clean, realign and lubricate mechanisms
 Replace or repair actuator
Actuator Failure:
Pneumatics cylinders or drives may fail due to the following main reasons:
1. Bad quality of air.
2. Eccentric Loads.
3. Moments beyond the allowed limits.
4. Insufficient Lubrication.
5. Unsuitable Lubricating Oil.
6. Operating conditions beyond the limits a(pressure, Temperature etc. )
Valve failure:
Pneumatic valves may fail due to the following reasons:
1. Bad quality of air.
2. Insufficient Lubrication.
3. Unsuitable lubricating Oil.
4. Operating conditions beyond the limits (Pressure, Temperature etc.)
5. Fluctuations in Voltages (in case of solenoid valves).

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 Module 7: Safety, Troubleshooting and Maintenance

Fault: Valve spool not changing position

 Low signal pressure
 The minimum operating pressure can be from 1bar to 3 bar depending on the valve
type
Fault: Valve spool not changing position
 Opposed signals on bi-stable types (fault with other part of the control)
 The signal on the left has not been removed so the new signal on the right has no
effect
 Check the valve giving the left signal and it’s control
Fault: Valve spool not changing position
 Sticking spool due to incorrect lubrication (swelling of seals)
 Lubricating a valve with a non-compatible oil can cause the seals to swell and grip the
spool
 Some non-compatible oils when dried out leave a residue that can glue the spool in
position
Fault: Valve spool not changing position
 Jammed spool due to the use of a long threaded fitting which has damaged the valve
bore
 Use only fittings designed for connection to pneumatic valve ports
 Fault: Slow changeover of the spool
 A blocked vent hole
 The space behind the pistons needs to breath
 If the valve is installed firmly against a flat surface the breathing hole can be blocked
 The restriction can cause slow or incomplete operation of the spool
Fault: Valve spool not resetting
 For mono stable valves this may be due to a broken spring
 Fault: Air escaping continually from exhaust ports
 Leaking due to damaged or worn seals
 For 5/2 valves this may alternatively be caused by leaking actuator seals

Solenoid valves Fault

Fault: The pneumatic output is OFF when the coil should be ON
 Check the electrical supply at the plug
 If this is OFF trace the supply back to the source
 If ON the fault may be:
 low voltage
 mechanical fault preventing the armature pulling in
 burnt out coil
 Coils must be firmly fixed to the solenoid stem
 If the coil is loose it will vibrate
 There will be heat build-up, less efficient holding of the armature and eventual failure
 Solenoids valves have matched coils and stems according to coil power
 A low power coil will not pull in the armature against the stronger spring of a high
power stem assembly
 A high power coil causes slamming of the armature on a low power stem resulting in
premature seal failure

Fault: Switch not turning ON when actuators piston is at the end of stroke
 The switch is positioned too far to one end on the actuator
 It is beyond the range of the magnet

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 Module 7: Safety, Troubleshooting and Maintenance

Service Units Failure:

Service Units may fail due to the following reasons:
1. Bad quality of air.
2. Unstable Lubricating Oil.
3. Operating conditions beyond the limits (Pressure, Temperature etc.)
4. Careless handling of service units (Knobs, Drain plugs)

Tubing Failure:
Tubing may fail due to the following reasons:
1. Minimum Bending radius is not maintained
2. Friction with moving parts.
3. Forcibly using with unsuitable connectors.
4. Direct exposure to temperatures beyond allowable limits.
5. Repeated kinking of tubing during operation/maintenance.
6. Maximum operating pressure above the allowable limit.
7. Continuous contact with water, coolant, solvent, chemicals, fumes etc….

Piston actuator fault

Possible reason for

Type of Failure Possible Remedy.
Failure

1. Eccentric loads
Leakage through
Piston rod seal. Use company specified guide
units.
2. Lateral Moments
beyond limit.
3. Non parallelity of
Piston rod seal.
Piston rods & guide rods.
Cover the piston rod/Remove
4. Sticky piston rod.
sticky material.
Piston rod Seal is 5. Misalignments Rod couplers.
Damaged.
6. High/Very low
Use Cylinders with temperature
surrounding
resistant sealing.
Temperature
7. Constant exposure to
Piston rod seal is Use Corrosion resistant
chemicals , coolants,
damaged cylinders.
chemical fumes etc..
1. Lateral load beyond the
Use Company specific guide units.
allowable limits.
2. Frequent lateral impact
Use stopper cylinders.
load.
Piston rod is bent
3. Normal cylinder is not
used for Heavy duty Use specially designed Heavy
application duty cylinders.
EX: Hammering

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 Module 7: Safety, Troubleshooting and Maintenance

Possible reason for

Type of Failure Possible Remedy.
Failure
1. Bad quality of air. Guarantee good quality of air

2. Insufficient Lubrication Guarantee sufficient lubrication.

Piston seal and other
wearing parts inside 3. Use of non-conforming Use company specified
the cylinder are oil for lubrication. Lubricating oil.
damaged.
Use cylinders with scraper ring to
4. Dust accumulation in
avoid dry dust entering the
the cylinder.
cylinder through Piston rod seal.

1. For heavy impact

applications use heavy duty
cylinder.
1. Piston is subjected to
2. Use external shock absorbers
repeated heavy impact
to de-accelerate the piston.
Piston is damaged. loads.
3. Use the cylinder within the
maximum allowable operating
pressure range.
2. Lateral Moment is 1. Use company specified guide
beyond the allowable limit. units.
1. Fine Dust
Guarantee good quality of air
accumulation inside the
supply.
valve.
2. Fine Dust accumulation Mount silencers on the exhaust
Sealing of Valve are inside the valve through ports, so that dust does not
damaged possibly open exhaust enter the valve body through
ports. there ports.
3. Use of non-conforming Use company recommended
lubricating oil. lubricating oil.
4. Surrounding Mount the valves in a thermally
temperature is beyond the insulated cabinet. Or mount the
allowable limits. valves away in a safe place.
Operating pressure
Sealing of valve are Use suitable valve for high
beyond max. allowable
damaged. pressure application.
limit.
1. Voltage surge. Guarantee the Voltage supply
within recommended limits,
2.Undersized coil
Coils are damaged. size properly and install
3.Water/dirt entry into coil solenoid valve at water proof
compartment locations.

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