12 Steps to Troubleshooting Pneumatic Systems

FOR IMMEDIATE RELEASE
(Free-Press-Release.com) January 21, 2010 -- Troubleshooting a pneumatic system has been considered an art, a science, or just hit-or-miss luck. In the minds of maintenance personnel, production managers, and plant managers, the word troubleshooting conjures up images of hours of downtime and lost production. However, when reduced to its basic elements, troubleshooting a pneumatic system is a step-by-step procedure. Using this process can speed up the ability to determine what the problem is, the probable cause of the malfunction or failure, and a solution.

Every pneumatic circuit has a logical sequence of operation that can involve timing logic, pressure sensing, position sensing, and speed regulation. Troubleshooting is initiated when the circuit does not operate properly.

Certain general diagnostic and testing steps can be applied to any troubleshooting problem, whether the problem occurred at startup of a new system or at a breakdown of an existing system.

Think safety first
Safety should always be a prime concern of maintenance personal. Compressed air is a volatile element in a pneumatic circuit. Air receiver tanks have exploded, causing severe injury to personnel and damage to property. It is imperative to relieve pressure in a receiver tank prior to making any repairs.

Air is also highly compressible, which is another reason to be cautious in the approach to troubleshooting a pneumatic system. When working with overhead loads that are supported by cylinders, but not mechanically locked into position, block the load before servicing the system to prevent falling or drifting.

Many pneumatic systems are controlled by electrical or electronic devices. Before attempting service or repair on these components, be sure the electrical power supply has been turned off.

Pneumatic directional control valves that use electrical solenoids to operate the valve spool are often equipped with manual overrides (Fig. 1) that can be used during troubleshooting to operate the system.

Pneumatic lockout valves (Fig. 2) are excellent safety devices that, when used properly on pneumatic systems, can prevent accidental operation. Ensuring a safe condition should always be the first step in troubleshooting pneumatic systems.

Ask the three Ws
When a breakdown in the system occurs, the pressures of downtime loom large in the minds of all concerned. Before beginning repair of a system, stop and ask these three questions:

What is or is not occurring in the system's operation?

When did the problem begin? Was it a sudden failure or a gradual failure?

Where in the machine cycle does the problem occur? Was it at startup or after the system has been operating for a while?

What is or is not occurring in the system can often be answered by the system operator. Answers to questions such as slow actuator speed or inability of the actuator to move could lead to looking for a low flow rate or low pressure.

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