Troubleshooting Pneumatic Circuits: Fluid Power

Fluid Power
1-800-Lab-Volt Troubleshooting Pneumatic Circuits

www.labvolt.com
86272-10
Instructor Guide
|3086272100000E~
Fluid Power
Troubleshooting Pneumatic Circuits

Instructor Guide
86272-10
A
First Edition
Published May 2013
© 2009 by Lab-Volt Ltd.

Printed in Canada
All rights reserved
ISBN 978-2-89640-343-1 (Printed version)

ISBN 978-2-89640-675-3 (CD-ROM)
Legal Deposit – Bibliothèque et Archives nationales du Québec, 2009

Legal Deposit – Library and Archives Canada, 2009
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in

any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without
prior written permission from Lab-Volt Ltd.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Lab-Volt. The Lab-Volt® materials described in this document are
furnished under a license agreement or a nondisclosure agreement.
The Lab-Volt® logo is a registered trademark of Lab-Volt Systems.
Lab-Volt recognizes product names as trademarks or registered trademarks of their

respective holders.
All other trademarks are the property of their respective owners. Other trademarks and trade
names may be used in this document to refer to either the entity claiming the marks and
names or their products. Lab-Volt disclaims any proprietary interest in trademarks and trade
names other than its own.
Safety and Common Symbols
III
Safety and Common Symbols
IV
To the Instructor
The Troubleshooting Pneumatic Circuits system, Model 6081-F, is an add-on to the

Pneumatics Fundamentals system, Model 6081-1. It is used to allow students to
develop their skills in troubleshooting.
The components that have been modified to include faults are:
C Conditioning Unit, Model 6411

C Accumulator, Model 6412
C Vacuum Generator, Model 6413
C Directional Valve, Push-Button Operated, Model 6420
C Directional Valve, Double-Air-Pilot Operated, Model 6422
C Loading Device, Model 6480
C Tees, Model 6490
C Long Line, Model 6492
How to Use the Faulty Components
In this guide, the faulty components are presented by numerical order with a
description of the mechanical modification, an exercise suggesting where to use the
faulty components, the answers to procedure step questions obtained with the faulty
components, and the answers to Troubleshooting Reports.
The exercises suggested in this manual are taken from the conventional manual
Pneumatics Fundamentals, part number 31290, or from the corresponding manuals
in job sheet format corresponding to the four units of the manual Pneumatics
Fundamentals. The manuals in job sheet format are titled Introduction to Pneumatics
(part number 39900), Basic Physical Concepts (part number 39901), Basic Controls
of Cylinders (part number 39902), and Basic Controls of Motors (part
number 39902).
Once the students have completed the Procedure steps of the suggested exercise,
they must complete the Troubleshooting Report shown in Appendix A to demonstrate
that they have correctly identified the component in trouble. It is suggested that you
duplicate the Appendix A and supply a copy to each student group who begins to
troubleshoot a circuit.
Since the students should not know which component is faulty when they perform
the exercises, it is suggested that you setup the circuits to troubleshoot when the
students are absent.
The order in which the faulty components are used is not important.
If you have many pneumatic systems, you can set up many faulty circuits to provide
work for many student groups. In this case, it is suggested to also set up some
circuits without faulty component.
V
To the Instructor
Identification
The faulty components are identified by the letter F in the base of the component.
The component must be turned over to see the letter. On the Loading Device, the
letter is engraved on the flange of the component. See Figure 1.
Figure 1. The arrow points toward the letter identifying a faulty component.
Answers to Procedure Step Questions
The answers to procedure step questions that are not affected by the faulty
components are not included in this guide.
Prerequisite
Before performing the troubleshooting tasks suggested in this guide, the students
should have completed the conventional manual Pneumatics Fundamentals, part
number 31290 [or the corresponding manuals in job sheet format titled Introduction
to Pneumatics (part number 39900), Basic Physical Concepts (part number 39901),
Basic Controls of Cylinders (part number 39902), and Basic Controls of Motors (part
number 39902). This manual (or the corresponding manuals in job sheet format)
is(are) required to perform the exercises suggested in this guide.
Security
C Before a student begins an exercise, ensure that the equipment is in good

condition and does not represent any risk when used.
C Make sure that the students understand the objectives of the work to be done.
VI
Table of Contents
Conditioning Unit, Model 6411-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Accumulator, Model 6412-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vacuum Generator, Model 6413-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Directional Valve, Push-Button Operated, Model 6420-F . . . . . . . . . . . . . . . . 7
Directional Valve, Double-Air-Pilot Operated, Model 6422-F . . . . . . . . . . . . . 9
Loading Device, Model 6480-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tees, Model 6490-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Long Line, Model 6492-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Appendix A Troubleshooting Report
We Value Your Opinion!
VII
VIII
CONDITIONING UNIT
Model 6411-F
FAULT DESCRIPTION
The pressure regulator 0-700 kPa (0-100 psi) of the Conditioning Unit has been
replaced with one having a range of 0-200 kPa (0-30 psi). The pressure gauge has
not been changed and shows a 0-700 kPa (0-100 psi) range.
Pressures higher than approximately 200-300 kPa (30-40 psi) are no longer
available.
APPLICATION
If you are using the conventional manual Pneumatics Fundamentals, part

number 31290, perform the following:
C Set up the circuit shown in Figure 3-19 of Exercise 3-3 using the faulty
Conditioning Unit, Model 6411-F.
C Ask the students to perform the Procedure steps of Exercise 3-3, Cylinders in
Series.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 3-4 of Job Sheet 3 in the manual Basic
Controls of Cylinders (part number 39902) using the faulty Conditioning Unit,
Model 6411-F.
C Ask the students to perform Procedure steps of Job Sheet 3, Cylinder in Series.
ANSWERS TO PROCEDURE STEP QUESTIONS
G 12.
Note: The students should observe that the pressure is limited to
approximately 200-300 kPa (30-40 psi). They may stop their
experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.
G 13. With a standard component:
INITIAL PRESSURE FINAL PRESSURE

PRESSURE MULTIPLICATION
(cap end of the cylinder) (rod end of the cylinder)
400 kPa (or 60 psi) 440 kPa (or 66 psi) approx. 1.1
Table 3-4 (or job sheet Table 3-1). Pressure multiplication.
1
With the faulty component:
INITIAL PRESSURE FINAL PRESSURE

PRESSURE MULTIPLICATION
(cap end of the cylinder) (rod end of the cylinder)
Unable to set the pressure

Not applicable Not applicable
to 400 kPa (or 60 psi)
Table 3-4 (or job sheet Table 3-1). Pressure multiplication.
G 15. With a standard component: Yes.
With the faulty component: No value at 400 kPa (or 60 psi) to compare.
G 16. With a standard component: No. The area ratio is low. The pressure
intensification is low.
With the faulty component: No value at 400 kPa (or 60 psi) to conclude.
TROUBLESHOOTING REPORT
G 1. No. Unable to set the pressure to more than 200-300 kPa (30-40 psi).
G 2. The compressed air supply, and the Conditioning Unit.
G 3. The Conditioning Unit does not supply pressure higher than 200-300 kPa
(30-40 psi). The pressure regulator may be defective.
Note: The students may check the compressed air supply on

another bench or use another Conditioning Unit.
2
ACCUMULATOR
Model 6412-F
FAULT DESCRIPTION
The input port of the Accumulator has been blocked. The Accumulator cannot be
filled with compressed air.
APPLICATION

C Set up the circuit shown in Figure 1-30 of Exercise 1-3.
Note: Place the faulty Accumulator, Model 6412-F, on the work surface.
The students will have to use it later in the exercise.
C Ask the students to perform Procedure steps 3 to 27 of Exercise 1-3, Air

Conditioning and Distributing Equipment.
C Set up the circuit shown in Figure 3-9 of Job Sheet 3 in the manual Introduction
to Pneumatics (part number 39900).
Note: Place the faulty Accumulator, Model 6412-F, on the work surface.
The students will have to use it later in the exercise.
C Ask the students to perform Procedure steps 3 to 27 of Job Sheet 3, Air

Conditioning and Distributing Equipment.
G 11. With a standard component: The time taken by the rod to fully extend is
shorter when the Accumulator is connected to
the circuit. The Accumulator provides a short-
term supply of compressed air to the cylinder.
With the faulty component: The time taken by the rod to fully extend is
the same with or without the Accumulator.
Note: The students should observe that the Accumulator has no

effect on the circuit operation.
3
With the faulty component: No.
G 24. With a standard component: The time taken by the rod to fully extend is
shorter when the Accumulator is connected to
the circuit. The Accumulator provides a short-
term supply of compressed air to the cylinder.
With the faulty component: The time taken by the rod to fully extend is
the same with or without the Accumulator.
Note: The students should observe that the Accumulator has no

effect on the circuit operation.
G 1. No. The extension time of the cylinder rod is the same with or without
accumulator.
G 2. A leak in the Accumulator branch, and the Accumulator.
G 3. The Accumulator is ineffective. No air leak is detected in the Accumulator

branch.
4
VACUUM GENERATOR
Model 6413-F
FAULT DESCRIPTION
The neck of the venturi has been increased. The Vacuum Generator now generates
very low vacuum. See Figure 2.
Figure 2. The neck of the venturi on the standard and faulty components.
APPLICATION

Vacuum Generator, Model 6413-F.
C Ask the students to perform Procedure steps 7 to 11 of Exercise 2-4,
Vacuum Generation.
Physical Concepts (part number 39901) using the faulty Vacuum
Generator, Model 6413-F.
C Ask the students to perform Procedure steps 7 to 11 of Job Sheet 4,
Vacuum Generation.
G 10. With a standard component: Yes. The Vacuum Generator removed air
from the chamber of the Double-Acting
Cylinder.
5
With the faulty component: No. The vacuum produced by the Vacuum
Generator is not sufficient to extend the
cylinder rod.
G 1. No. The cylinder rod does not extend.
G 2. The Vacuum Generator, and the Double-Acting Cylinder.
G 3. The Vacuum Generator does not generate vacuum.
6
DIRECTIONAL VALVE, PUSH-BUTTON OPERATED
Model 6420-F
FAULT DESCRIPTION
The actuator in the valve has been removed. Pressing the push-button does not
change the position of the spool in the valve.
APPLICATION

Directional Valve, Push-Button Operated, Model 6420-F.
Directional and Speed Control of Cylinders.
Controls of Cylinders (part number 39902) using the faulty Directional Valve,
Push-Button Operated, Model 6420-F.
Directional and Speed Control of Cylinders.
G 34. With a standard component: Yes. FCV1 controls the extension time and
FCV2 controls the retraction time of the
cylinder.
With the faulty component: No. The cylinder rod does not extend.
G 40. With a standard component: Yes, it is possible.
With the faulty component: No. The cylinder rod does not extend.
7
G 1. No. The cylinder rod does not extend when pressing the push-button of
DCV1.
G 2. The Conditioning Unit; Directional Valve, Push-Button Operated DCV1;

Flow Control Valve FCV1; and Double-Acting Cylinder.
G 3. The Directional Valve, Push-Button Operated.
8
DIRECTIONAL VALVE,
DOUBLE-AIR-PILOT OPERATED
Model 6422-F
FAULT DESCRIPTION
The U-cup on one of the pistons that actuate the spool of the valve has been
removed. The spool of the valve does not change position when the
corresponding pilot port is pressurized at less than 150 kPa (20 psi). See
Figure 3.
Figure 3. The arrow points toward the faulty pilot port of the valve.
APPLICATION

Directional Valve, Double-Air-Pilot Operated, Model 6422-F.
Note: Make sure to connect the faulty pilot port of the Directional
Valve, Double-Air-Pilot Operated to the Long Line module.
C Ask the students to perform Procedure steps 14 to 22 of Exercise 4-1, Indirect

Control Using Pilot-Operated Valves.
9
Controls of Motors (part number 39903) using the faulty Directional Valve,
Double-Air-Pilot Operated, Model 6422-F.
Note: Make sure to connect the faulty pilot port of the Directional
Valve, Double-Air-Pilot Operated to the Long Line module.
C Ask the students to perform Procedure steps 14 to 22 of Job Sheet 1, Indirect

EXTENSION TIME OF THE CYLINDER ROD

(s)
READING
DIRECT CONTROL INDIRECT CONTROL
First Reading >2 <1
Second Reading >2 <1
Third Reading >2 <1
Mean Value >2 <1
Table 4-1 (or job sheet Table 1-1). Extension time of the piston rod.
EXTENSION TIME OF THE CYLINDER ROD

(s)
READING
First Reading >2 unable to extend the rod
Second Reading >2 unable to extend the rod
Third Reading >2 unable to extend the rod
Mean Value >2 unable to extend the rod
Note: The students should observe that the cylinder rod does
not extend when pressing the push-button of DCV1. They may
stop their experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.
10
With the faulty component: No possible comparison. The cylinder rod

does not extend.
G 19. With a standard component: Pilot lines reduce delays caused by air
compressibility and friction in long tubing
lines.
With the faulty component: No possible conclusion. The cylinder rod

does not extend.
G 20. With a standard component: No. The lack of return springs in double-
piloted valves allows the spool position to
be maintained without maintaining pilot
pressure.
With the faulty component: No possible observation. The cylinder rod

does not extend.
G 1. No. The cylinder rod does not extend.
G 2. The Conditioning Unit; Directional Valve, Push-Button Operated DCV1;

Long Line; Directional Valve, Double-Air-Pilot Operated; and Single-
Acting Cylinder.
G 3. The Directional Valve, Double-Air-Pilot Operated.
11
12
LOADING DEVICE
Model 6480-F
FAULT DESCRIPTION
The spring in the Loading Device has been replaced by one having a higher force
constant (spring constant). This causes the Loading Device to give results lower
than actual values.
APPLICATION

C Set up the circuit shown in Figure 2-6 of Exercise 2-1 using the faulty Loading
Device, Model 6480-F.
Pressure vs Force Relationship.
Physical Concepts (part number 39901) using the faulty Loading Device,
Model 6480-F.
Pressure vs Force Relationship.
APPLIED PRESSURE CALCULATED MEASURED

ON FULL PISTON AREA CYLINDER FORCE CYLINDER FORCE
600 kPa (or 90 psi) 345 N (or 78 lbf) 345 N (or 78 lbf)
Table 2-1 (or job sheet Table 1-1). Cylinder force versus pressure.
13
APPLIED PRESSURE CALCULATED MEASURED

ON FULL PISTON AREA CYLINDER FORCE CYLINDER FORCE
Table 2-1 (or job sheet Table 1-1). Cylinder force versus pressure.
Note: Because the spring in the Loading Device has been

replaced by one having a higher force constant (or spring
constant), the measured cylinder force is much lower than the
actual value.
G 1. No. The measured cylinder forces do not match with the calculated
values.
G 2. The Conditioning Unit; Double-Acting Cylinder; and Loading Device.
G 3. The Loading Device.
Note: The students may use another Double-Acting Cylinder or

Loading Device to identify the faulty component with certitude.
14
TEES
Model 6490-F
FAULT DESCRIPTION
One of the ports on each tee of the Tees module has been blocked. This prevents
air flow through these ports. The location of the blocked ports is shown in
Figure 4.
Figure 4. The arrows point toward the blocked ports of the Tees module.
APPLICATION

C Set up the circuit shown in Figure 3-24 of Exercise 3-4 using the faulty Tees
module, Model 6490-F.
Note: Make sure to connect the Double-Acting Cylinder to a blocked

port of the Tees module.
C Ask the students to perform the Procedure steps of Exercise 3-4, Cylinders in
Parallel.
15
Controls of Cylinders (part number 39902) using the faulty Tees,
Model 6490-F.
Note: Make sure to connect the Double-Acting Cylinder to a blocked

port of the Tees module.
C Ask the students to perform the Procedure steps of Job Sheet 4, Cylinders in
Parallel.
G 6. With a standard component: Yes. The Double-Acting Cylinder extends

first.
With the faulty component: No. The rod of the Double-Acting Cylinder
does not extend.
G 9. With a standard component: Yes. The Double-Acting Cylinder extends

first.
With the faulty component: No. Synchronizing is not possible since the
rod of the Double-Acting Cylinder does not
extend.
G 1. No. The rod of the Double-Acting Cylinder does not extend.
G 2. The Tees module, and the Double-Acting Cylinder.
G 3. One of the ports of the Tees module is blocked.
16
LONG LINE
Model 6492-F
FAULT DESCRIPTION
A needle valve has been added between the two ports of the Long Line to restrict
the air flow. The setting of the needle valve corresponds to approximately 1/8th of
a turn in the counterclockwise direction from the closed position (fully clockwise).
See Figure 5.
Figure 5. Location of the needle valve between the ports of the Long Line.
APPLICATION

C Set up the circuit shown in Figure 4-6 of Exercise 4-1 using the faulty Long
Line, Model 6492-F.
Note: Make sure to connect the Single-Acting Cylinder and Pressure

Gauge to the ports shown in the Figure 4-6.
C Ask the students to perform the Procedure steps 14 to 22 of Exercise 4-1,

Indirect Control Using Pilot-Operated Valves.
17
Controls of Motors (part number 39903) using the faulty Long Line,
Model 6492-F.
Note: Make sure to connect the Single-Acting Cylinder and Pressure

Gauge to the ports shown in Figure 1-6 of the manual Basic Controls
of Motors (part number 39902).
C Ask the students to perform Procedure steps 14 to 22 of Job Sheet 1, Indirect

EXTENSION TIME OF THE CYLINDER ROD (s)

READING
First Reading >2 <1
Second Reading >2 <1
Third Reading >2 <1
Mean Value >2 <1
Note: While repeating the extension time measurement, the

students should observe that the cylinder rod retracts when
pressing the push-button of DCV2 and "re-extends" as soon as
the push-button is released (this action is observed while the
pilot line, on the Long Line side, is still pressurized. They
should also observe that there is a delay before the cylinder rod
extends when pressing the push-button of DCV1 causing the
extension time with the faulty component to be longer than with
a standard component.
EXTENSION TIME OF THE CYLINDER ROD (s)

READING
First Reading >2 >1
Second Reading >2 >1
Third Reading >2 >1
Mean Value >2 >1
18
Note: Notice that the extension time of the cylinder rod is

greater than 1 second with the faulty component while it is less
than 1 second with a standard Long Line.
With the faulty component: Yes or no. It depends on the setting of the
restriction in the Long Line.
G 19. With a standard component: Pilot lines reduce delays caused by air
compressibility, and friction in long tubing
lines.
With the faulty component: We cannot conclude with certitude from

these observations.
G 1. No. Indirect control should reduce the delays caused by air

compressibility, and friction in long tubing lines, but it does not.
G 2. The Directional Valve, Push-Button Operated; Long Line; Directional

Valve, Double-Air-Pilot Operated; and Single-Acting Cylinder.
G 3. The Long Line.
19
20
Appendix A
Troubleshooting Report
G 1. Once the Procedure steps are completed, can you conclude that the
circuit operates normally? If not, describe the symptom(s).
G 2. Identify the component(s) that can cause the fault.
G 3. Analyze your circuit and/or test the suspected components (out of the
circuit or by modifying the circuit connections) to identify the component
that is the most probable cause of the fault. You may also compare the
actual results with those previously obtained with the standard
components.
Name the faulty component and give a brief description of the fault
(where applicable, describe your approach to identify the component).
G 4. Ask the instructor to validate your conclusion.
A-1
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Fluid Power

1-800-Lab-Volt Troubleshooting Pneumatic Circuits

Troubleshooting Pneumatic Circuits

© 2009 by Lab-Volt Ltd.

ISBN 978-2-89640-343-1 (Printed version)

Legal Deposit – Bibliothèque et Archives nationales du Québec, 2009

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in

The Lab-Volt® logo is a registered trademark of Lab-Volt Systems.

Lab-Volt recognizes product names as trademarks or registered trademarks of their

The Troubleshooting Pneumatic Circuits system, Model 6081-F, is an add-on to the

The components that have been modified to include faults are:

C Conditioning Unit, Model 6411

How to Use the Faulty Components

Answers to Procedure Step Questions

C Before a student begins an exercise, ensure that the equipment is in good

Conditioning Unit, Model 6411-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Appendix A Troubleshooting Report

We Value Your Opinion!

If you are using the conventional manual Pneumatics Fundamentals, part

ANSWERS TO PROCEDURE STEP QUESTIONS

G 13. With a standard component:

INITIAL PRESSURE FINAL PRESSURE

Table 3-4 (or job sheet Table 3-1). Pressure multiplication.

With the faulty component:

INITIAL PRESSURE FINAL PRESSURE

Unable to set the pressure

Table 3-4 (or job sheet Table 3-1). Pressure multiplication.

G 15. With a standard component: Yes.

G 2. The compressed air supply, and the Conditioning Unit.

Note: The students may check the compressed air supply on

If you are using the conventional manual Pneumatics Fundamentals, part

C Set up the circuit shown in Figure 1-30 of Exercise 1-3.

C Ask the students to perform Procedure steps 3 to 27 of Exercise 1-3, Air

C Ask the students to perform Procedure steps 3 to 27 of Job Sheet 3, Air

ANSWERS TO PROCEDURE STEP QUESTIONS

Note: The students should observe that the Accumulator has no

G 12. With a standard component: Yes.

With the faulty component: No.

Note: The students should observe that the Accumulator has no

G 25. With a standard component: Yes.

With the faulty component: No.

G 2. A leak in the Accumulator branch, and the Accumulator.

G 3. The Accumulator is ineffective. No air leak is detected in the Accumulator

If you are using the conventional manual Pneumatics Fundamentals, part

ANSWERS TO PROCEDURE STEP QUESTIONS

G 1. No. The cylinder rod does not extend.

G 2. The Vacuum Generator, and the Double-Acting Cylinder.

G 3. The Vacuum Generator does not generate vacuum.

DIRECTIONAL VALVE, PUSH-BUTTON OPERATED

If you are using the conventional manual Pneumatics Fundamentals, part

ANSWERS TO PROCEDURE STEP QUESTIONS

G 32. With a standard component: Yes.

With the faulty component: No.

G 40. With a standard component: Yes, it is possible.

G 2. The Conditioning Unit; Directional Valve, Push-Button Operated DCV1;

G 3. The Directional Valve, Push-Button Operated.

If you are using the conventional manual Pneumatics Fundamentals, part

C Ask the students to perform Procedure steps 14 to 22 of Exercise 4-1, Indirect

C Ask the students to perform Procedure steps 14 to 22 of Job Sheet 1, Indirect

ANSWERS TO PROCEDURE STEP QUESTIONS

G 17. With a standard component:

EXTENSION TIME OF THE CYLINDER ROD

First Reading >2 <1

Second Reading >2 <1

Third Reading >2 <1

Mean Value >2 <1