MXT Tech 213 Insdustrial Pneumatics Module 1 1

BASIC PNEUMATICS LEARNING MANAUAL
Mx Tech 213 – Industrial Pneumatics

for
Bachelor of Science in Mechatronics
No. of Hours per Semester: 162
Credit Units : 3
Course Objectives:
1. Relate course to the vision and mission of the COT and CTU;
2. Observe the highest standards of safety;
3. Develop knowledge on fundamental principles of pneumatics;
4. Understand basic symbology in pneumatics;
5. Appreciate the application of pneumatics;
6. Know the fundamentals of creating pneumatic control circuits;
7. Apply the knowledge of pneumatics;
8. Develop capability to troubleshoot and repair pneumatics components;
and
9. Appreciate the industrial application of pneumatics.
Page 1 of 73
CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

Corner M. J. Cuenco Avenue and R. Palma St.,
Mechatronics Instructor
Cebu City, Philippines 6000 http://www.ctu.edu.ph
email: information@ctu.educ.ph
FOREWORD
Automation of industrial processes and mass production system for products
and services are inevitable consequence of modernization. Before the Industrial
Revolution, people were farmers, and life was pretty slow. They used filing cabinets,
pencil and paper for their documentations, but recently, with the invention of
computers, hard disks, email and gigabytes all has been changed. Every time
technology changes, everything around it changes, and it
is an exponential process. Technology increases, and then, using the new
technology, it increases even more. And one of the components in industrial
automation is pneumatics, wherein the students will be dealing about the usage of
compressed air and its corresponding components.
It is the objective of the author to prepare this Basic Pneumatics Learning
Manual for the Bachelor of Science in Mechatronics students who will be taking Mx
Tech 213 – Industrial Pneumatics. This course provides the fundamental concepts
and theories for safely operating pneumatic components and systems. Topics
include:pneumatic theory, compressors, humidity, units of pressures, methods of
drying, pipe materials, pneumatic fittings, pneumatic actuators, mounting, pneumatic
valves, preventive maintenance, regulators, pneumatic circuit designing, servicing
safety, and troubleshooting. It also tackle the fundamentals of pneumatics such as
component symbols, functions and application, and pneumatic circuit diagram
Page 2 of 73

making. It also includes the fundamentals of electricity, and fault finding activities of
simple pneumatic control system and safety regulations.
This Learning Manual will be enhanced to contribute the industry requirement
of industrial pneumatics experts.
JOSEPH C. PEPITO
Page 3 of 73

TABLE OF CONTENTS
Title Page
I. Course Objectives 1
II. Foreword 2
III. Table of Contents 4
IV. CTU Vision and Mission 5
V. Safety Precautions 6
VI. Notes of Safety and Operations 9
VII. History and Definition of Pneumatics 10
VIII. Applications of Pneumatics 11
IX. Basic Characteristics Air 11
X. Basic Pneumatics System 12
XI. Units of Pressure 14
XII. Compressed Air Production and Distribution 15
XIII. Air Compressors 18
XIV. Criteria for the Selection of a Compressor 22
XV. Air Humidity 29
XVI. Methods of Air Drying 32
XVII. Compressed Air Distribution 35
XVIII. Two Types of Pipe Line Installation 38
XIX. Types of Pipe Material 39
XX. Types of Fittings 40
XXI. Pneumatic Actuators 40
XXII. Types of Cylinder Mounting 47
XXIII. Types of Cylinder Sealing 48
XXIV. Pneumatics Valves 49
XXV. Five Group of Valves According to Function 50
XXVI. Additional Notes (Facts and Theory of Air) 60
Page 4 of 73

VISION
The center of excellence and development in research, instruction, production,
and extension services for progressive leadership transcending global technological,
business and industry-driven education.
MISSION
Provides advanced professional and technical instruction for special purposes,
industrial trade, teacher education, agriculture, fishery, forestry, engineering,
aeronautics and land-based programs, arts and sciences, health sciences,
information technology and other relevant fields of study. It shall undertake
research, production and extension services, and provide progressive leadership
across the areas of specialization for global empowerment.
Aims of the College of Technology:

1. Equip students with competencies and entry-level skills in various technology
areas;
2. Instill the highest standard of safety;
3. Value work as an inherent nature of the individual in the era of technological
advancement;
4. Satisfy the manpower requirement of industry;
5. Excel in quality technology education;
6. Establish partnership for excellence;
7. Uphold commitment to competent technician, engineers, and blue collar
professionals;
8. Develop the student and faculty members’ socio-cultural, moral, spiritual, and
nationalistic consciousness;
9. Preserve a culture of excellence as an individual; and
10. Enhance collaboration with lead agencies towards environment management.
Page 5 of 73

SAFETY PRECAUTIONS
A thorough safety program is a “must” for anyone working with

electricity.Electricity can be dangerous and even fatal with those who do not understand
and practice the simple rules of SAFETY.There many fatal accidents involving electricity
by well-trained technicians who either threw over-confidence or carelessness, violate the
basic rules of personal SAFETY.The first rule of personal safety is always,
“THINK FIRST”
This rules always applies to all industrial work as well as electrical

workers.Develop a good habit of workmanship. There are generally three kinds of
accidents, which appear all to frequently among electrical students and technicians. Your
knowing and studying about them and observing simple rules will make you safe person
to work with. You could personally be saved from painful and expensive experiences-you
might be saved to live a rewarding retirement age.
Safety is simply a matter of applying common sense precautions. The rules of

safety are concerned with the prevention of accidental injury. Firts aid involves the
treatment of injuries sustained when an accident occurs.
The general rules of shop safety apply equally the electrical-electronics

laboratory.The following shop safety rules should be observed at all times:
1. Don’t clown around or engage in horseplay. Many painful injuries are

caused by the careless and thoughtless antics of the “clown”.
2. Get your teacher’s approval before starting your work. This will save you
time and help prevent accidents. Remember, your teacher is here to help.
3. Report all injuries at once, even the slightest. A small cut can develop
series complications if not properly treated.
4. Wear safety glasses. When grinding or working in areas where sparks or

chips of metal are fying. Your eyes are priceless possession.
Page 6 of 73

5. Keep the floors around your work area clean and free of litter, which
might cause someone to slip or stumble.
6. Use tools correctly and do not use them if they are not in proper working
conditions.
7. Observe the proper methods of handling and lifting objects. Get help to
lift heavy objects.
8. Do not talk to or distract a fellow students when he is operating a

machine.
9. Never leave a machine while it is running or running down. Stay with it

until it stops completely.
10. Obtain permission before you use power tools.
11. Probably the best advice anyone can follow when working with electricity
is:
THINK-PLAN AHEAD!
The following are special safety rules for the electrical-electronics laboratory:
1. Although the normal healthy person will encounter no dangerous voltage

while performing the Laboratory Activity, circumtances occur under
which a surprisingly electric shock may be experienced.Surprising shocks,
while not particularly dangerous in themselves, may cause secondary
injury through violent mascular contraction that can hurl a person against
the wall or workbench or possibly another more dangerous source of
current.
2. Practice a precaution used by experienced engineers and technicians.

Always keep one hand in your pocket (or behind you) when measuring
current and voltage.If two hands are in contact with the circuit, the
current flows across the chest and heart regions which is very dangerous.
Page 7 of 73

3. If in doubt, with regards to the wiring of the circuit, ask the teacher to
check it out before you apply power.Electricity has no respect for
ignorance.
4. Make it a habit to short outb electrolytic or other large value capacitors

with an insulated screwdriver before attempting to work on
circuit.Capacitors can hold a charge for a long time after the power is
removed.
5. Know the location of fire extinguishers.
6. Certain components, such as resistors and vacuum tubes get quite hot
while operating. Give them time to cool off before attempting to remove
them.
7. Do not work around electrical equipment if floors are damp or wet.
8. Do not work on electrical circuit while the power is on.
9. Be sure that equipment is in proper working order before use.Frayed

[ower cords and cracked or chipped plugs are major source of accidents.
10. Ask for instruction before using any item of test equipment for the first
time, even if you think you know how to use it. A little knowledge can be
dangerous thing; and if some can go wrong, it will. Test equipment is
often expensive to repair.
11. Electricity-electronics is a tremendous field and most of us do well to

understand small segments of it. Ask question when in doubt. Be humble!
Page 8 of 73

NOTES ON SAFETY AND OPERATIONS
In the interest of your own safety you should observed the following:
1. Pressurized air lines that become detached can cause accidents. Switch off
pressure immediately.
2. First connect all tubing and secure before switching on the compressed air.
3. Warning!!! Cylinder may advance or retract as soon as the compressed air

is switched on.
4. Do not operate a roller lever valve manually during fault finding (use a
tool).
5. Observe general safety regulations.
6. Limit switch should be fixed so that they contact only the side of the trip
cam ( and not the front)
7. Do not exceed with the permissible working pressure.
8. Pneumatic Circuit Construction
a. Use the plastic tubing of 4mm external diameter to connect the

components.
b. The plastic tube is to be inserted fully into the connector up to the

stop; no tightening is necessary.
9. Releasing the quick push-pull connector: The tube can be released by
depressing the collet.
10. Switch off the air supply before disconnecting the circuit.
Page 9 of 73

Pneumatics
History
The earliest pneumatics transmission dates from 1700, when the
French physicist Denis Papin used the power from waterwheel to
compress air that was transmitted through tubes. About a century
later the British inventor George Medhurst received a patent use
compress air to drive a motor, although credit for the first practical
application was given to the British inventor George Law, who in 1865
devised the rock drill, in which an air-driven piston operated a hammer
tool. The rock drill was widely adopted and used in drilling of the Mont
Cenis railroad tunnel in the Swiss Alps, which opened in 1871, and for
the Hoosac Tunnel in Western Massachusetts, which opened in 1875.
Another significant advance was the invention of the pneumatic
railroad air brake by the American inventor, engineer and industrialist
George Westinghouse about 1868.
Origin
• from the Greek word “pneuma”
• means breath or wind
• the soul in philosophy
Pneumatics is the branch of technology, which deals with the study and
application of use of pressurized gas to affect mechanical motion. It can also be
define as branch of physics that is concerned with the mechanical properties of
gases.
Page 10 of 73

Another definition from American Public University is that, pneumatics is the
study of air and other gases at rest and in motion, specially under pressure, and
application of that knowledge in design and control of machines.
Some Applications of Pneumatics
• Bottling & filling machines

• Woodworking machinery
• Machine tool
• Components and material transfer
• Pneumatics robots
• Auto gauging
• Air separation machine
• Vacuum lifting machine for thin sheets
• Dental drill
• Fabric positioning
• Industrial robots
• Packaging machine
• Sealer machine
• Riveting
• Rock Drill
Basic Characteristics of Air

• Available everywhere for compression in unlimited quantities
• Easily transported in pipelines
• Can easily be stored in a reservoir
• Insensitive to temperature fluctuations
• It offers no risk of explosion or fire
• Environmentally clean
• Fast working medium
Page 11 of 73

The Basic Pneumatic System
Figure 1. Basic Pneumatic System
AIR PRODUCTION SYSTEM

1. Compressor
Air taken in at atmospheric pressure is compressed and delivered at a higher
pressure to the pneumatic system. It thus transforms mechanical energy into
pneumatic energy.
Page 12 of 73

2. Electric Motor
Supplies the mechanical Power to the compressor. It transforms electrical
energy into mechanical energy.
3. Pressure Switch
Controls the electric motor by sensing the pressure in the tank. It is set to a
maximum pressure at which it stops the motor, and a minimum pressure at
which it restarts it.
4. Check Valve
Lets the compressed air from the compressor into the tank and prevents it
leaking back when the compressor is stopped.
5. Tank
Stores the compressed air. Its size is defined by the capacity of the
compressor. The larger the volume, the longer the intervals between
compressor runs.
6. Pressure Gauge
Indicates the Tank Pressure.
7. Auto Drain
Drains all the water condensing in the tank without supervision.
8. Safety Valve
Blows compressed air off it the pressure in the tank should rise above the
allowed pressure.
9. Refrigerated Air Dryer
Cools the compressed air to a few degrees above freezing point and
condenses most of the air humidity. This avoids having water in the
downstream system.
10. Line Filter
Being in the main pipe, this filter must have a minimal pressure drop and the
capability of oil mist removal. It helps to keep the line free from dust, water and
oil.
Page 13 of 73

THE AIR CONSUMING SYSTEM
1. Air Take-off
For consumers, air is taken off from the top of the main pipe to allow
occasional condensate to stay in the main pipe, when it reaches a low point a
water take off from beneath the pipe will flow into an Automatic Drain and the
condensate will be removed.
2. Auto Drain
Every descending tube should have a drain at its low end. The most efficient
method is an Auto Drain which prevents water remaining in the tube should
manual draining be neglected.
3. Air Service Unit
Conditions the compressed air to provide clean air at optimal pressure, and
occasionally adds lubricant to extend the life of those pneumatic system
components which need lubrication.
4. Directional Valve
Alternately pressurizes and exhausts the two cylinder connections to control
the direction of movement.
5. Actuator
Transforms the potential energy of the compressed air into mechanical work.
Shown is a linear cylinder; it can also be a rotary actuator or an air tool etc.
6. Speed Controllers
Allow an easy and stepless speed adjustment of the actuator movement.
Units of Pressure
• Pressure are in “bar g” gauge Pa = Pg + atmosphere

pressure ( the value above • For quick calculations
atmosphere) assume 1 atmosphere is
• Zero gauge pressure is 1000 mbar
atmospheric pressure • For standard calculations 1
• Absolute pressures are used for atmosphere is
calculations 1013 mbar
Page 14 of 73

• 1 bar = 100000
• For measuring lower
N/m² (Newtons per pressures the millibar
square metre) (m bar) is used
• 1 bar = 10 N/cm² • 1000 mbar = 1 bar
• For measurements in
pounds per square inch
(psi)
1 psi = 68. 95mbar
14.5 psi = 1bar
There are many units of pressure measurement. Some of these and their
equivalents are listed below.
1 bar = 100000 N/m² (Newton per square meter)
1 bar = 100 kPa (kilo Pascal)
1 bar = 14.5 psi (pressure per square inch)
1 bar = 10197 kgf/m² (kilogram force per square meter)
COMPRESSED AIR PRODUCTION AND DISTRIBURTION
Compressed Air Production
• For the production of compressed air, compressors are required to compress the
air to desired working pressure. One usually finds that pneumatic drives and controls
have a central supply of compressed air. The power conversion and transmission
Page 15 of 73

need not then be calculated and planned for each user. The equipment is supplied
with compressed air by pipelines from the compressor plant.
• Portable compressors are used mainly in the construction industry or for

machines which frequently change site.
• When planning, allowance should be made for expansion and the purchase of
new pneumatic equipment. It is any case better to design the plant generously &
larger than immediately required, rather than to establish at a later date that the
production plant is overloaded. It is always an expensive business to expand the
compressor plant later on.
• The cleanness of the air is important. Clean air ensures that the compressor
plant has a longer life. It should also be ensured that the correct type of compressor
is used.
• The type of compressor used depends on the operational demands with regard
to working pressure and delivery volume.
• Compressor sizes range from less than 1 1/s with little or no preparation
equipment, to multiple compressor plant installations generating hundreds of cubic
meters per hour
• Sizes are defined as follows:

− Small compressors are up to 40 litres per sec and input of no more than 15 kW.
− Medium compressors are between 40 and 300 litres per second and input of
between 15 and 100 kW.
− Large compressors anything above the medium limit.
Page 16 of 73

Figure 2. Compressed Air Preparation System
Page 17 of 73

Air Compressors
• Two Principles Used in Compressor Operation
1. Displacement Principle – air is compressed by containing it in a chamber and

then reducing the volume of this chamber. This type is called piston compressor.
2. Air-flow Principle – air is drawn in one side and compressed it by mass
acceleration (Turbine)
Types of Compressors
1. Reciprocating Piston Compressor – is the most widely used compressor. It can

be used both pressure requirement from low to high pressure
Examples:
Figure 3. Single Stage Piston Compressor
Page 18 of 73

Figure 4. Double Stage Compressor with Inter-cooling
Figure 5. Diaphragm Compressor
Page 19 of 73

Piston Compressor – is a compressor with rotating pistons and at the
2. Rotary
same time, chambers are compacted and compressed.
Examples:
Figure 6. Sliding Vane Rotary Compressor
Figure 7. Screw Compressor
Page 20 of 73

Figure 8. Roots Blower
3. Flow Compressor – these compressor works in air-flow principle and are

especially suitable for large delivery volume.
Examples:
Figure 9. Axial-flow Compressor
Page 21 of 73

Figure 10. Radial-flow Compressor
Pressure
Delivery Volume
Type of Compressor Range
(cubic meter per hour)
(in Bar)
1. Rotary Compressor 150 – 2,000 m²/hr 0.15 – 8 Bars
2. Screw Compressor 800 – 50,000 m²/hr 0.8 – 25 Bars
3. Piston Compressor 80 – 25,000 m²/hr 1- 1000 Bars

4. Turbo Compressor 300 – 200,000 m²/hr 5 – 300 Bars
Table 1. Delivery Volume
Criteria for the Selection of a Compressor

1. Delivery Volume – the amount of air which the compressor delivers. Two ways
of specifying the delivery volume;
a. theoretical delivery volume – the expected delivery volume capacity of the
compressor unit.
Page 22 of 73

b. effective delivery volume – the actual delivery volume capacity during
operation.
2. Pressure
Two Distinct Type of Pressure;
a. Working pressure – is the compressor outlet pressure or the pressure in the
receiver and the pipelines to the user. It is the amount of pressure at the
output end of a compressor or receiver.
b. Operation pressure – is the pressure which is required at the operating

position. The amount of pressure nearest the point of performing work at the
output end of the pneumatic system.
Important:
Constant pressure is essential for reliable and accurate operation. The
following are related to the constant pressure;
− the speed
− the forces
− the time sequence of the working elements
3. Drive
Depending on the operational requirements, compressors are driven
either by an electrical motor or by an internal combustion engine. In factories,
compressor plant is not stationary, the drive is mostly by means of internal
combustion engines (petrol, diesel)
4. Regulation
In order to match the delivery volume of the compressor to the
fluctuating consumption, it is necessary to regulate the compressor. Various types
of regulation are available for this purpose. The delivery volume is regulated
between the adjustable limiting values of maximum and minimum pressure.
Page 23 of 73

Different Types of Regulation
No-load Low-speed On-off

Regulation Regulation Regulation
a. Exhaust a. Speed
regulation regulation
b. Shut-off b. Suction throttle
regulation regulation
c. Grip-arm
regulation
Table 2. Different Types of Regulation
1. NO-LOAD REGULATION
a. Exhaust regulation – is the simplest type of regulation, the compressor
works against a pressure relief valve. When the pressure in the receiver
has reached the set value, the safety valve opens and exhausts to
atmosphere. A check valve prevents the receiver from emptying
completely.
Figure 11. Exhaust Regulation
Page 24 of 73

b. Shut-off regulation – a type of regulation that shut-off the suction side.
The compressor intake is closed. The compressor cannot draw air in and
continues to run in the vacuum range. This type of regulation is found
particularly on rotary piston compressor, and also on reciprocating piston
compressor.
Figure 12. Shut-off Regulation
c. Grip-arm regulation – a type of regulation where in the suction valve is

kept open by means of a grip-arm, and the compressor any air. This has
been used in piston compressors.
Figure 13. Grip-arm Regulation
Page 25 of 73

2. LOW-SPEED REGULATION
a. Speed regulation – the speed of the internal combustion engine is
regulated via an adjusting link. The speed adjustment can be made by
hand or automatically controlled by the working pressure. The electrical
drive, speed control can be provided in steps by using a pole-changing
motor.
b. Suction throttle regulation - a type of regulation that throttling the air

intake. Specific partial load can thus be set. This type of regulation is used
on rotary piston compressors and turbo-compressors.
3. ON-OFF REGULATION
This is a type of regulation that has two operating conditions (full load or
standstill). The drive motor of the compressor is switched off on maximum
pressure. When the pressure has dropped to minimum pressure, the
motor is switched on.
Figure 14. On-Off Regulation
Page 26 of 73

5. Cooling
When compressing air in the compressor, heat is generated and must be
removed. The most suitable type of cooling for the compressor depends on the
amount of heat generated. Cooling fins on smaller compressors allow the heat to be
removed by radiation. Larger compressors are equipped with an additional fan to
remove heat.
In the case of a compressor plant with drive power excess of 30k W, air
cooling is no longer sufficient. The compressors are then equipped with water
circulation cooling or fresh water cooling. Frequently, a larger cooling plant with
cooling tower is not installed because of the capital outlay. Good cooling lengthens
the life of the compressor & provides better and cooler air. Sometimes subsequent
cooling can be saved or be performed with less power.
Figure 15. Cooling Fins and Water Circulation Cooling
Page 27 of 73

6. Installation Site
The compressor station should be installed in a room on its own and
sound proofed towards the outside. The room should be well ventilated, and the
free air should be as cool, dustfree and dry as possible.
• High temperatures are produced • Avoid locations where the air may
when air is compressed, have a high humidity such as above
• Compressor house well a pond, river or canal
ventilated located on an outside • Avoid locations where wind
north facing wall eddies whip up dust, grit and litter
• Inlet filter to inhale only • An intake on the factory roof must
clean dry air, keep away from: be protected from the weather and
− Fumes from parked vehicle with emissions from ducting and
engine running chimneys
− Solvent fumes from paint plant or
store
7. Compressed Air Receiver

The compressed air receiver serves to stabilize the compressed air
supply. It smoothens pressure fluctuations in the network when air is consumed.
In addition, the large surface area of the receiver cools the air. Thus, a portion of
the moisture in the air is separated as water directly from the receiver.
• Typical medium size compressor installation
• Integrated compressor unit including inlet filter, electrically driven compressor,
after cooler and water separator.
• Air receiver to smooth demand surges, and provide additional cooling and water
collection
Page 28 of 73

Air Humidity
Relative Humidity - it is the ratio of the partial pressure of water vapor in the
mixture to the saturated vapor pressure of the water at prescribed temperature.
Relative Humidity = absolute humidity/saturation quantity x 100%
Relative Humidity
Atmospheric air always contains a percentage of water vapor. The amount
of moisture present will depend on the atmospheric humidity and temperature.
When atmospheric air cools, it will reach a certain point at which it is saturated with
moisture, known as the dew point. If the air cools further it can no longer retain all
the moisture.
If the air cools further it can no longer retain all the moisture and the
surplus is expelled as miniature droplets to form a condensate.While coarse
separation of condensate is effected in the separator after the recooler, fine
separation, filtering and other subsequent treatment of the compressed air is dealt
with at the point of usage. Particular attention should be paid to the moisture that is
present in compressed air. Water (moisture) is introduced to the air network with
the air drawn in by the compressor. The amount of moisture present depends
primarily on the relative humidity which in turn is dependent on the air temperature
and the weather conditions.
The absolute humidity is the quantity of water which is contained in one m³

of air. The saturation quantity is the quantity of water which one m³ can absorb at
the temperature concerned. The relative humidity is then 100% maximum (dew
point temperature).
Page 29 of 73

Example 1:
At dew point of 20°C, the quantity of water in one m³ air is 17.3 grams.
(Use the Dew Point Curve)
Example 2:
Quantity of water occurring under the following conditions:
Drawn in volume V = 400m³/h
Pressure p = 8 bars
Temperature T = 323°K
Relative Humidity = 60%
Absolute Air Humidity =?
Solution:
RH = AbsAH/SQ x100%
AbsAH = RH x SQ / 100%
= 60% x 80g/ m³ / 100%
= 48g/m³
For drawn-in volume of 400m³/h, then the water w/c occurs is:
48g/m³ x 400m³/h = 19,200g/h
= 19.2 kg/h
Page 30 of 73

Figure 16. Dew point Curve
Page 31 of 73

Methods of Air Drying
1. Absorption (deliquescent) Drying
- the compressed air is forced through a drying agent such s dehydrated chalk or
magnesium chloride which remains in solid form, lithium chloride or calcium
chloride which reacts with the moisture to forma solution which is drained from the
bottom of the vessel. The drying agent must be replenished at regular intervals as
the dew point increases.
The main advantages of this method are that it is low initial and operating cost,
but the inlet temperature must not exceed 30°C, the chemicals involved are highly
corrosive necessitating carefully monitored filtering to ensure that a fine corrosive
mist is not carried over to the pneumatic system.
Figure 17. Adsorption Drying
Page 32 of 73

2. Adsorption (dessicant) Drying
- a chemical such as selica gel or activated alumina in granular form is contained

in a vertical chamber to physically absorb moisture from the compressed air passing
through it. When the drying agent becomes saturated, it is regenerated by drying,
heating or by flow of previously dried air. The advantage of this process is the low
dew points are possible.
Figure 18. Adsorption Drying
3. Refrigerant (Low-temperature) Drying
- is a mechanical unit incorporating a refrigeration circuit, and two heat

exchangers. Humid high temperature air is pre-cooled in the first heat exchanger by
transferring part of its heat to the cooled output air.
Page 33 of 73

It is then cooled by the refrigerator principle of heat extraction as a result of
evaporating freon gas in the refrigerator circuit, in heat exchanger. At this time,
moisture and oil mist condense and are automatically drained. The cold dry air
return pipe passes through air heat exchanger and gains heat from the incoming
high temperature air. This prevents dew forming on the discharge outlet, increases
volume and lowers relative humidity.
Figure 19. Refrigerant Drying
Important Note:
A large capacity main line filter should be installed after the air receiver to remove
contamination, oil vapours from the compressor and water from the air. This filter
must have minimum pressure drop and the capability to remove oil vapour from the
compressor in order to avoid emulsification with condensation in the line. A built-in or
an attached auto drain will ensure a regular discharge of accumulated water.
Page 34 of 73

Compressed Air Distribution
Owing to increased rationalization and automation of manufacturing
equipment, the air requirement in factories continues to rise. Each machine and
each needs a certain volume of air, and is provided with air from compressor via a
pipe system. The pipe diameter should therefore be selected such that the pressure
drop between receiver and user does not exceed 10kPa.
A higher pressure drop endangers the economics of the system and considerably
reduces the performance. When planning a new installation, allowance should be
made for a possible expansion to the compressor plant, i.e higher air consumption
and the pipelines should therefore be generously dimensioned. Later installation of
larger pipe system is often very expensive.
1. Dimensioning the Pipes
Basis of pipe diameter;
1. Flow Volume
2. Pipe Length
3. Pressure Drop (permissible)
4. Working Pressure
5. Number of Restriction in the Pipeline
In practice, use nomogram as aid of determining the equivalents and pipe
diameter
Example:
The air consumption in factory is 4m³/min (240m³/h). The increase over a
period of about three years will be 300%. The results in 12m³/min (720m³/h). The
total consumption is 16m³/min (960m³/h). The pipeline will have a length of 280m,
and it contains 6 T-pieces, 5 normal elbow pieces, 1 two-way valve. The permissible
pressure drop is ∆p = 10kPa (0.1bar/1.45psi). Working pressure is 800kPa. What is
the pipe diameter required?
Page 35 of 73

Solution:
Line A (pipe length) is joined with B (take-in volume) and extended to C
(axis 1). Line E (working pressure) is joined with G (pressure loss) and one then
obtains an intersection at F (axis 2). The intersection of axis 1 and 2 are joined
together. One obtains an intersection at line D (inside pipe width) and this specifies
the pipe diameter.
Figure 20. Nomogram (Pipe Diameter)
Page 36 of 73

1 = Two-way valve
2 = Corner valve
3 = T-piece
4 = Slide valve
5 = normal elbow
piece
Figure 21. Nomogram (Equivalent Lengths)
Page 37 of 73

Two Types of Pipeline Installation (Main)
1. Dead-end Line – an installation type that usually applicable to a few number of
machines tap to the pipeline.
Figure 22. Dead-end Line
2. Ring Main Line – an installation that is applied if many machines will be tapped to
the pipeline.
Figure 23. Ring Main Line
Page 38 of 73

Note:
The branch line should be taken off from top of main line & installed downward
gradient of 1 to 2%. This is to prevent any condensate from the main line to run in
the branch. Drainage points should be provided to drain water from the line.
Figure 24. Pipe Dropping
Types of Pipe Material

1. Standard Gas Pipe – it can be a black or galvanized form which is less liable to
corrode.
2. Stainless Steel Pipe – primarily used when very large diameters in long straight
main lines are required.
3. Copper Tube – this is used where corrosion, heat resistance and high rigidity are
required.
4. Rubber Tube – rubber hose or re-enforced plastic. It is most suitable for air
actuated hard tools as it offers flexibility for freedom of movement for the
operator.
5. PVC or Nylon Plastic Tubing – it is commonly used for the interconnection of
pneumatic components. Within its working temperature limitations it has
obvious advantages for installation, allowing easy cutting to length and
rapid connection by either compression or quick-fit fittings.
Page 39 of 73

Types of Fittings
1. Insert – provide a reliable retaining force inside and outside of the tube. The tube
is pressed by the sleeve when screwing in the cap nut. The tube entering
into the tube and thus represents a considerable extra flow resistance.
2. Push-in – has a large retaining force and the use of a special profile seal ensures
positive sealing for pressure and vacuum. There is no additional flow
resistance, as the connection has the same inner flow section as the inner
diameter of the fitting tube.
3. Self-sealing – it has a built-in mechanism so that air does not exhaust after
removal of the tube and is also applicable for copper free applications.
PNEUMATIC ACTUATORS
Actuators – are components such as cylinder or rotary device that directly helps
convert pneumatics energy into mechanical energy.
Two Basic Type of Pneumatic Actuator
1. Single Acting Cylinder

- it has one air inlet to produce power stroke in one direction.
Figure 25. Single-acting Cylinder
Types of Single Acting Cylinder
Page 40 of 73

1. Piston Cylinder – sealing my means of flexible material that is embedded in a
metal or plastic piston.
Figure 26. Piston Cylinder
2. Diaphragm Cylinder – pancake or clamping
- a built-in diaphragm which can be made of rubber, plastic or even metal, replaces
the function of the piston
Figure 27. Diaphragm Cylinder
Page 41 of 73

3. Rolling Diaphragm Cylinder
- it has a similar construction with diaphragm when compressed air is admitted,

the diaphragm unrolls along the inner wall of the cylinder and moves the piston rod
outwards.
Figure 28. Rolling Diaphragm Cylinder
Characteristics of Single Acting Cylinder
1. it has a built-in spring

2. limwited stroke
Applications:
a. Clamping
b. Ejecting
c. Pressing
d. Lifting
e. Feeding
2. Double Acting Cylinder

- it has two air inlets to produce extending and retracting power strokes.
Page 42 of 73

Figure 29. Double-acting Cylinder
Special Designs of Double-acting Cylinder
1. Cylinder with Double Sided Piston Rod Cylinder – this cylinder has a piston
rod protruding from both sides.
Figure 30. Double Sided Piston Cylinder
2. Tandem Cylinder – it involves two double-acting cylinder which have been

joined to form a single unit.
Page 43 of 73

Figure 31. Tandem Cylinder
3. Multi-position Cylinder – this consist of two or several double-acting cylinders.
Figure 32. Multi-position Cylinder
4. Rodless Cylinder – this cylinder is use in a very long strokes.
Figure 33. Rodless Cylinder

Page 44 of 73

5. Slide Units – is a precision linear actuator of compact dimensions which can be
used on a manufacturing and assembly robotic machines.
Figure 34. Slide Units
6. Hollow Rod Cylinder – this cylinder provides a direct connection between

vacuum generating equipment and a vacuum pad attached to the rod working end.
Figure 35. Hollow Rod Cylinder
7. Air Chuck (Gripper) – an actuator designed to grip components in robotic type

applications.
Figure 36. Air Chuck (Gripper)
Page 45 of 73

8. Rotary Actuators – a cylinder with the piston rod has a gear-tooth profile with the
piston rod drives a gear wheel.
Figure 37. Rotary Actuators
9. Cable Cylinder – a cable is attached to each side of the piston and guided over
rollers.
Figure 38. Cable Cylinder
10. Rotary Vane Cylinder – a cylinder that has a limited angle of rotation.
Figure 39. Rotary Vane Cylinder

Page 46 of 73

Characteristics:
1. a definite force is applied on both advance and return movements
2. longer stroke capability compared to single-acting cylinder
Types of Cylinder Mounting
Types of Cylinder Mounting:
Page 47 of 73

Types of Cylinder Sealing
Types of Cylinder Sealing:
Page 48 of 73

PNEUMATIC VALVES
COMPOSITION OF PNEUMATIC CONTROL SYSTEM
- Energy Supply
- Input Elements
- Processing Element
- Final Control Element
- Actuating Devices
Valves – are devices for controlling or regulating “start”, “stop” and direction as well
as pressure or flow of a pressure medium conveyed by hydro pump or stored in s
container.
- it can be described in terms of; number of ports, switching positions, normal
position and the method of operation.
Designations of Symbols;
Page 49 of 73

Five Groups of Valves According to Function;
1. Directional Valve
2. Non-return Valve
3. Pressure Control Valve
4. Flow Control Valve
5. Shut-off Valve
I. Directional Valve
-is a device that determine the flow of air between its ports by opening, closing or
changing its internal connections.
Representation of Directional Valves;
Page 50 of 73

Types and Symbols Directional Valves;
Page 51 of 73

Methods of Actuation;
Page 52 of 73

Design Characteristics of Directional Valves;
1. Poppet Valves
a. Ball seat valve
b. Disc seat valve
Page 53 of 73

2. Slide Valves
a. Longitudinal slide valve
b. Longitudinal Flat Slide Valve
Page 54 of 73

c. Plate Slide Valve (Butterfly)
II. Non-return Valves

-are devices which preferentially stop the flow in one direction and permit flow in
the opposite direction.
Types of Non-return;
1. Check Valve – this can stop the flow completely in one direction, and their flows
in the opposite direction with as low as pressure loss as possible. Blocking of the
one direction can be affected by cones, balls, plates or diaphragms.
1. Check Valve
Page 55 of 73

2. Shuttle Valve – this valve is also called double control valve or double check
valve. This non-return valve has two inlets X and Y and one outlet A. If
compressed air applied to inlet X, the ball seals off inlet Y and the air flows from
X to A. Alternatively, the air flows from Y to A inlet X is closed. It is also called
OR valve/component.
3. Throttle Relief Valve – this is also known as a speed regulating valve. The air
flow is throttled in one direction. A check valve blocks the flow of air in one
direction, and the air flow can flow only through the regulated cross-section. In
the opposite direction, the air can flow freely through the opened check valve.
These valves are used for speed regulation of pneumatic cylinders.
Page 56 of 73

4. Quick Exhaust Valves – are used to increase the piston speeds in cylinders.
This enables lengthy return times to be avoided, particularly with acting cylinders.
The valve has a blockable pressure connection P, blockable exhaust R and an
outlet A. If pressure is applied at the connection P, the sealing disc completely
covers the exhaust orifice R. The compressed air thus flow to A. If the pressure is
removed from P, the air coming from A moves the sealing disc against
connection P and closes it. The exhaust air can flow directly to atmosphere,
without having to follow a long and possibly narrow path through the control lines
to the pilot valve.
5. Two Pressure Valve – is also known as an AND valve. It is used mainly for
interlocking controls, check function or logic operations
Page 57 of 73

III. Pressure Control Valves
-are elements which predominantly influence the pressure, or are controlled by
the magnitude of the pressure.
Three Categories;
1. Pressure Regulating Valve
2. Pressure Limiting Valve
3. Sequence Valve
1. Pressure Regulating Valve
Parts:
1. Spring Damping
2. Adjusting Screw
3. Diaphragm
4. Valve Seat
5. Diaphragm
6. Plunger
8. Spring
2. Pressure Limiting Valve
Page 58 of 73

3. Sequence Valve
IV. Flow Control Valve

-influence the volumetric flow of the compressed air, in both directions.
V. Shut-off Valve
- this will permit or prevent flow.
Page 59 of 73

Page 60 of 73

Page 61 of 73

Page 62 of 73

Page 63 of 73

Page 64 of 73

Page 65 of 73

Page 66 of 73

Page 67 of 73

Page 68 of 73

Page 69 of 73

Page 70 of 73

Page 71 of 73

Page 72 of 73

References:
Introduction to Pneumatics, Festo Philippines, 1991

Pneumatics Technology, SMC Pneumatics, 1991
FESTO Didactic Learning System 2009/2010
Learning Guide in Industrial Electronics, B.J. Santa Maria Jr and E.N. Oliva
Norgren Pneumatics
Page 73 of 73


MXT Tech 213 Insdustrial Pneumatics Module 1 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MXT Tech 213 Insdustrial Pneumatics Module 1 1

Uploaded by

Copyright:

Available Formats

BASIC PNEUMATICS LEARNING MANAUAL

Mx Tech 213 – Industrial Pneumatics

No. of Hours per Semester: 162

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

and services are inevitable consequence of modernization. Before the Industrial

technology changes, everything around it changes, and it

is an exponential process. Technology increases, and then, using the new

technology, it increases even more. And one of the components in industrial

compressed air and its corresponding components.

It is the objective of the author to prepare this Basic Pneumatics Learning

include:pneumatic theory, compressors, humidity, units of pressures, methods of

drying, pipe materials, pneumatic fittings, pneumatic actuators, mounting, pneumatic

valves, preventive maintenance, regulators, pneumatic circuit designing, servicing

safety, and troubleshooting. It also tackle the fundamentals of pneumatics such as

component symbols, functions and application, and pneumatic circuit diagram

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

simple pneumatic control system and safety regulations.

This Learning Manual will be enhanced to contribute the industry requirement

of industrial pneumatics experts.

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

Aims of the College of Technology:

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

A thorough safety program is a “must” for anyone working with

This rules always applies to all industrial work as well as electrical

Safety is simply a matter of applying common sense precautions. The rules of

The general rules of shop safety apply equally the electrical-electronics

1. Don’t clown around or engage in horseplay. Many painful injuries are

4. Wear safety glasses. When grinding or working in areas where sparks or

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

8. Do not talk to or distract a fellow students when he is operating a

9. Never leave a machine while it is running or running down. Stay with it

1. Although the normal healthy person will encounter no dangerous voltage

2. Practice a precaution used by experienced engineers and technicians.

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

4. Make it a habit to short outb electrolytic or other large value capacitors

7. Do not work around electrical equipment if floors are damp or wet.

8. Do not work on electrical circuit while the power is on.

9. Be sure that equipment is in proper working order before use.Frayed

11. Electricity-electronics is a tremendous field and most of us do well to

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

3. Warning!!! Cylinder may advance or retract as soon as the compressed air

a. Use the plastic tubing of 4mm external diameter to connect the

b. The plastic tube is to be inserted fully into the connector up to the

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

Some Applications of Pneumatics

• Bottling & filling machines

Basic Characteristics of Air

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

Figure 1. Basic Pneumatic System

AIR PRODUCTION SYSTEM

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

• Pressure are in “bar g” gauge Pa = Pg + atmosphere

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

COMPRESSED AIR PRODUCTION AND DISTRIBURTION

Compressed Air Production

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

• Portable compressors are used mainly in the construction industry or for

• Sizes are defined as follows:

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO

CEBU TECHNOLOGICAL UNIVERSITY JOSEPH C. PEPITO