Pneumatics Electro - Pneumatics Presentation Friesland (Compatibility Mode)

WELCOME TO OUR TRAINING
ON
PNEUMATICS & ELECTRO-PNEUMATICS
AUTOMATION SYSTEM
Operation and Troubleshooting
1
APPLIED ENGINEERING TECHNOLOGY INITIATIVE
OBJECTIVES
At the end of this course, participants will be able to:
1. understand the basic physical properties of compressed air, basic SI

units and other physical quantities used in Pneumatic & Electro-
Pneumatic systems.
2. Understand the operation and application of standard pneumatic
components; valves and actuators etc.
3. Draw & Interpret Pneumatic & Electro-Pneumatic control schematic
diagrams.
4. Perform Pneumatic & Electro-Pneumatic control circuit design using
standard symbology;
5. Understand the correct operation, control sequences and procedures
for the safe use of various Pneumatic & Electro-Pneumatic
Components.
6. Carry out Maintenance, Troubleshoot & Repair faults in Pneumatic &
Electro-Pneumatic Automation systems.
2
CONTENT
 Fundamentals of pneumatics automation system
 Meaning of pneumatic
 Application of Pneumatic systems
 Advantages and Disadvantages of pneumatics
 Properties of air and Gas laws
 SI units and conversions - bar, KPa, Psi, mmHg
 Components of a Pneumatic System
 General Components of a Pneumatic Systems
 Air generation, Types of Compressors
 Air Preparation, Air Drying: Refrigeration drying, Absorption Drying and
Adsorption Drying.
 Compressed Air Filters
 Pressure Regulating Valve
 Compressed Air Lubricator
 The service unit
 Fittings, Piping and Distribution network
3
CONTENT…
 ISO Symbols
 Symbols for the Power Supply Section
 Symbols of Actuators
 Directional Control Valves: Ports and Switching Positions
 Port designation
 Types of Actuation symbols
 Non-return, Flow Control, Logical, and Pressure Control Valve
 Symbols of the Principal Working Elements
 Component designation
 Actuators
 Single-Acting Cylinder
 Double-Acting Cylinder
 Cylinder Construction and Types
 Rotary Actuators - Cylinder and Swivel Drive
 Directional control valve
 3/2-Way Valve: Normally Closed Position
 3/2-Way Valve: Normally Open Position
 Pilot Control
4
CONTENT…
 3/2-Way Roller Lever Valve, Pilot Actuated
 4/2-Way Valve
 5/2-Way Double Pilot Valve, Pneumatically Actuated
 5/3-Way Valve, Pneumatically Actuated, Both Sides
 Non-return valves and logical valve
 Dual-Pressure Valve (AND Function)
 Shuttle Valve (OR Function)
 Non-return Valve and Quick Exhaust Valve
 Flow Control Valve and One-Way Flow Control Valve
 Combinational valves
 Pressure Sequence Valve
 Time Delay Valve, Normally Closed Position
 Control Circuit Diagram Layout & Designations Standards
 Control Diagram for one cylinder
 Direct and Indirect Actuation
 Circuit Diagram: Dual Pressure Valve (AND Function)
 Circuit Diagram: Shuttle Valve (OR Function)
5
CONTENT…
 Circuit Diagram: 5/2-Way Double Pilot Valve (Speed Control)
 Circuit Diagram: Quick Exhaust Valve
 Circuit Diagram: Pressure Sequence Valve
 Circuit Diagram: Time-Delay Valve
 Circuit Diagram for two cylinders
 Circuit Diagram: Coordinated Motion
 Circuit Diagram: Overlapping Signals
 Function Diagram: Overlapping Signals
 Circuit Diagram: Roller Lever Valve with Idle Return
 Electro-pneumatic System Elements
 Basic Electricity & Electromagnetism
 Electrical Components
 Basic Electrical Control Circuits
 Electro-pneumatic Components
 Electro-pneumatic Control Circuits
 Special Connections of Control logics
 Programmable Control Systems
 Maintenance and Troubleshooting of pneumatic components and systems
 Hands-on practical exercises, simulations (Fluid SIM) & implementation
6
INTRODUCTION TO PNEUMATICS
AUTOMATION SYSTEMS
• The word “Pneumatics” was derived from the Greek
word “Pneuma” which means breath or wind.
• In contemporary technical use, pneumatics refers to

the generation, control and transmission of power
using compressed air as a medium.
• Pneumatic control systems are used extensively in

machineries and in factories to provide control
motions, including linear, rotary and limited angle
rotary motions.
7
APPLICATIONs OF PNEUMATICS
AUTOMATION SYSTEMS
 Door Control
 Packaging
 Positioning
 Packing
 Orienting
 Filling
 Branching of
 Clamping
Material flow
 Stamping (Sorting)
 Pressing  High speed cutting
 For operating big ball valves in process, chemical,
pharmaceutical industries, oil refineries, water
processing and waste disposal industries.
8
PNEUMATICS AUTOMATION SYSTEM
APPLICATIONs ….
Horizontal displacement of the
load
Cutting a work
Piece
Holding a work Piece
APPLIED ENGINEERING TECHNOLOGY INITIATIVE 9
APPLICATIONs ….
Line diverter for 2 tracks
conveyor system
Device to overcome
difference in level

APPLICATIONs ….
Changing the direction of conveying
Feed station with

rotary drive

11
APPLICATIONs ….
Feeding the mould on concrete slab

press

ADVANTAGES OF PNEUMATICS
AUTOMATION SYSTEM
1. Air is a freely available energy source.
2. Can be easily stored in air receivers.
3. Fast fluid motion and Device responses.
4. Offers Little or No risk of fire Explosion.
5. fairly insensitive to temperature fluctuations.
6. No risk of Environmental Pollution.
7. Devices are Rust resistant.

DISADVANTAGES OF PNEUMATICS
AUTOMATION SYSTEM
1. Air requires good Preparation
2. The System is prone to vibrations.
3. High Noise Level
4. Limited to low pressure applications.
5. Cannot provide precise actuator and

positioning control.

PROPERTIES OF AIR
 Air is a mixture of gases
 Air also carries contaminant particles
 Air is compressible
 Heat causes expansion of air and increases its

moisture carrying content
 Cooling of Air causes Condensate (water

droplets)

COMPOSITION OF AIR
 Surface of the Globe is
entirely covered by Air. Composition by Volume
 Air is composed mainly Nitrogen 78.09% N2
of nitrogen and oxygen Oxygen 20.95% O2
 Also traces of Argon, Argon 0.93% Ar
Hydrogen, Carbon Water vapour
dioxide, Sulphur & Others Varies%
dioxide, Water vapour,
contaminant particles
etc... Can be found at
various degrees
 80% of the contaminants particles in air such as dust,
are usually of sizes invisible to the human eye
16
SUMMARY OF BASIC SI UNITS
 Pressure = Force / Area

 Flowrate = Volume / Time
17
AIR IS COMPRESSIBLE
 Air is compressible and will assume the shape of
any container it is put into.

COMPRESSED AIR
 Compressed air exerts a

force of constant value
to every internal contact
surface of the pressure
containing equipment.
 Compressed air exerts a

force that can be applied
to do work.
19
THERMAL PROPERTY OF AIR
 Air expands when it is heated

 Increase in kinetic energy of molecules
Expanded
Air
Air v2
Heat

WATER IN THE AIR
 Humidity is the measure of water vapour contained in air.
 Absolute Humidity: is the mass of water vapour, actually

present in 1 m3 of air.
 Saturation Quantity: is the mass of water vapour, which 1m3

of air can absorb at a particular temperature
 Relative Humidity = (absolute humidity / saturation quantity)

X 100%.This percentage is the proportion of the maximum
amount that can be held at the prevailing temperature.
 Dew point is the point in temperature scale (Dew point temperature)

at which air is saturated with water vapour.
At Dew point: the R.H. = 100%
Below Dew point temperature, condensate will form
21
DEW POINT
Example: The maximum amount of water that can be present in 1m3 of air
at 20o C and at atmospheric pressure (1bar) is approximately 17 gram/m3
22
MOISTURE CAPACITY OF AIR Vs
TEMPERATURE
The moisture in air increases with

increase in temperature
Moisture Content
Air Temperature
23
AIR WATER CONTENT Vs
TEMPERATURE CHART
24
WATER IN COMPRESSED AIR
 When large quantities of air are compressed, noticeable amounts
of water are formed (Condensate)
 The natural moisture vapour contained in the atmosphere is
squeezed out like wringing out a damp sponge
fully
saturated
air
Condensate
Drain Cork
25
THE GAS LAWS
 For any given mass of air the variable properties are
pressure, volume and temperature.
 By assuming one of the three variables to be held at a
constant value, we will look at the relationship between the
other two for each case
 Constant temperature P.V = T constant
 Constant pressure
V
= P constant
T
P
 Constant volume = V constant
T
26
P1*V1 = P2*V2
Constant temperature
P.V = T constant
27
V1/T1 = V2/T2
Constant pressure
V
= P constant
T
28
General Gas Equations
P1*V1 = P2*V2 V1/T1 = V2/T2 P1/T1 = P2/T2
General Gas Equation:
(P1V1 / T1) = (P2V2 / T2) = (P3V3 / T3)
T1
T2
T3
29
PRESSURE
 Pascal’s law: a force of 1 Newton acting evenly on a 1
square meter surface, produces a pressure of 1 Pascal
 Pressure = Force / Area
 1 atm = 1.013 X 105 Pa (N/m2)
= 14.70 psi
= 1.013 bar
Pressure is typically measured in the industry by pressure

Gauge 4 6
80
8
2 40
120
lbf/in2
bar 10
30
ATMOSPHERIC PRESSURE
 The atmospheric
pressure is caused
by the weight of air
above us
 It gets less as we
climb a mountain,
more as we descend
into a mine
 The pressure value is
also influenced by
changing weather
conditions
31
STANDARD ATMOSPHERE
 A standard atmosphere is defined by
The International Civil Aviation Organisation.
The pressure and temperature at sea level is
1.01325 bar absolute and 288 K (15OC)
1.01325 bar
32
VACUUM AND ATM. PRESSURE
 The power of atmospheric

pressure is apparent in
industry where pick and Vacuum
Head
place suction cups and
vacuum forming Suction
cup
machines are used
 Air is removed from one

side allowing atmospheric
pressure on the other side
to do the work
33
OPERATIONAL PRESSURE RANGEs
17 16
 Pressures are in “bar g” 16 15
gauge pressure ( the 15 14 Extended
value above atmosphere) 14 13 Industrial
Absolute pressure bar a

 Zero gauge pressure is
13 12 range
Gauge pressure bar g

12 11
atmospheric pressure 11 10
 Absolute pressures are 10 9 Typical
9 8 Industrial
used for calculations 8 7 range
Pa = Pg + Patmosphere 7 6
 For quick calculations 6 5 Low
assume 1 atmosphere is 5 4 range
4 3
1.0 bar 3 2
 For standard calculations 2 1
1 0 Atmosphere
1 atmosphere is 0 Full vacuum
1.01325 bar
34
COMMON PRESSURE UNITS
 There are many units of pressure measurement.
Some of these and their equivalents are listed
below.
 1 bar = 100000 N/m2
 1 bar = 100 kPa
 1 bar = 14.50 psi
 1 bar = 10197 kgf/m2
 1 mm Hg = 1.334 mbar approx.
 760 mm Hg = 1bar approx.
 1 Torr = 1mmHg abs (for vacuum)
35
COMPONENTS OF A PNEUMATIC SYSTEM
The general components/devices of a Function
Components / Devices
pneumatic system are as mentioned here in Group
their respective group of functions, from the
compressed air supply devices to the final ACTUATORS
working elements (Actuators).
• Air Flow :From bottom to top
• Control Chain:S P A principle: Supply,

Processor, Actuate
:I P O principle: Input,
Processing, Output
• Air supply : Through Tubing or

Piping
AIR
36
COMPONENTS OF A PNEUMATIC SYSTEM …
Air Generation, Preparation, and Distribution/Consumption
Air under goes three main processing stages (Air Generation, Air Preparation, & Air
Distribution/Consumption) within the Pneumatic system.
37
AIR GENERATION --- COMPRESSORS
A compressor is a device for transforming a gas from a
condition of low pressure to a higher desired pressure
level.
The compressor generates the high pressure air
required by the system.
COMPRESSORS
POSITIVE DISPLACEMENT DYNAMIC

COMPRESSOR COMPRESSOR
PISTON DIAPHRAM RADIAL-FLOW AXIAL -FLOW

COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR
ROTARY
COMPRESSOR
SLIDING 2-AXLE
VANE SCREW BLOWER
COMPRESSOR COMPRESSOR
38
CROSSECTION OF DIFFERENT COMPRESSOR ELEMENTS
A typical compressor consists of parts such as Pre-filters, Prime-Mover,
suction & discharge ports, Regulators (Relays/switches/Valves), Gauges,
After-coolers, condensate drain, Integrated dryer & the main compression
element/chamber which can either be oil-lubricated or oil-free .
Various Compression Elements/Chambers are shown here:
Displacement
Compressors
Dynamic
Compressors
39
COMPRESSORS cont…..
The piston draws air in through the suction valve during the downward stroke,
Reciprocating Piston compresses it during the upward stroke and pushes it out through the pressure
Compressor valve.
Pressure: Single-stage up to approx. 600 kPa (6 bar)
Two-stage up to approx. 1500 kPa (15 bar)
Screw compressor The air drawn in through the suction nozzle is moved axially through two impellers
at high speed to the pressure side.
Pressure: Up to approx. 1000 kPa (10 bar)
Radial flow Through rapidly rotating blades, the air is accelerated radially. The kinetic energy of
compressor the air is converted into pressure energy.
Pressure: With multi-stage design up to approx. 1000 kPa (10 bar)
Sliding vanes in an eccentrically located rotor divide the compressor chamber into
Sliding vane closed cells. By reducing the size of the cells during the revolution, the air is
compressor compressed
(Rotary compressor ) Pressure : Single-stage uo to approx. 400 kPa (4 bar)
Two-stage up to approx. 800 kPa (8 bar)
Axial compressor Through rapidly rotating blades, the air is accelerated radially. The kinetic energy of
the air is converted into pressure energy.
Pressure: Up to approx. 600 kPa (6 bar)
40
MULTI-STAGE COMPRESSORS
Because it is economically and technologically difficult to achieve high air
pressure value from a single compression, multi-stage compression
systems are employed to achieve high pressure values from many type of
compressors.
Here is a Two Stage Reciprocating compressor
Intercooler
1. Atmospheric air will be sucked
by the big cylinder and
compressed to a certain
pressure in the first stage.
Stage 1 Stage 2
2. Compressed air will be cooled
in an intercooler.
3. Cooled air will be compressed
in the second stage to the final Discharge
delivery pressure by the smaller Suction port
port
cylinder.
41
MULTI-STAGE COMPRESSORS …
Here is a Two Stage Rotary Screw Compressor
42
A TYPICAL SYSTEM INSTALLATION
COMPRESSORs
43
INTEGRATED COMPERESSOR
SYSTEM
Integrated compressor
unit includes inlet filter,
Compression element,
after cooler, Integrated
Dryers, and water
separator etc.
Safety valve
Pressure gauge Distribution
Integrated pipe
compressor
and after cooler SWP
10bar
Isolating valve
Air receiver
Drain valve
Condensate drain
44
INTEGRATED COMPERESSOR SYSTEM …
1: Monitoring Display
2: Cooling Fan
3: Cooling Coil
4: Oil Filter
5: Air Filter
6: Compression chamber
7: Motor (Prime mover)
45
INTEGRATED COMPERESSOR SYSTEM …
An Integrated compressor with a Refrigeration dryer: showing various fluid
flow line in the system.
Supply
Filter
46
A BELT DRIVE (MOBILE) COMPRESSOR UNIT
47
COMPRESSORs CAPACITY
There are two main factors that define the capacity and
selection of a compressor:
 The Pressure
 Working pressure
Which is a function of the force applied
at compression chamber.
It is typically indicated in bar/psi values
e.g. 8, 10, 20, 30, 40bar
 The Volumetric Delivery Capacity

 Flow Rate
This is the amount of Compressed Air the Compressor is capable of
delivering per time. E.g. 5.5, 32 l/s etc.
48
COMPRESSOR--- FLOW RATE
 Flow rate is measured as Mathematical Derivation of
a volume of air flow per Flow Rate
unit of time  Pressure P = F/A
 Popular units are : F=PxA
 Litres per second
l/s  Fluid Work = F x D
 Cubic metres per minute  Fluid Power = F. Work/Time
m3/m
 Standard cubic feet per = (P x A x D)/T
minute (same as cubic  Volume (V) = AxD
feet of free air) scfm
 Fluid Power = P x V/T
 1 m3/m = 35.31 scfm
=PxQ
 1 dm3/s = 2.1 scfm
 Flow Rate Q = Volume/Time
 1 scfm = 0.472 l/s
P = V/T (m3/s)
 1 scfm = 0.0283 m3/min A Volume
= VelocityxArea
= V x A (m3/s)
A P Volume
49
FLOW RATE CONVERSION CHART
50
COMPRESSOR SELLECTION CHART
With the knowledge of the required compressor’s Working pressure and Flow
rate; one can then make a choice from the technical data chart of a selected
vendor as shown below: Noting also: the Electrical power, Noise level and other
integrated facilities of the compressor e.g oil-lubricated, oil-free, dryer etc.
51
COMPRESSOR REGULATION
In order to match the delivery volume of the compressor to the reservoir volumetric
capacity and pressure, with also the fluctuating consumption from equipments, it is
necessary to regulate the compressor. This regulation also affords the compressor
a resting or idle time. There are two main groups of regulation systems:
1. Load/Unload regulation is the most common regulation method and involves

the acceptance of variations in pressure between two limit values -- max.
pressure (cut-out point) & min. pressure (cut-in point). This takes place by
completely stopping the flow rate at the higher pressure (off-loading) and
resuming the flow rate (loading) when the pressure has dropped to the lowest
limit value. Pressure variations depend on the permitted number of load/unload
cycles per time unit, but normally lie within the 0.3 to 1 bar range.
2. Continuous flow rate regulation involves the continuous control of the drive
motor or inlet valve according to variations in pressure. The result is normally
small pressure variations depending on the regulation system’s amplification
and its regulating speed.
Various methods are employed to achieve any of the above regulation system as
shown in the next slide.
52
METHODs OF REGULATION
START/STOP METHOD: Compressors below 5–10 kW are often controlled by completely
stopping the electric motor when the pressure reaches an upper limit value and by restarting
it when the pressure drops below the lower limit value. This method demands a large system
buffer volume or large pressure difference between the upper and lower limits, in order to
minimize the heat load on the electric motor. This is an energy-efficient and effective
regulation method, provided the number of starts is kept low.
Note: This and many other compressor regulation methods are coordinated by
Pressure
an integrated Pressure switch. Switch
53
METHODs OF REGULATION …
PRESSURE RELIEF WITH THROTTLED INLET METHOD: This is the most
common regulation method currently in use for medium-high capacity
compressors. It combines a maximum regulation range (0-100%) with low
energy consumption: only 15–30% of full load power at an off-loaded
compressor (zero flow) state. The inlet valve is closed, but with a small opening
used at the same time a blow-off valve opens and releases the discharge air
from the compressor. The system demands a system buffer volume (air
receiver), the size of which is determined by the desired difference between
loading and off-loading pressure limits and by the permitted number of unloading
cycles per hour.
Pressure
Switch
54
HINTS ON COMPRESSORS INSTALATION
 High temperatures are  Avoid locations where
produced when air is the air may have a high
compressed, thus efficient humidity such as above
cooling is important a pond, river or canal
 Inlet filter is required to  Avoid locations where

inhale only clean air, keep wind eddies whip up
away from: dust, grit and litter
 fumes from other systems
with engine running  An intake on the factory
 solvent fumes from paint roof must be protected
plant or store etc.
from the weather and
emissions from ducting
and chimneys
55
HINTS ON COMPRESSORS INSTALATION…
• Compressors must be installed in a relatively cool, clean, dust free

and dry room.
• If any heat radiating pipes are passing through the compressor
room, care must be taken that these pipes are properly insulated.
( Example: Steam pipes)
• Air cooled compressors require relatively cool breeze. They must
be installed in a cool area. For 22KW power rating, natural cooling
by surrounding air is sufficient. Above that the compressors must
be cooled by blowers/cooling fans.
56
COMPRESSORS INSTALLATION …
• Exhaust fans must be installed direct under the roof so that

hot air be quickly carried out of the room.
• Compressor working in a cool place is more efficient.
57
AIR RESERVOIR/RECEIVER
A reservoir is installed downstream of a
compressor to provide and stabilize
compressed air supply. It is a simple metallic
container built to withstand the operating
pressure and with various monitoring/control
gauges and valves. A reservoir compensates
the pressure fluctuations when the compressed
air is taken from the system. If the pressure in
the reservoir drops below a certain value, the
compressor will compensate until the set
Pressure value is reached again. This has the
advantage that the compressor does not need
to operate continuously.
The size of a compressed air reservoir
depends on the:
• Delivery volume of the compressor
• Air consumption for the applications
• Network size (any additional requirements)
• Permissible pressure drop in the supply
network
58
AIR PREPARATION
The aim of compressed air preparation is to remove contaminations such
as dust, oil in the form of vapour (aerosol), & water vapour.
The air generated from compressor should route through various filters,
Dryers, Regulator, & Lubricator to attain the required air quality class.
Air Preparation Equipment are:
DRYERS FILTERS:
• Refrigeration type • Pre-filters
• Adsorption type • Line filters (oil, water, solid)
• Absorption type • Service units (FRL)
• After-cooler
59
AIR FILTRATION QUALITY
Air filtration quality is defined by ISO 8573-1 Compressed air for
general use, it defines the:
 Allowable levels of contamination in a pneumatic air,
indicated by a given three quality class numbers e.g.( 1.2.1).
 The three Air Quality Class number specify the levels of the
following contaminants:
 1 for: solid particles
 2 for: Water (Moisture Content)
 1 for: Oil (Vapour)
 Example, an air quality class is stated as three air quality
numbers e.g. 1.7.1 (this number is interpreted from the table in
the next slide)
 solids 0.1 µm max
and 0.1 mg/m3 max
 water not specified
 0.01 mg/m3 max
 See the table in the next slide
COMPRESSED AIR QUALITY CLASS TABLE
ISO 8573-1 Solid, water and oil contaminant classes at a glance:
Residual Solids Residual Water Residual Oil

Class Pressure
Particle size Concentration Concentration Concentration
Dew Point
µm mg/m3 oC g/m3 mg/m3
1 0.1 0.1 -70 0.003 0.01

2 1 1 -40 0.12 0.1
3 5 5 -20 0.88 1
4 15 8 +3 6.0 5
5 40 10 +7 7.8 25
6 - - +10 9.4 -
7 - - Not Not specified -
specified
Pressure dew point is the temperature to which compressed air must be cooled
before water vapour in the air starts to condense into water (Condensate). 61
AIR PREPARATION …
Addition of a central dryer to a system depends on the efficiency of the
compressor, and the application required air quality class. Thus, some system
can do without it while others require a central dryer.
Dryer Unit
62
REFRIGERATION DRYER
The most common type of dryer today is the refrigeration dryer. Refrigeration
drying means that the compressed air is cooled, which allows a large amount of
the water to condense out of the compressed air and be separated. Cooling the
compressed air takes place via a closed refrigeration system.
FILTER
AIR OUTLET
AIR INLET
63
ADSORPTION DRYER
The general working principle of adsorption dryers; is to pass the
compressed moist air over hygroscopic material (typical materials
used are silica gel, molecular sieves, activated alumina) which traps
the moisture in the air and so that the air come out more dried.
AIR
OUTLET
ADSORBER ADSORBER
AIR
INLET
HEATER
64
ABSORPTION DRYER
Some materials (absorbent) are found to bond with other gaseous substance. The
absorption material can either be a solid or liquid e.g. Sodium chloride and sulfuric
acid. Thus when compressed moist air are passed over the absorbent material, the
moisture in the air are absorbed, leaving the compressed air dried. Absorption drying
is not of major significance in present-day practice, since the operating costs are too
high, it involves high consumption of absorbent materials and the efficiency too low
for most applications.
65
A COMPARISM OF DIFFERENT
DRIERS
Pressure Dew point Maintenance

Type Initial Cost
(degree Celsius) requirements/cost
Aftercooler 10 Medium Routine

Refrigerant 2 to 5 Medium Routine
Adsorption -40 to -70 High Minimal
(Desiccant)
Chemical 15 to 30 Low Frequent
Absorption
(Deliquescent
Regular)
66
FILTERS
Filters generally separate and collect compressed air contaminants.
 There are two main material filteration types:
 Solid/water filters
 Oil filters
 Angled louvers spin the air as it

enters the bowl
 Various Filter Element traps
different solid particles sizes as
shown in the next page.
 Baffle prevents turbulent air
splashing water on to the filter
element
 Water droplets and large solid
particles spun outwards against
bowl and run to the bottom
 Solid/water filters
67
FILTER ELEMENTS…
68
FILTER... (with manual drain)
The bowl of this class of filters are drained manually through an attached valve
 Daily visual inspection is

required to ensure the water
contaminant level is
prevented from rising to a
level where it can be drawn
through the filter element
 A quarter turn valve allows
the contaminant to be ejected
under pressure
 Threaded end allows a tube
connection for draining to a
Drain Valve
suitable container
Condensate
drain
69
Semi-automatic drain
 When the pressure is

turned off at the end of the
day or at any other time the
drain valve will open
automatically
 In most applications the
normal daily cycle will keep
the bowl cleared
 If the bowl needs draining
while under pressure this
can be achieved manually
by pushing up on the pipe
connector
70
Semi-automatic drain
 When air pressure is OFF the
valve springs to the open
position and draining occurs
 Water contained in the bowl will
be cleared
 Over time additional water may
drain from the supply pipework.
When it enters the bowl it will
clear through the valve
 If the level becomes too high
before the pressure is turned off
it can be drained under
pressure manually
 Push up on the pipe connector
and hold until draining is
complete
71
Fully automatic drain valve
 In normal working under

pressure, the float will lift
when the water level rises
 This causes the valve to
open and the water is
ejected
 The float falls when the
water drain out and the
valve closes
 When the pressure is
turned off at the end of the
day or at any other time the
drain valve will open
automatically
72
OIL FILTER
 Oil Filters are required for

applications where the air
is to be exceptionally
clean and free of oil
 For use in food and drug
processing, air bearings
and paint spraying etc.
 Sub-micrometre particle
removal down to 0.01 µm
 Air should be pre-filtered
down to 5 µm to prevent
short element life due to
solid particle build up

Coalescing Oil filter element
 Air enters the inside of
the element and passes
through the filter to the
outer surface
 Perforated stainless steel
supporting formers for up
to 10 bar differential
 Filter media: borosilicate
glass micro fibre
 Foam sock diffuses air
flow to low velocity to
prevent oil re-entry
 Ends set in resin to seal
74
Coalescing Oil filter element
 Oil aerosol particles
coalesces (join together)
when they contact the
element media
 The pathways through the
media are so fine and
complex that the particles
cannot pass through
without contact
 Oil soaks and drains to
the bottom of the sock
where it drips in to the
bowl
75
OIL FILTERS
 Flow ratings are lower

than equivalent sized
standard units
 Filter area large for rated
flow to keep air velocity
low and prevent oil re-
entrainment
 Standard service life
indicator monitors the
pressure drop to warn
when element requires
replacing
76
PRESSURE REGULATOR
Pressure Regulators are required to Reduce supply pressure P1 to a suitable
working pressure P2 for the operated machine/system.
 When there is no flow demand the poppet valve closes to hold the
pressure at P2
 Flow demand will open the poppet valve wide enough to satisfy the flow
rate at pressure P2
 P2 can be set on a gauge fitted to the regulator
Adjustable
4 6
Knob
80 8
2 40 120
lbf/in2
bar 10
Poppet
Valve
Pressure
4 6
Gauge
80
40 8
2 120
lbf/in2
bar 10 P1 P2
P1 P2
77
Pressure regulator...
 To increase pressure P2, pull

the adjusting knob up to
disengage the locking teeth
 Turn clockwise until new P2
4 6
80
8
pressure reached
2 40
120
lbf/in2
 The higher spring force
bar 10
pushes the valve open
 The rising pressure P2 acts
under the diaphragm to
balance the spring and allow
the valve to close
 Once the desired setting has
P1 P2
been established push down
the locking adjusting knob to
prevent inadvertent changes
78
Pressure regulator...
 This page shows the

relieving regulation to
allow pressure to be
4 6
80
reduced to the setting
40 8
2
Diaphragm 120
 The higher back pressure
lbf/in2
bar 10
force under the diaphragm
lifts it clear of the valve
spindle
 P2 can now exhaust until
the diaphragm seals
P1 P2
79
FILTER REGULATOR
 Filter and regulator can
also be designed as a
single unit as shown here
 Air is first filtered then
directed to the primary
side of the regulator
 Pressure is then reduced
to a working value
 Only one unit to install
 Cost saving when
compared to two separate
units – Filter and
Regulator.
80
AIR LUBRICATION
 For efficient running of pneumatic equipment and long life of
seals and wearing surfaces, correct lubrication is essential.
Lubrication is done by a device called lubricator.
 Where non-lube equipment is used it has been pre- lubricated

on assembly and will last for the normal life expectancy of that
equipment without further lubrication.
It will not be detrimental however to include this equipment on
lubricated air supplies and is likely to result in an extension of
the normal life of the equipment
 For the best results light lubrication is applied continuously

from an air line lubricator. This is particularly relevant in
adverse applications where there may be high speed and high
temperature running or where the condition of the
compressed air has been poor.
81
LUBRICATORS
Lubricators are simple mechanical device which store and dispense the
lubrication oil accordingly into the compressed air thus, lubricating the valves
and actuators in the system.
 For lubricating over long
distances where particles
Non- must reach the furthest
Lubricated
air In
Lubricated
air Out
parts of intricate systems
 Suited for control
circuitry, multiple valve /
actuator systems
 Oil drips are atomised in
the bowl
 Only the finest 10% of oil
particles leave the bowl
 Drip rate is adjustable
Lubrication Oil
82
Air Lubrication...
 In a lubricator, oil drips are atomised and the tiny oil particles
form a very fine mist in the air supplying the application
 The amount of oil delivered is automatically adjusted as the air

flow changes. The result is constant density lubrication. For
any setting the oil particles per cubic meter of air are the same
regardless of the flow rate
 Example of typical lubrication oil: it is recommended to use an

oil with the required special viscosity.
 Examples of Pneumatic Oil types from several manufacturers :
- ELF : Spinelf 22 - ESSO : Spinesso 32
- LABO : Prima 32 - MOBIL : DTE 22
- SHELL: Tellus 22 - FESTO : OFSW 32
83
AIR SERVICE UNIT (FRL’s)
 The individual functions of compressed air preparation
devices, i.e. filtering, regulation and lubrication, can be
fulfilled by an individual unit called the ‘service unit’
 FRL stands for Filter, Regulator and Lubricator
 They form a unit that will prepare the condition of compressed

air just before delivering it to pneumatic equipment or
machinery
 This ensures the air supply is clean and dry, the pressure is at
the correct level and fine particles of oil are carried in the air to
lubricate the wearing parts within valves, cylinders and tools
 A convenient method of combining these components is to

use a modular system as shown in the next slide.
84
AIR SERVICE UNIT...
 A modular unit is as shown
beside comprising:
 Shut off valve to isolate
upstream air and exhaust
downstream air
 Combined filter and pressure

regulator with gauge
 A Lubricator
All connected together with Quick

clamps
85
AIR DISTRIBUTION NETWORK
The compressed air from the supply system ( Comp. & Receiver) goes
through a distribution pipe network to the utility equipment. In order to
ensure reliable and trouble-free air distribution, a number of points must
be observed. This includes primarily the correct sizing of the pipe
system, also the pipe material, flow resistances, pipe layout and
maintenance.
• As a rule pneumatic components are designed for a maximum
operating pressure between 8-10 bar.
• In a professionally installed air distribution network the pressure
drop between compressor and the consuming device should not
exceed 0.8bar.
86
Mainline Piping Material
 Copper
 Brass
 High-quality steel
 Steel tubing
(galvanised)
 Plastic
* Pipelines should be easy to install, resistant to corrosion.

Mainline typical pipe sizes are: 1” to 4”

TYPES OF DISTRIBUTION NETWORK
88
A Typical Distribution Network
 Ring main installation

 Dead leg with a drip leg
drain on each corner to
collect and remove
water
 Pipes slope to each
corner
 Take off drops
connected to the top of
the main pipe to avoid
water pick up
 FRL units before each
application
89
A Typical Distribution Network..
 An Intermediate reservoir can also be installed to
compensate for head loss and pressure drop.
Intermediate
Reservoir
90
Drip leg drain & Tee off Point
 Automatic drain valve for
terminating a dead leg
 Water automatically drained
when pressure is on, also
when shut down
 Fit with an isolating shut off
valve for maintenance
 Built in bleed valve to
depressurise the unit prior to
maintenance
 Tee off points rise vertically
upwards before dropping to
the take off point
 Keep pipes as short as
possible
91
TUBING AND FITTINGS
 The components of a pneumatic control system
are connected with flexible Tubing & Fittings ,
Hose or rigid pipes
 A variety of fittings ranges are produced to fulfil
the needs of general and specific industries
 The variables include:
 methods of connection
 Thread patterns & sizes
 tube sizes
 angles of connection
 number of connections
 materials of construction
 applications
 industry standards
92
General Purpose Fittings
 Pneumatic fittings comes in various standard shapes in both
taper and parallel threading as shown below:
 Different materials steel, brass, plastic are also in use depending
on industry standard.
Bulkheads
Reducers
Expanders Adaptors
Tees
Cross
Banjos
Elbows Unions
Hose connectors
93
Port/Thread Sizes
For the majority of pneumatic applications fittings will be required
in the following ranges of Parallel & Tapered Types:
 Tapered: R 1/8 , R 1/4 , R 3/8 , R 1/2 , R 3/4
 Parallel: M 5, G 1/8 , G 1/4 , G 3/8 , G 1/2 , G 3/4 , G 1
 NPTF 1/8 , 1/4 , 3/8 , 1/2
Parallel Tapered
94
Sealing the thread
 Parallel threaded fittings
fits to parallel port and
seal on a washer between Parallel
the fitting and the face of
the component’s port.
 Tapered threaded fittings

fits to tapered port and
rely on a lightly wedged
fit and use sealant
between the threads of
the fitting and port Tapered
95
Tube Sizes
 Tube sizes are identified
by their o/d (outside
diameter)
 The metric range covers
4, 5, 6, 8, 10, 12, 14, 16, 22,
28 mm o/d
 The inch range covers
1/ , 5/ , 3/ , 1/ , 5/ , 3/ , 1/ ,
8 32 16 4 16 8 2
5/ , 3/ o/d
8 4
96
Tube and Hose Materials
 Plastics
 Polyamide ( Nylon )
 Nylon, food grade
 Polyurethane
 Terylene braided PVC
 Metal braided rubber
 Weld tube
 Copper
 Annealed
 Half hard standard duty
 Half hard heavy duty
 Aluminium
 Steel
 Double wall brazed
97
Types of Pneumatic Tube &
Fittings Connections
 Push-In Fittings, very
quick joint with the
tube
 Push-On Fittings, neat,
quick joint using a
finger tight nut
 Compression Fittings,
firm joint, for plastic or
metal tube:
 internal nut version
 external nut version
98
Advantages of Tubing & Fittings
 No thread cutting is required
 corrosion-free piping and connectors
 Aesthetic appearance
 Do it yourself; Quick & Easy installation within hours
 Distribution network is easily expandable
 Light weight. Hence, no heavy metal brackets are required to
support the pipes.
 All piping and connectors are of food grade (FDA Approval)
Disadvantage:
 Plastic tubing is limited by wall thickness and operating

temperature

SYMBOLS AND STANDARDS
The development of pneumatic systems is assisted by a uniform approach to the
representation of the elements and the circuits. The symbols used for the individual
elements display the following characteristics:
• Actuation and return actuation methods

• Number of connections (all labeled for identification)
• Number of switching positions
• General operating principle
• Representation of the flow path
The technical construction of the component is not taken into account in the
abstract symbol form.
The symbols used in pneumatics are detailed in the standard DIN ISO 1219,
"Circuit symbols for fluidic equipment and systems”
100
SYMBOLS FOR AIR SUPPLY EQUIPMENTS
101
ACTUATORS
Pneumatic actuators are devices providing final power
and motion to the automated system, machines and
processes. They include linear actuators (cylinders) and
rotary actuators.
Actuators are made in a wide variety of sizes, styles and
types including the following:
 Single acting Cylinders with and without spring return
 Double acting Cylinders
– Non cushioned and fixed cushioned
– Adjustable cushioned
– Magnetic
 Rodless Cylinders
 Rotary Actuators
 Grippers
 Vacuum Heads
 Suction cups
 Bellows
102
CYLINDERS
A pneumatic cylinder is a mechanical device typically made up of a
piston & cylindrical case, that is ideal for producing powerful linear
movement.
 Operated by compressed air through designated air ports on the

cylinder
 Adverse conditions can be easily tolerated such as high
humidity, dry and dusty environments.
 The bore of a cylinder determines the maximum force that it can
exert.
 The stroke of a cylinder determines the maximum linear
movement that it can produce.
 The maximum working pressure depends on the cylinder
design.
 Thrust & Speed are controllable through flow regulators.
103
A Cylinder’s Basic Structure
1 cushion seal DOUBLE ACTING
2 magnet
3 cushion sleeve
4 barrel
5 guide bush
6 rod and wiper seal
7 front end cover
8 front port
9 reed switch
10 piston rod
11 wear ring
12 piston seal
13 rear end cover
14 cushion screw
SINGLE ACTING
104
Single acting spring return
 Single acting cylinders have  Normally in
a power stroke in one  Normally out
direction only
Clamping Cylinder
Single acting NO spring

 Gravity or other
external force to
return the rod
105
Double acting Cylinders
 Double acting cylinders use compressed air to power
both the outstroke and instroke.
 Superior speed control is possible
 There are
 Non-cushioned types
 Fixed cushioned types
 Adjustable cushioned types
 Magnetic Piston types
 Rod through
106
Rodless cylinders
 Contain the movement produced within the same overall
length taken up by the cylinder body.
 For example, action across a conveyor belt, or for vertical
lifting in spaces with confined headroom.
 Movement is from a carriage running on the side of the
cylinder barrel.
 A slot, the full length of the barrel allows the carriage to be
connected to the piston.
 Long sealing strips on the inside and outside of the
cylinder tube prevent loss of air and ingress of dust.
107
MOUNTINGS ACCESSORIES
Cylinder Mountings
 With mountings
ROD COUPLER FLANGE FOOT
Cylinders are rigidly FLANGE
fixed to the machine or
allowed to swivel as
part of a linkage in one
ROD CLEVIS
or more planes. FOOT
CLEVIS
 Fixing points can be

the cylinder body or ROD EYE
piston rod end.
NUT
108
Mounting Accessories...
TIE ROD FLANGE SWIVEL FLANGE
TRUNNION
SUPPORT
CLEVIS FOOT
TRUNNION
FLANGE
NUT
109
Rigid mountings
Tie rod extension Front Flange
Rear Flange Foot
110
Articulated mountings
Centre Rear Eye

Rear Clevis Trunnion
Rod Clevis Rear Hinge Universal rod Eye
Front Hinge Universal

rear Eye
111
Cylinder Installation
 Load sizing, Alignment, and Positioning are very
important for the installation of cylinders.
 A cylinder should be installed so that side loads
on the piston rod bearing are reduced to a
minimum or eliminated.
 A side load is a force component acting laterally
across the axis of the bearing.
 Five typical installations that produce a side load
are shown bellow with their possible solutions.
 Side loads can rarely be eliminated completely,
but by employing good engineering practice they
can be reduced to an acceptable level.
112
Side load one
 Avoid attaching an
unsupported load to the
piston rod.
 Wherever possible
support the load on slide
or roller guides
Side load two

 The weight of a long outstroked
piston rod alone can produce a
high bending moment.
 It may be possible to hang the

rod end from a roller track.
113
Side load three
 Misalignment of the
cylinder and a guided load
can easily jam the cylinder
completely.
 Installation of a front fork

and slot will eliminate this
type of side load.
114
Side load four
 An offset load is a
common source of
bending moment acting
on the end of a piston
rod.
 Install external heavy

duty bearings to relieve
the side load on the
cylinder bearing.
115
Side load five
 A horizontally mounted rear hinged cylinder will have the
weight of the cylinder body creating a bending moment.
 Fit a central trunnion at the point of balance
116
Bellows
 Bellows are durable single acting concertina like
actuators.
 Extend when inflated.
 Provide powerful short strokes.
 Have all round compliance allowing them to bend in any
direction.
 Can be used as air springs and are ideal for insulating the
vibration of supported loads.
117
VACUUM HEADS/GENERATORS
b) Bellows suction cups

a) Flat suction cups
118
STRUCTURE OF PNEUMATIC
GRIPPERS…
c) 3-point grippers
b) Parallel grippers
d) Angle grippers
a) Radial grippers
119
ROTARY ACTUATORS
 Used for turning components, operating process
control valves, performing a wrist action in
robotic applications.
 Can provide angular reciprocating rotation up to
360o
 Rotary vane types
 Rack and pinion types  Double acting with 270o angle of
rotation
120
Rotary rack and pinion
 Double acting rack and pinion
 Double acting double torque
121
PNEUMATIC VALVES
Pneumatic valves are mechanical or electro-mechanical devices
specially designed to switch air flow to & fro various devices. From
the simplest switching of a single flow path on and off, to the
exacting of proportional flow to control pressure.
 The range of pneumatic valves is vast, thus to help select a

valve they are placed in a variety of categories such as:
 Design principle/ Style

 Method of operation
 Function/application

Typical Valve
Structure/Components
8
 Component parts of a 7 9
typical 5/2 solenoid valve 6
with spring return
 (1) Solenoid 5
 (2) Piston
 (3) Spool with disc seals
 (4) Valve body 1
 (5) Return spring

 (6) working ports 2, 4
2
 (7) Pressure indicator
 (8) Manual override
 (9) Electric connectors 4 3

Valve Design Style
 Style reflects the look of a valve as well
as the underlying design principle,
installation arrangement for example
sub-base, manifold, & in-line. Valve
style also depends on the
vendor/manufacturer. Examples of
Norgren valve styles are Nugget, ISO
Star and Super X

Method of Operation
 An operator is the
mechanism that causes a
valve to switch/change state
 They are classified as
Manual, Mechanical , Push Shrouded Mushroom Twist
Pneumatic, and Electrical. Button Button Button
Manually
Operated
Pneumatically Key
Switch Emergency
Operated Operated
Air Port Stop
Electrically
Roller
Operated One Way
Plunger Tip
Solenoid
Mechanically
Coil
Operated
Valve Application
 Category by Application is for valves described by their
function or task in a pneumatic system.
 Examples are: Quick exhaust valve, Shut-off valve,

Directional Control/processing valve, and Flow control
valve, Timer Valve.
 Note that any standard valve could be in any category

depending on the function it has been selected for in a
system

Valve Port Size
 Valve Size refers to a
valve’s threaded port .  Example of port sizes in
progression: M5, G1/8 ,
 For similarly designed
G1/4, G3/8 , G1/2, G3/4, G1.
valves the amount of air
flow through the valve
usually increases with the
port size. G3/8
M5 G1/2
 Port size alone however G1/8
G1/4
cannot be relied upon to
give a standard value of
flow as this is dependent
G1 G3/4
on the design of the valve
internals.

VALVES SYMBOLS
Valve symbols are interpreted according to the line diagram on it, they typically
indicate the valve’s switching positions, number of ports, method of operations, and
condition of flow part as shown & interpreted below:
128
Valves Numbering System and Standard
A numbering system is used to designate the ports of directional control
valves and is in accordance with DIN ISO 5599-3. Prior to this a
lettering system was utilized and both systems of designation are
presented here:
Example
129
METHODS OF ACTUATION SYMBOLS
130
OPERATIONAL STRUCTURE OF VALVES
3/2-Way Valve: Mechanically Operated,

Spring return, Normally Closed
3/2-Way Valve:, Manually Operated,

Spring return, Normally Opened.
131
OPERATIONAL STRUCTURE OF VALVES…
3/2-Way Valve: Pneumatically

Operated, Spring return, Normally
Closed.
Piloted valve
3/2-Way: Roller (Mechanically)

Pilot Operated, Spring return,
Normally Closed.

5/2-Way Valve: Pneumatically Operated, Pneumatically returned.

5/2-Way Valve: Double Pneumatically Operated with Manual Override

4/3-way plate slide valve: mid-position closed, Manually Operated

VALVES SYMBOLS …
Non Return Valves
Logic Valves
Flow Control Valves
136
Dual-Pressure Valve (AND Function)
Shuttle Valve (OR Function)

Check Valve (Spring Loaded) Quick Exhaust Valve
One-Way Flow
Control Valve
1 2
Flow Control Valve
Pressure regulating Valves
symbols …
Pressure
Regulating Valves
139
Time Delay Valve, Normally Closed Position
Pressure Sequence Valve

AUXLLARY SYMBOLs…
141
A PNEUMATIC SYSTEM CIRCUIT DIAGRAM/LAYOUT
The structure of the circuit diagram correspond to the control chain & components
functions, represented from the bottom to the top in the direction of air flow.
 Component Identification by letter:
Power
o Working Elements (Actuators) ……………… A
component
Identification o Control & Processing Elements (Valves) ..…V (ACTUATOR)
code for o Input Switches/Sensor Elements (Valves) … S
components o Supply Elements/Accessories ……………..... Z
Control
o Compressor ………………………..…………...P Element
 System number beginning with 1; (1S1) used
Processing
only when the entire circuit consists of more than
Element
one Actuator control system. supply elements
begins with 0 (0Z).
Input
 Components number beginning with 1; (1S1 ) Elements
continuous numbering of the same class of
components from left to right, bottom to top
 Working Element with a making line (Point of
contact) to input element 1S3 indicated as:
Air Supply
Actuated valves in a circuit can also be identified by : Elements
a cam symbol
 From top to bottom
Example • Actuator 1A
Circuit •Control element 1V2
Diagram • Process element 1V1
• Input elements 1S1,1S2,1S3 142
shown • Air supply elements 0Z,0S APPLIED ENGINEERING TECHNOLOGY INITIATIVE
PNEUMATIC CONTROL SYSTEM CIRCUIT DIAGRAMS…
Direct and Indirect Actuation
Dual-Pressure Valve
(AND function) Shuttle Valve (OR Function)
143
5/2-Way Double Pilot Quick Exhaust Valve Control

Valve (Speed Control)
Pressure Sequence Valve
144
Time Delay Valve Control
145
Sequential Coordinated Motion
146
ELECTRO-PNEUMATICS
In Electro-Pneumatics Automation Systems, Electrical and
Pneumatic components work together as a single automation
system; here, compressed air is used as a working medium while
electricity acts as the control medium.
147
ELECTRO-PNEUMATIC SYSTEM ELEMENTS
Pneumatic Electrical
Elements Elements

BASIC ELECTRICITY…
Electricity is a general term encompassing phenomena – such as heat, sound, light;
resulting from the presence and flow of electric charge. Here in particular, Electricity refers
to the flow of electrical current in electrical wire, circuit & devices. Basic source of
electricity includes Public power system (PHCN), Power Generators etc. Electricity power
is available in two main forms; the Alternating Voltage (VAC) (from Mains) e.g. 220Vac and
Direct Voltage (VDC) e.g. 24Vdc
Solar Panel & battery Electrical Power Supply

220 Vac from other sources of Systems used to covert AC
mains Supply Electricity power to DC power
Three important parameters are very important to the use of electricity as highlighted below:
Electric current is a flow of electric charge through a medium. This charge is typically
carried by moving electrons in a conductor such as wire, & circuit components. It is
measured in amperes (A)
Voltage between two points is equal to the Electrical Potential Difference between
those points. It is the electrical driving force (EMF) required for an electric current to flow
between two points. It is measured in Volts (V).
149
BASIC ELECTRICITY…
Resistance of an electrical element/device is the measure of its opposition to
the passage of an electric current; the inverse quantity is electrical
conductance, measuring how easily electricity flows along a certain path. Thus
good electrical conductors have low resistance. It is measured in Ohms (Ω)
Coil element Resistor
Ohm’s Law is a basic law that shows the relationship between the 3 electrical
properties. Ohm's law states that the current through a conductor between two
points is directly proportional to the potential difference across the two points,
and inversely proportional to the resistance between them.
The mathematical equation that describes this relationship is:
150
BASIC ELECTROMAGNETISM
We can make an electromagnet by
wrapping a coil of wire wound around
a core. The core is usually soft iron,
which conducts magnetic lines of flux
with relative ease. When current is
passed through the coil, the core
becomes magnetized. The ability to
control the strength and direction of
the magnetic force makes
electromagnets useful. A large
variety of electrical devices such as
Solenoid valves, circuit breakers,
contractors, relays, and motor
starters use electromagnets and
electromagnetic principles to
operate.

ELECTRICAL COMPONENTS
Note:
Coil operating
parameters:
Voltage e.g. 24v
Current e.g. 10A
Power e.g. 5w
152
ELECTRO-PNEUMATIC COMPONENTS
Plunger solenoid
Solenoid connector
Coil
Note:
Coil operating
parameters:
Voltage e.g. 24v
Current e.g. 10A
Power e.g. 5w
153
ELECTRO-PNEUMATIC COMPONENTS…

3/2 way Piloted valve: Solenoid Operated with
Manual override, spring returned,Normally closed
155
Unactuated
Actuated
156
Unactuated
Actuated
157
Unactuated Actuated
158
ELECTRICAL COMPONENTS…
Reed Switch Actuated
159
ELECTRICAL COMPONENTS…
Timer
Sensors
160
ELECTRO-PNEUMATIC COMP. SYMBOLs
161
Solenoid valves.
162
Solenoid valve.
163
Limit switches.
164
ELECTRO-PNEUMATIC COMP. SYMBOLs…
Solenoid valve
Symbol
Relay/Contactor
Symbol
165
ELECTRO-PNEUMATIC COMP. SYMBOLs…
Inductive proximity
switch
166
ELECTRO-PNEUMATIC CONTROL CIRCUIT
The pneumatic and electrical circuits/diagrams are parts of an electro-pneumatic
system diagram as shown below:
In the pneumatic part, air signal flow is represented from bottom to top as usual.
While in the electrical part, current signal flow is represented from top to bottom
(+24v to 0v)
In the electrical circuit diagram, the current paths are numbered consecutively from
left to right: 1, 2…...
The common circuit diagram elements (1Y1) form the interfaces between the
pneumatic and the electrical circuits. In this case as shown below, it is the solenoid
valve 1Y1. Electrical
Pneumatic
RELAY 167
APPLIED ENGINEERING TECHNOLOGY INITIATIVE CONTACT MAP
ELECTRO-PNEUMATIC CONTROL CIRCUIT..
168
169
BASIC ELECTRICAL CONTROL LOGIC
170
BASIC ELECTRICAL CONTROL LOGIC…
171
Electrical retaining contact Circuit

– Dominant On
172
Electrical retaining contact Circuit

– Dominant Off
173
174
175
3 4 5
4 5 5
176
ACTUATORS DISPLACEMENT STEP DIAGRAM
In a displacement-step diagram, the
motion sequences of an actuator in a
control system are presented graphically :
• Movements of the cylinder within a step
are represented by a line moving
diagonally upwards (advancing) or
downwards (retracting).
• Horizontal lines represent the position of
the cylinder in the advanced or retracted
end position.
• If the movements of several actuators
are to be represented, they are arranged
under each other for every individual step.
• This arrangement clarifies the
relationship between the movements of
the individual actuators in every step.
177
ELECTRO-PNEUMATIC CONTROL CIRCUIT...
Inductive loads such as solenoid valve and coil operated devices have tendency of
causing current surge across their connected terminals. This phenomenon is
destructive to the electrical contacts thus, to minimise this, protective devices such
as diode, varistors etc. are connected across their terminals as shown below:
178
HARD-WIRED CONTROLS
1Y1
1Y2
PROGRAMMABLE CONTROLS
1Y1
PLC
1Y2
179
PNEUMATIC AUTOMATED 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.
180
MAINTENANCE TIPS …
Proper Selection, Installation, & Management
Direct Implication Indirect Implication
• Appropriate selection/sizing of • By opting for an Automatic facilities to

compressor & air reservoir increase efficiency/productivity.
• Proper selection of layout & pipe • By implementing a professional
line Preventive/Predictive maintenance
• Use of good quality service units program.
• Use of centralized/decentralized • By training the employees, on how to
drying system in order to remove effectively use & maintain the system.
moisture.
181
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.
182
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.
183
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.
184
Preventive Maintenance Schedule
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.
185
Do’s & 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.
186
Do’s & Don'ts : 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.
187
Do’s & Don'ts : Valves
• Directional control valves should be preferably mounted vertically (reduces uneven

wear and tear of seals).
• Connectors 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.
• 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.
188
Do’s & Don'ts : 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
lock nut is fastened.
189
Do’s & Don’ts : 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
190
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
191
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 equipments, 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.
192
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
 ejected particles can injure
the eyes
 Electric shock
 Moving mechanical parts
 Work should be carried out
using approved practices
and observing relevant
legislation

TROUBLESHOOTING TIPS…
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.
194
MONITORING INDICATORS
Monitoring indicators are very useful source of information during
troubleshooting:
4 6
 Pressure gauges show 2 40

80
120
8
the presence and level of lbf/in2

bar 10
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  Fault finders must keep well
pneumatic power will be clear of the path of all
isolated, pressure exhausted actuators, mechanisms and
and moving parts other hazardous moving
mechanically locked parts
 In practice it may be
necessary to have the
 Electrical equipment should
machine or device partly or
be checked using only the
fully powered up to locate a
proper test instruments
fault
 To gain access to test a
suspect device, it may also be  Notes: While removing
necessary to remove and electrical connections label
override the guards. them carefully. While
replacing the components
 This clearly presents many
please take care of the
dangers and great caution and
polarity.
awareness is required by the
fault finding team
 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
Common faults and solutions
 Symptom  Possible Solutions

The machine is working  If weak supply pressure
but is falling off in  Fit larger pipe
performance due to  Install local receiver
slower operation
 Install larger
 Possible Causes compressor
 Upstream flow  If strong supply pressure
restriction or air
 Check for kinked tube
starvation
downstream and renew
 Downstream flow
 Lubricate mechanisms
restriction
 Fit air line lubricator
 Lack of lubrication

Common faults and solutions
 Symptom  Possible Solutions

One actuator is falling off  Readjust flow regulators
in performance due to  Renew tube
slower operation  Fit air line lubricator
 Possible Causes  Clean, realign and
 Flow regulators set too lubricate mechanisms
low  Replace or repair
 Tube kinked actuator
 Lack of lubrication
 Out of alignment
 Objects in actuator path
 Piston rod bent
 Barrel dented

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 ( pressure, Temperature etc. )
200
Type of Failure Possible reason for Possible Remedy.
Failure
Leakage through Piston 1. Eccentric loads Use company specified
rod seal. guide units.
2. Lateral Moments
beyond limit.
Piston rod seal. 3. Non parallelity of Piston
rods & guide rods.
Piston rod Seal is 4. Sticky piston rod. Cover the piston

Damaged. rod/Remove sticky
material.
5. Misalignments Rod couplers.
6. High/Very low Use Cylinders with

surrounding Temperature temperature resistant
sealing.
201
Type of Failure Possible reason for Possible Remedy
Failure
Piston rod seal is 7. Constant exposure to Use Corrosion resistant

damaged chemicals , coolants, cylinders.
chemical fumes etc..
Piston rod is bent 1. Lateral load beyond the Use Company specific
allowable limits. guide units.
2. Frequent lateral impact Use stopper cylinders.

load.
3. Normal cylinder is not Use specially designed

used for Heavy duty Heavy duty cylinders.
application
EX: Hammering
202
Failure
Piston seal and other 1. Bad quality of air. Guarantee good quality of
wearing parts inside the air
cylinder are damaged.
2. Insufficient Lubrication Guarantee sufficient
lubrication.
3. Use of non-conforming Use company specified

oil for lubrication. Lubricating oil.
4. Dust accumulation in Use cylinders with scraper

the cylinder. ring to avoid dry dust
entering the cylinder
through Piston rod seal.
203
Failure
Piston is damaged. 1. Piston is subjected to 1 . For heavy impact
repeated heavy impact applications use heavy
loads. duty cylinder.
2. Use external shock
absorbers to de-
accelerate the piston.
3. Use the cylinder within

the maximum allowable
operating pressure range.
2. Lateral Moment is 1. use company specified

beyond the allowable limit. guide units.
204
Valve failure:
Pneumatic valves may fail due to the following reasons:
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).
205
Failure
Sealing of Valve 1. Fine Dust Guarantee good quality of air supply.
are damaged accumulation inside
the valve.
2. Fine Dust Mount silencers on the exhaust ports, so
accumulation inside that dust does not enter the valve body
the valve through through there ports.
possibly open exhaust
ports.
3. Use of non- Use company recommended lubricating

conforming lubricating oil.
oil.
4. Surrounding Mount the valves in a thermally insulated
temperature is beyond cabinet. Or mount the valves away in a
the allowable limits. safe place.
206

failure
Sealing of valve are Operating pressure Use suitable valve for

damaged. beyond max. allowable high pressure
limit. application.
Coils are damaged. 1. Voltage surge. Guarantee the Voltage

2. Undersized coil supply within
3. Water/dirt entry into recommended limits,
coil compartment size properly and install
solenoid valve at water
proof locations.
207
 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

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

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 210
 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
211
Solenoid valves Fault
 Fault: The pneumatic

output is OFF when the
coil should be ON
AUTO POWER OFF
OFF
1000V 750V
DC 200V 200V AC
20V 20V
2V 2V
200mV 200mV
200 20M
uA
 Check the electrical

2mA 2M
20mA 200K
20A
200mA 20K
DC
200mA 2K
20mA 200
AC 2mA 200
20A
uA
supply at the plug 20A
!
10A cont
mA uA
!
COM
250mA MAX
20A 30sec MAXFUSED
UNFUSED
!
1000Vdc
750Vac
V
MAX
ISO-TECHIDM91
 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
213
 Solenoids valves have  2W = 1.0mm orifice diameter

6W = 1.6mm orifice diameter
matched coils and stems
8VA = 1.6mm orifice diameter
according to coil power
 A low power coil will not
pull in the armature
against the stronger
24V =
spring of a high power
6W
stem assembly
 A high power coil causes
slamming of the armature
on a low power stem 1.6
resulting in premature
seal failure 1.6
0 1

Reed switches Fault
 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
215
Limit switches Fault
 Fault: The switch

mechanism appears to be
moving but the switch is Pre-travel
not changing over
 1.This may be due to a
cam operating the roller
Operating
in the pre travel band only travel
 re-adjust to include the
operating travel
 2. Broken contact due to
vibration and mechanical
fatigue
 3. Burnt contacts due to
unsuppressed loads

Service Units Failure:
Service Units may fail due to the following reasons :
2. Unstable Lubricating Oil.
3. Operating conditions beyond the limits (Pressure, Temperature etc.)
4. Careless handling of service units (Knobs, Drain plugs)
217
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. Contenous contact with water, coolant, solvent, chemicals, fumes
etc….
218
END OF PROGRAM
THANK YOU
219

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WELCOME TO OUR TRAINING

1. understand the basic physical properties of compressed air, basic SI

• In contemporary technical use, pneumatics refers to

• Pneumatic control systems are used extensively in

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 10

Feed station with

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

Feeding the mould on concrete slab

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 12

1. Air is a freely available energy source.

2. Can be easily stored in air receivers.

3. Fast fluid motion and Device responses.

4. Offers Little or No risk of fire Explosion.

5. fairly insensitive to temperature fluctuations.

6. No risk of Environmental Pollution.

7. Devices are Rust resistant.

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 13

1. Air requires good Preparation

2. The System is prone to vibrations.

3. High Noise Level

4. Limited to low pressure applications.

5. Cannot provide precise actuator and

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 14

 Air also carries contaminant particles

 Heat causes expansion of air and increases its

 Cooling of Air causes Condensate (water

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 15

 Pressure = Force / Area

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 18

 Compressed air exerts a

 Compressed air exerts a

 Air expands when it is heated

APPLIED ENGINEERING TECHNOLOGY INITIATIVE 20

 Absolute Humidity: is the mass of water vapour, actually

 Saturation Quantity: is the mass of water vapour, which 1m3

 Relative Humidity = (absolute humidity / saturation quantity)

 Dew point is the point in temperature scale (Dew point temperature)

The moisture in air increases with

 Constant temperature P.V = T constant

P1*V1 = P2*V2 V1/T1 = V2/T2 P1/T1 = P2/T2

General Gas Equation:

(P1V1 / T1) = (P2V2 / T2) = (P3V3 / T3)

Pressure is typically measured in the industry by pressure

 The power of atmospheric

 Air is removed from one

Absolute pressure bar a

Gauge pressure bar g

working elements (Actuators).

• Air Flow :From bottom to top

• Control Chain:S P A principle: Supply,

• Air supply : Through Tubing or

POSITIVE DISPLACEMENT DYNAMIC

PISTON DIAPHRAM RADIAL-FLOW AXIAL -FLOW

7: Motor (Prime mover)

 The Volumetric Delivery Capacity

1. Load/Unload regulation is the most common regulation method and involves

 Inlet filter is required to  Avoid locations where

• Compressors must be installed in a relatively cool, clean, dust free

• Exhaust fans must be installed direct under the roof so that

Air Preparation Equipment are:

Residual Solids Residual Water Residual Oil

1 0.1 0.1 -70 0.003 0.01

Pressure Dew point Maintenance

P1V1 = P2V2 V1/T1 = V2/T2 P1/T1 = P2/T2