Fault Tracing

For pneumatic and electro-pneumatic systems

Contents

Introduction Safety Fault effect Common faults Component fault tracing Solenoids Switches Valves

Simulated faults System fault tracing Monitored conditions Fault tracing procedure Simulated system pneumatic Simulated system PLC

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Introduction

Modern component design and manufacture coupled with planned preventive maintenance provide a high level of performance and reliability In the event of a machine or system break down, the heavy cost of lost production time makes it essential to restore normal running in the minimum time

If a machine or system shows a fall off in performance or stops working, there is a race to trace and correct the fault as fast as possible A methodical approach and experience of likely problems is the prerequisite of the fault tracing engineer

Safety in fault tracing

Safety in fault finding

In any fault tracing exercise personal safety and the safety of others is paramount Work should be carried out using approved practices and observing relevant legislation Ideally all electrical and pneumatic power will be isolated, pressure exhausted and moving parts mechanically locked

Safety in fault finding

In practice it may be necessary to have the machine or device partly or fully powered up to locate a fault To gain access to test a suspect device, it may also be necessary to remove and override the guards. This clearly presents many dangers and great caution and awareness is required by the fault finding team

Fault finders must keep well clear of the path of all actuators, mechanisms and other hazardous moving parts Electrical equipment should be checked using only the proper test instruments

Safety in fault finding

DANGER! Jammed actuator The actuator will be preexhausted 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 depressurised and use a tool to clear the jam

Safety in fault finding

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

Safety in fault finding

DANGER! An exhausted system can leave some components with trapped pressure An actuator controlled by a 3 position valve may be pressurised regardless of whether the main pressure has been exhausted or not Removing a connection to one end or overriding the valve will cause sudden actuator movement
Click the illustration to start and stop animation

Safety in fault finding

Some of the dangers to consider include: Sudden exhausts to the face:

noise can injure the ears ejected particles can injure the eyes

Electric shock Moving mechanical parts

Fault effect

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 performance, slow Faulty product, inaccurate Machine stops

A fault tracing and correction procedure must be put into action

Common faults and solutions

Common faults and solutions

Symptom The machine is working but is falling off in performance due to slower operation Possible Causes

Possible Solutions If weak supply pressure

Fit larger pipe Install local receiver Install larger compressor Check for kinked tube downstream and renew Lubricate mechanisms Fit air line lubricator

Upstream flow restriction or air starvation Downstream flow restriction Lack of lubrication

If strong supply pressure

Common faults and solutions

Symptom One actuator is falling off in performance due to slower operation Possible Causes

Possible Solutions

Flow regulators set too low Tube kinked Lack of lubrication Out of alignment Objects in actuator path Piston rod bent Barrel dented

Readjust flow regulators Renew tube Fit air line lubricator Clean, realign and lubricate mechanisms Replace or repair actuator

Common faults and solutions

Symptom Faulty product due to machine adjustments Possible Causes

Possible Solutions

Stops or mechanisms out of adjustment Limit valve or sensor moved out of position causing a short stroke Failed ON sensor causing a skipped step in the sequence Insufficient power to a stamping or pressing actuator

Readjust mechanisms, stops and limit sensors Check suppressor and circuit then replace sensor Modify the logic control to stop the machine in the event of any sensor failing ON Increase pressure to the actuator or replace the actuator with a larger one

Common faults and solutions

Symptom Machine stops Possible Causes

Possible Solutions

Failed pneumatic or electrical power supply Limit valve or sensor moved out of position Mechanical jam preventing an actuator from operating a limit switch Failed to OFF sensor breaking the sequence

Re-establish power supplies, reset machine and restart Adjust and tighten sensor Ensure pressure is released from both sides of the actuator before clearing a jam Check suppressor and electrical circuit then replace sensor

Component fault tracing

Solenoids

Solenoid pilot valves

Fault: the pneumatic output is continuously ON when the valve coil is de-energised Check the manual override (if fitted) it may have been left in the ON (1) position
0 1

Solenoid pilot valves

Fault: The pneumatic output is OFF when the coil should be ON Check the electrical supply at the plug If this is OFF trace the supply back to the source If ON the fault may be:

AUTO POWER OFF 1000V DC 200V 20V 2V 200mV 200 uA 2mA 20mA 20A 200mA DC 200mA 20mA AC 2mA 200 20A uA

OFF

750V 200V AC 20V 2V 200mV 20M 2M 200K 20K 2K 200

20A

mA uA

COM

! ! ! 250mA MAX 10A cont 1000Vdc FUSED 20A 30sec MAX 750Vac UNFUSED MAX

ISO-TECHIDM91

low voltage mechanical fault preventing the armature pulling in burnt out coil

Solenoid pilot valves

A suppressor fitted within the plug may fail If so it is likely to fail open circuit This will not stop the coil from working but will leave it unsuppressed This could damage the circuit that is switching the coil Short circuit failure will blow a fuse or damage the switching circuit

+24 V

0V

Solenoid pilot valves

A weak or broken spring will prevent the armature from sealing the supply, causing air to flow to the outlet and exhaust Alternatively the armature may be held in the up position by the air pressure after the coil is de-energised 2

Solenoid pilot valves

Cut or deeply embedded seats, can cause leakage but needs to be extensive before the valve is unusable

Solenoid pilot valves

Coils must be firmly fixed to the solenoid stem For a.c. solenoids the reaction of the alternating magnetic field causes axial reactive forces on the coil If the coil is loose it will vibrate There will be heat build up, less efficient holding of the armature and eventual failure

Click the illustration to start and stop animation

Solenoid pilot valves

Solenoids valves have matched coils and stems according to coil power A low power coil will not pull in the armature against the stronger spring of a high power stem assembly A high power coil causes slamming of the armature on a low power stem resulting in premature seal failure

2W = 1.0mm orifice diameter 6W = 1.6mm orifice diameter 8VA = 1.6mm orifice diameter

24V = 6W

1.6

1.6

Solenoid pilot valves

Solenoid coils are continuously rated which means they can be left energised indefinitely When energised for a long time it is normal for a coil to become too hot to hold comfortably Overheating can result if coils are continuously energised in a confined space with no means of ventilation

100%ED

Switches

Reed switches

Fault: Switch contacts permanently made 1. Used directly with an unsuppressed solenoid coil where the arcing has fused the contacts together 2. Too high a current has passed through the contacts

Fit a suppressor
+24 V 0V

Fit an inductor
L
470H

+V Load 0V

a surge current caused by very long leads (capacitive coupling) too high a load

Standard leads

Extended leads

Reed switches

Indicating light (l.e.d.) permanently ON although the switch functions normally 1. On three wire types this is most likely due to the brown and black wire being reversed 2. If this is not the problem it is likely the contacts have failed closed

Protection diode Black Blue Brown 0V Coil 0V +V

Protection diode Black Blue Brown 0V Coil 0V +V

Reed switches

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

Click the illustration to start and stop animation

Reed switches

Fault: System not responding to a switch at the actuators mid-stroke position It is likely that the piston speed is too fast

The bandwidth of the magnetic field is approximately 6mm. If this distance is covered in less time than the response time of the equipment being signalled then it will not be successful

Click the illustration to start and stop animation

Limit switches

Fault: The switch mechanism appears to be moving but the switch is not changing over 1.This may be due to a cam operating the roller in the pre travel band only

Pre-travel

Operating travel

re-adjust to include the operating travel

2. Broken contact due to vibration and mechanical fatigue 3. Burnt contacts due to unsuppressed loads

Valves

Power Valves

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

Power Valves

Fault: Valve spool not changing position Opposed signals on bistable 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 its control

Power Valves

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

Power Valves

Fault: Valve spool not changing position Jammed spool due to the use of a long threaded fitting which has damaged the valve bore Use only fittings designed for connection to pneumatic valve ports

Power valve

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

Power valve

Fault: Valve spool not resetting For mono stable valves this may be due to a broken spring

Power valve

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

Simulated Faults

Simulated circuit

This simple circuit simulates an application Click on the circuit to see it in operation The lever valve is operated and the cylinder operates automatically The lever valve is reset to stop the cylinder in the fully instoked position The next series of slides show the effect on this circuit of various faults

Click the illustration to start and stop animation

Fault simulation 1

Click the circuit for fault 1 The cylinder stops in the outstroked position where it should be operating the trip valve The trip valve (a1) has not operated and cannot signal the 5/2 valve The fault is likely to be loose mountings of valve (a1) so that it is not being tripped properly

Click the illustration to start and stop animation

Fault simulation 2

Click the circuit for fault 2 The cylinder stops in the outstroked position operating the trip valve The trip valve (a1) has operated but is not signalling the 5/2 valve The fault is likely to be a kinked or trapped tube

Click the illustration to start and stop animation

Fault simulation 3

Click the circuit for fault 3 The cylinder completes one cycle but cannot start the next cycle The trip valve (a1) has operated but not reset The 5/2 valve has opposed signals so remains in the reset state The fault is likely to be jamming of the valve operating mechanism against an obstruction

Click the illustration to start and stop animation

Fault simulation 4

Click the circuit for fault 4 The piston rod stops in a part stroked position The piston rod has jammed against an obstruction The cylinder is preexhausted and will impact to the end of stroke when the obstruction is cleared Freeing the jam while there is pressure applied is dangerous

Click the illustration to start and stop animation

Systems Fault Tracing

System fault tracing

With a failed system it is usually difficult to know where to start the search The fault tracing process is one of back tracking from the event that should have happened but has not It may be local such as a jammed actuator or the back tracking process may take you through several stages of logic before the fault is revealed

Resources

The speed with which faults can be located within a system depend on the following facts: How well the engineer knows and understands the machine The number of monitored conditions The quality of the documentation and if it is up to date
Saturday, May 5, 2012

Monitored conditions

Pressure gauges show the presence and level of pressure Pressure indicators show the presence of pressure Lamps show the presence of electrical power LEDs show that a solenoid is receiving power or that a reed switch or sensor is turned ON

4 2 40

6 80 120 8

lbf/in2 bar

10

Monitored conditions

In the absence of monitored conditions the fault tracing procedure will take a little longer: Pneumatic connections have to be tapped to check for the presence of pressure Electrical connections have to be accessed to check for voltage

AUTO POWER OFF

OFF
1000V DC 20V 2V 200mV 200 uA 2mA 20mA 20A 200mA 200mA AC 20mA 20A 2mA 200 uA 200 2K 200V 750V 200V AC 20V 2V 200mV 20M 2M 200K 20K

20A

mA uA

COM

! 1000Vdc 750Vac MAX

250mA MAX 10A cont FUSED 20A 30sec MAX UNFUSED

ISO -TECH IDM91

Fault tracing procedure

1. Identify the actuator that has failed to complete or make its stroke 2. Establish the direction of movement at this step, outstroke + or instroke 3. Inspect the state of the inputs and outputs of the valve controlling the actuator 4. Are these correct for the intended stroke ?

If YES: the fault is with the actuator or between valve and actuator

jammed actuator flow regulator sealed tube squashed

If NO: are the inputs correct ?

If YES the fault is with the valve If NO follow the incorrect signal path to find the fault

Inputs and Outputs

It will help if you become familiar with the pattern of inputs and outputs at a power valve When a system stops the pattern will be a guide to the fault Few systems will have such convenient monitoring indicators as shown on the next slides but the pattern can be established Where push in fitting are used, pushing the tube towards the valve but not releasing the collet will give a springy or slack reaction indicating whether pressure is present or not

Building blocks

All circuits are made from basic building blocks The circuits illustrated are single actuator building blocks pneumatic and electopneumatic inputs Click each circuit to animate and observe the changing pattern of monitored conditions, inputs (signals) and outputs (power) Click again to stop or start at different steps
Click the illustration to start and stop animation

Inputs / outputs for 5/2 Valve

These are the four patterns that exist normally during the operation of an actuator If an actuator fails to move, patterns 1 or 2 suggest a jammed actuator or low pressure, patterns 3 or 4 suggest a failed signal If an actuator stops at part stroke, any of these patterns suggest a jammed actuator

+ 0

+ 0

+ 0

+ 0

All combinations are shown on the next slide with suggested reasons why the actuator has not operated

5/2 Valve i/o patterns

+ 0 + 0 + 0 + 0 + 0 + 0 + 0 + 0 1 1 1 1 1 1 1 1

Jammed or lost signal 0 ? Jammed or lost signal 1 ? Jammed at part - stroke ? Jammed at part + stroke ? Signal 1 not released ? Signal 0 not released ? Valve supply lost ? Valve supply lost ?

+ 0 + 0 + 0 + 0 + 0 + 0 + 0 + 0

1 1 1 1 1 1 1 1

Valve supply lost ? Supply lost plus false signal ? Valve not changing position ? Valve not changing position ? Split actuator or valve seal ? Split actuator or valve seal ? Split actuator or valve seal ? Split seals plus false signal ?

Back tracking to the fault

The back tracking procedure is identified with the next two example simulations 1. System with pneumatic logic 2. System with PLC logic

Fault simulation (pneumatic logic)

Click the circuit to animate the sequence A+B+B-C+C-AIt stops near the end of the third cycle Follow the fault tracing procedure
1. Actuator C should have moved minus

2&3. The inputs are not correct follow either of these 4. The cascade valve has not changed. The lower input is not correct 5. Follow the path of this signal. This comes from valve c1. It can be seen the roller is missing and the valve has not operated

Click the illustration to start and stop animation

Fault simulation (PLC Logic)

Click to animate A+A-B+B-C+C-A+B+C+ABC-ABC+A-B-CIt stops at the end of the last AFollow the fault tracing procedure
1. Actuator B should have moved minus

2. The input a0 from the previous movement A minus is not ON 3. As a result the output to send B minus has not been given

4. Following the fault path to the a0 sensor reveals that it has slipped out of range of the piston in actuator A

Click the illustration to start and stop animation

End