1
Q
In a pneumatic system, what are 2 functions of the Exhaust Mufflers?
A
-Reduce air noise level
-Prevent dirt from getting into exhaust ports of directional control valves
2
Q
What are required for EACH portion of the system that can be isolated?
A
Safety/Pressure Releif Valves
3
Q
Does temperature influence the ability of air to retain water vapour? True or False and give an example
A
True. When it’s cold, there is no water vapour in the air that’s why it’s so clear in winter
4
Q
What is the purpose of intercooler and after coolers?
A
Its to remove heat coming from the air compressor
5
Q
Where does the intercooler cool air?
A
Between the multi-stage compressor
6
Q
Where does the Aftercooler cool the air?
A
After it has been compressed
7
Q
What 2 things can you use as the cooling medium?
A
-Air
-Water
8
Q
Where would a water or air Aftercooler be installed?
A
Typically installed right after the compressor
9
Q
What are the functions of an Air Reservoir?
A
-Stores air for system demands
-Acts as a cooling system (allows moisture to settle)
10
Q
Larger Reservoirs are classified as what and what 4 things must they have?
A
-Unified Pressure Vessel
-Relief/Safety Valve
-Drain Valve
-Fusible plug
-Pressure Gauge
11
Q
True or False: does a Unified Pressure Vessel need to be routinely inspected?
A
True.
12
Q
What is a Centralized Grid in a Pneumatic System?
A
It’s a compressor that has one line that provides air to branching out feeder lines
13
Q
Define a Decentralized Grid piping system
A
When you have multiple compressors with their own individual piping system
14
Q
Explain what a Loop piping system is and how efficient is this?
A
-A main line that forms a continuous loop with one or more compressors
-Most efficient
15
Q
What is a “Drop” or “Drop Line” in an Air line arrangement?
A
Drop is the vertical line that branches and feeds into the machine
16
Q
What is a Drop line usually connected with?
A
-Shut off valve
-FRL
17
Q
What does FRL mean and where is it usually connected to?
A
-Filter, Regulator, Lubricator
-It’s usually connected with the Drop line
18
Q
For Piping Considerations, what should you do to the size of the main line and why?
A
It should be increased to accommodate expansion
19
Q
Why should you install Safety Valves in piping system?
A
-For emergency shut offs
-Can isolate area without affecting plant operation
20
Q
When installing piping airlines, what happens when you oversize it?
A
-Increases efficiency
-Cost more to install
21
Q
What happens to the air pressure when you undersized piping?
A
It causes a pressure drop which will require higher pressure from the compressor
22
Q
Why are black pipes still commonly used for Pneumatic Piping Systems and what is a downside to using it?
A
-Cheaper
-Rust
23
Q
What are 3 factors that is caused by a leak?
A
-Energy waste
-Increase Expense
-Reducing Performance
24
Q
How much would air line leaks cost the company annually if left unchecked?
A
Thousands of dollars annually
25
What does the Air Filter predominantly remove?
Moisture
26
What other contaminates comes from atmospheric air, distribution lines, compressor, air?
Atmospheric air: dirt
Distribution lines: rust
Compressor: atomized oil
Air: Water
27
What does a Deflector do inside of the air filter?
Causes the air to spin inside the bowl
28
How does contaminates and debris stick to the wall of the bowl and make its way down to the drain?
Centrifugal Force
29
How many ways can a unit drain out contaminate?
-Manually (open valve to drain water)
-Automatically (automatic drain system in FRL)
30
Where does the Air exit through?
A mesh filter 5-40 microns screen)
31
How can you remove the bowl and what should you use to clean it?
-Yes, you can unscrew the bowl
-Use soapy water to clean it
32
When the air pressure is too high or too low, what issues occur?
-not function properly
-cease to function
-cause damage
33
When Fluctuating Pressure is present what problems can occur?
Time Delay Systems can malfunction
34
True or False: air at constant pressure is always given regardless of flow rates and changing loads?
True
35
When you have constant air pressure in your main line, what do you need to install to step down the air pressure to get what you need?
A Regulator
36
What device can you use if the air pressure is too high or too low?
Air Regulator
37
What is the outcome of fluctuating air pressure and how does this happen?
-Time Delays System malfunction
-High pressure fills up the time delay chamber to fast
-Low pressure fills time delay chamber to slow
38
What is the purpose of installing a Time Delay device and how does it work ?
-If you want things to happen in steps or sequence (not all at the same time)
-Air fills a chamber, when it reaches maximum capacity, a door will open for the air to escape
39
How many types of Pressure Regulators are there and what are they?
2 types:
-Direct acting
-Pilot Operated
40
What is this symbol?
Pressure Regulator
41
What is a Balanced-Poppet regulator and how does it work?
-Designed to equalize air pressure on both valve poppet
-Produces better pressure control
-Allows to control load variations better
42
What is the symbol for Oil Lubricator?
A Diamond with a small slit line on the top inside the box
43
From inside the Lubricator, what causes the oil to be extracted out of the oil chamber?
Venturi effect
44
Where should you install your oil Lubricator?
Closes to the actuator or machine you want to operate
45
What is the function of a Water Trap and what is its symbol look like?
-To catch large amounts of water
-Diamond with a straight horizontal line on the bottom end of the diamond
46
What's the difference between a Main Line vs a Pilot line on Pneumatic Symbols and what valves does do they supply?
Main Line: Straight solid line
Pilot Line: Dash lines
Main Line: Carries air that powers machines (4/5 valves, actuators)
Pilot Line:Carries small air that signal valves etc..(3/2 valves, Time Delay)
47
What are the Pressure and Flow of the Main Line?
High Pressure/ High Flow
48
What are the Pressure and Flow of a Pilot Line?
Low Pressure and Low Flow
49
What is the Pressure and Flow of a Drain Line?
Low Pressure and High Flow
50
What are the visual differences between a Pilot Line and a Drain Line when looking at Pneumatic Symbols?
Pilot Line: long dashed lines
Drain Line: short dashed lines
51
What symbol is this?
Connected flow lines
52
What symbol is this?
Hydraulic Line
53
What symbol is this?
Flow lines crossing but not connecting
54
What is this symbol?
Compressor
55
What symbol is the one on the bottom (circle,dot in the middle and straight line )
Pressure Source
56
What is this symbol and what is its function?
-Air Receiver and T junction
-Air Receiver is an air tank that stores air in the tank. Its purpose is to hold air instead of turning in the compressor again and again
57
When installing air lines, why should you install Drop Lines coming up from the main air line feed? What is the purpose of this?
-You branch out the drop line out and up from the mainline then back down to separate water from the main line(water is still in there)
-This prevents water from getting into your tools
58
What is this symbol? Hint, there's 3
Filter,Regulator,Lubricator. FRL
59
What symbol is this?
-Simplified Air Service Unit
OR
-FRL
60
What are the 3 main Pressure Regulators and what are the KEY differences between them?
Pressure Regulator:
-Most common/basic
-Used on light tools/air lines
-Used with FRL
Balanced Poppet Regulator
-More stable version of basic regulator
-More consistent air pressure
-Handles higher flow
-Less pressure drop
-Used on machines that cycle on and off quickly, packaging equipment, automation systems
Pilot Operated Regulator
-Used small pilot air signal to control larger main valves
-Very high flow capacity
-Very stable in pressure
-Used on large pneumatic presses
-plant wide systems
-Bug actuators and high CFM demand
61
Where would you use or find a basic Pressure Regulator?
-Air lines
-FRL
-Small air tools
62
Where would you find a Balanced Poppet Regulator?
Used in places where air pressure stability matters
-Machines that cycle on and off quickly
-Packaging equipment
-Automation Systems
63
Where would you find or use a Pilot Operated Regulator?
-Places that require very high flow capacity (plant wide air systems)
-Large hydraulic presses
-Bug actuators or high CFM demand
64
What symbol is this?
Oil Mist Lubricator
65
What type of oil does an Oil Lubricator usually use and what is the ISO?
-SAE 10W
-ISO 32
66
What does SAE stand for and what does 10 mean and W?
-Society Automotive Engineers(grading system)
-10 is thickness of oil (thinner = lower number) in winter
-W = winter
67
What do you need to install after the air compressor to remove oil in the air that came from the compressor?
-Oil Separator
-Install near the after cooler discharge
68
Where should Lubricators be installed ?
Close to the unit they need to lubricate
69
What does dripping oil in the Lubricator mean?
The Lubricator needs to be adjusted
70
What is this symbol?
Air Dryer
71
What symbol is this?
Cooler
72
Check Valve
-Air direction goes towards the opening of the "V". Cannot come back
73
What is a Directional Control Valve and give an example
-Controls the direction of air
-Decide where air goes
-Controls movement of Actuators
-Can start, stop or reverse motion
Ex:
Single acting cylinders (one movement)
Double acting cylinders (moves forward and back)
74
How many position(s) are the first and second squares?
1 square = 1 Position
2 squares = 2 Positions
75
What does the arrow in a square mean?
Direction of Air flow
76
What does this symbol mean?
-Shut off positions.
-Indicates at lines at right angles
-Air cannot pass through
77
What do the lines outside the box indicate?
-Inlet and Outlet Ports
-Where air enters and exits
78
What is this symbol?
Spring Loaded Check Valve
79
What is the purpose of a Check Valve?
-Allows air to go only one direction
-Prevents Back Flow
-Keeps pressure in a system when flow stops
Ex: Stops air from flow back to compressor
80
How do you know the number of Ports and the number of Positions? How do you write down that number?
-On right box (if there's 2) count each line that goes through the box
-Count both ends of an arrow
-2/2 (2 ports, 2 positions)
81
On 3/2 DCV, which number is the Port and which number is the Positions?
-3 Ports (ports is always first)
-2 Positions
82
How many ports and positions?
2/2
83
How many ports and positions? And is it normally open or closed?
3/2
Normally closed
84
How many ports and positions? Is this normally open or closed?
4/2
Normally open
85
How many ports and position and is the Mid position open or closed?
-5/3 (count ports on the very right side of positions)
-Mid position is closed
86
What symbols is this?
-General Manual Operation
-Symbol tells the operator how it's operated
87
If the push button and the lever are the same functions, why are the symbols all the same?
It shows the operator how the DCV is controlled or used.
88
What is this symbol?
Push Button
89
What is this symbol
Lever Operated
90
What is this symbol and explain how it works with the dent?
-Detent Lever Operated
-Lever stays in the position after pulling it due to the "dent " mechanism
91
What symbol is this?
Foot Pedal
92
What symbol is this?
Spring Return
93
What symbol is this?
Spring Centered
94
What symbol is this?
Roller Operated
95
What symbol is this?
Idler Return Roller
96
What symbol is this and is this mechanical,pneumatic,electrical or combined? And what does it do?
-Pneumatic
-Direct Pneumatic Actuator
-Sends air directly to actuator
97
Why are there different methods of Valve Actuations?
Some situation needs:
-Manual Control (lever)
-Fast Repetitive operation (air)
-Remote Control or Automation(Electrical)
-Safety or Fail Safe Operation
Manual- Human
Pneumatic -Air
Electrical -Solenoid
Combined- Electrical Signal controls Air
98
What symbol is this and is this Mechanical, Pneumatic, Electrical or Combined? And what does it do?
-Indirect Pneumatic Actuation
Pneumatic
-Sends air signal first to a valve or higher airflow system then actuator
99
What symbol is this and is this Mechanical, Pneumatic, Electrical or Combined?
-Pressure Release
-Pneumatic
100
What symbol is this and is this Mechanical, Pneumatic, Electrical or Combined? And what does it do?
-Single Solenoid
-Electrical
-Solenoid shifts the valve allowing air to control actuator
101
What symbol is this and is this Mechanical, Pneumatic, Electrical or Combined?
-Double Solenoid Operation
-Electrical
102
What symbol is this and is this Mechanical, Pneumatic, Electrical or Combined? And what does it do?
-Double Solenoid and Pilot Operation with Manual Override
-Combined
Function:
-Electricity moves the spool one way (not Spring loaded)
-Pilot sends small air to valve
-Actuator is activated
-Manual Override means you can switch the valve for testing without electricity
103
Give 1 example and purpose for Mechanical Valve Actuation
Example- Foot Pedal
Purpose- operator manually controls cylinder
104
Give 1 example and 1 purpose on Pneumatic Valve Actuator
Example: Air Pilot (box with airline ports) moving pneumatic cylinder
Purpose: for fast,repeatable operation
105
Give 1 example and 1 purpose for an Electric Valve Actuator
Example: Solenoid valve controlling Lowerator arm (actuator)
Purpose: controlled by an electrical signal by PLC
106
Give 1 example and 1 purpose on a Combined Valve Actuator.
Example: CNC machine cylinder. PLC sends signal to pilot valves to move cylinder
Purpose: Remote, Precise control of heavy cylinders using both electricity and air
107
Define these two Position Terms for a Valve Actuator:
-NORMAL
-ACTUATED
-NORMAL means the start position is at rest
-ACTUATED means the valve is being operated.
108
Is a Flow Control Valve the same as a Pressure Regulator Valve? Explain.
They are both different:
-Flow Control Valve controls Air/Fluid (controls the air for an actuator)
-Pressure Regulator Valve controls Air pressure levels in the system (reduce high pressure to stable levels)
109
What symbol is this and what does the Curve lines and Arrow lines mean?
-Flow Control Valve (Adjustable
-Curve line means flow restriction
-Arrow line means Adjustable
110
What does this symbol mean?
One Way Flow Control Valve
Level 3
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