AIT 120 - Pneumatic Systems

1. Interpret pneumatic schematics, including identification of schematic symbols, process flow, and operation of the components and systems.
2. Operate a pneumatic system, including adjustment of pneumatic pressure control valves in the given hydraulic systems.
3. Perform maintenance of pneumatic components, including inspection, removal, and replacement.
4. Install components of pneumatic systems.
5. Test components of pneumatic systems.
6. Troubleshoot malfunctioning components of pneumatic systems.

1. I. Interpreting schematic(s) and component symbols
   1. National Fluid Power Association (NFPA) schematic symbols
   2. International Organization for Standardization (ISO) schematic symbols
2. Operating a pneumatic system
   1. Determining/adjusting pneumatic system operating pressure using a regulator
   2. Operation of relieving and non-relieving pneumatic regulators
   3. Pressure vs. force/torque output characteristics of cylinders and motors
   4. Pascal`s law and reading system pressure
   5. Interpreting and converting air pressure units of measure
   6. Compressibility characteristics of air and their impact on system operation
   7. Operation of circuits
      1. Pneumatic directional control valves with manual and electric operators
      2. Directional control valve types
         1. Spool centers
         2. 2-position
         3. 3-position
         4. Pilot operated
         5. Cam-operated
      3. Directional valve port configurations       
   8. Reading a pressure gauge
   9. Adjusting pneumatic regulator pressure 
   10. Manufacturers’ documentation to determine correct operating pressure
   11. Operation of a branch shutoff valve to enable flow to a system branch
3. Selecting and adjusting pneumatic actuator speed using a flow control valve
   1. Operation
      1. Needle valve
      2. Flow control valve
      3. Meter-in circuits
      4. Meter-out circuits
   2. Flow vs. speed characteristics of a pneumatic cylinder and a motor
   3. Effect of system pressure on pneumatic actuator speed
   4. Adjusting actuator speed
      1. Needle valve
      2. Flow control valve
      3. Manifold mounted flow control valves
   5. Adjusting flow control valves in meter-in/meter out configurations
   6. Measuring actuator speed
4. IV. Inspecting, draining, and changing a pneumatic filter
   1. Replacing a cartridge filter
   2. When to replace a filter
      1. Inspection
      2. Pressure differential
      3. Manufacturer`s recommendations
   3. Interpreting filter specifications/models to determine correct filter
   4. Manufacturer`s documentation to determine frequency of change
   5. Operating the drain on a pneumatic filter
   6. Operating water removal systems on a pneumatic filter
   7. Recognizing symptoms of excessive water in a compressed air system
   8. Manifold types, construction and purposes
   9. Dryers types, construction and purpose
5. Inspecting, filling, and adjusting a pneumatic lubricator
   1. Manufacturers’ documentation to determine correct lubricant
   2. Proper lubricating media definition
   3. Inspecting fluid level in a lubricator
   4. Adding lubricating oil to a lubricator
   5. Setting lubrication rate on a lubricator
6. Connecting, adjusting, and disconnecting flexible and rigid pneumatic conductors
   1. Safety procedures for pressure removal before disconnecting conductors
   2. Attaching/tightening
      1. Steel tubing
         1. Various wrench types
         2. Ferrule fittings
      2. Fittings to components
         1. Threaded and unthreaded ports
         2. Appropriate wrenches 
         3. Appropriate sealant use 
         4. Appropriate O-ring use
      3. Hose fittings
         1. Wrenches and straight-thread
         2. Barb
         3. Ferrule
         4. Push-on 
   3. Position/alignment of conductors for proper operation
   4. Interpreting pipe, hose, and tubing specifications
   5. Identification of type and size of hose, tubing, and fittings (given a sample)
   6. Identification of fittings and application (given a sample) and limitations for use of each
7. Operating an air compressor
   1. Types of air compressors
   2. Calculating air consumption from a receiver given a pressure change
   3. Interpreting/converting between air flow rate units
   4. Safe start up of an air compressor system, including pre-start inspection
   5. Safe shut down and drainage of a reciprocating air compressor system
   6. Operating manual valves to direct system flow
   7. Manufacturer`s documentation to determine correct operating pressure
   8. Adjusting the cut in and cut out pressure switch for system pressure
   9. Adjusting working pressure with a regulator
8. Installation and testing of basic pneumatic linear or rotary circuits 
   1. Installing and connecting pneumatic components in basic functional circuits given a schematic
   2. Replacing subplate-mounted directional valve in a pneumatic system
   3. Replacing a threaded port valve
   4. Mounting and aligning a pneumatic cylinder or a motor 
   5. Testing a pneumatic system to determine that it is performing correctly
   6. Types of cylinder and motor mounting methods and their applications
9. Installation and testing of basic pneumatic circuits that use vacuum generators
   1. Installing and connecting a vacuum generator and vacuum cups given a schematic
   2. Interpreting vacuum units of measurement
   3. Pascal’s law in relation to vacuum
   4. Calculating lifting force of a vacuum cup given vacuum level and manufacturer`s data
   5. Common hose types, fittings, and sealants used in vacuum applications
   6. Types of vacuum systems and safeguards
10. Troubleshooting basic pneumatic linear or rotary circuits
    1. Basic components
    2. In-circuit troubleshooting tests
    3. Flow and pressure instruments to take readings during in-circuit testing
    4. Flow vs. pressure
       1. Drop characteristics of pneumatic components and conductors
       2. System operation impact
    5. Systematic methodologies
    6. Types of failures of basic pneumatic components