AIT 120 - Pneumatic Systems

1. Determine and adjust pneumatic system operating pressure using a regulator.
2. Select and adjust pneumatic actuator speed using a flow control valve.
3. Inspect, drain, and change a pneumatic filter; inspect, fill, and adjust a pneumatic lubricator.
4. Connect, adjust, and disconnect flexible and rigid pneumatic conductors.
5. Startup and shutdown a reciprocating air compressor, and adjust operating pressure using a pressure switch.
6. Install, test, and troubleshoot the operation of components in a basic: pneumatic linear or rotary circuit, and pneumatic circuit that uses vacuum generators (given a schematic for each).

1. Determining/Adjusting Pneumatic System Operating Pressure using a Regulator
   1. Operation of relieving and non-relieving pneumatic regulators
   2. Pressure vs. force/torque output characteristics of cylinders and motors
   3. Pascal’s law (its importance in reading system pressure)
   4. Interpreting/converting between air pressure units of measure
   5. Compressibility characteristics of air; their impact on system operation
   6. Operation of circuits using:
      1. Pneumatic direction control valves with manual and electric operators
      2. Various types of: spool centers, 2-position/3-position, pilot operated, cam-operated, and 2/3/4/5 way designs
   7. Reading a pressure gauge
   8. Manufacturer’s documentation to determine correct operating pressure
   9. Adjusting pneumatic regulator pressure
   10. Operating a branch shutoff valve to enable flow to a system branch
2. Selecting/Adjusting Pneumatic Actuator Speed (Using a Flow Control Valve)
   1. Operation of:
      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 using:
      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
3. Inspecting, Draining, and Changing a Pneumatic Filter
   1. Replacing a cartridge filter
   2. When to replace a filter based on:
      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
4. Inspecting, Filling, and Adjusting a Pneumatic Lubricator
   1. Manufacturer’s 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
5. Connecting, Adjusting, and Disconnecting Flexible and Rigid Pneumatic Conductors
   1. Safety procedures (to make sure pressure is removed before disconnecting conductors)
   2. Attaching/tightening pneumatic:
      1. Steel tubing, using wrenches and ferrule fittings
      2. Fittings to components with threaded ports, using wrenches and thread sealant when appropriate
      3. Hose, using wrenches and strait-thread, barb, ferrule, and push-on fittings
   3. Adjusting the 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
6. Startup/Shutdown a Reciprocating Air Compressor, and Adjusting Operating Pressure Using a Pressure Switch
   1. Calculating air consumption from a receiver (given a pressure change)
   2. Interpreting/converting between air flow rate units
   3. Start up an air compressor system safely (including pre-start inspection)
   4. Shut down and drain a reciprocating air compressor system safely
   5. Operating manual valves to direct system flow
   6. Manufacturer’s documentation to determine correct operating pressure
   7. Adjusting system operating pressure using a pressure switch
   8. Adjusting working pressure with a regulator
7. Installing, Testing the Operation of Components in a Basic Pneumatic Linear or Rotary Circuit (Given a Schematic)
   1. Installing/connecting pneumatic components in basic functional circuit (given a schematic)
   2. Replacing subplate-mounted directional valve in a pneumatic system
   3. Replacing a threaded port valve
   4. Mounting/aligning a pneumatic cylinder or a motor
   5. Operating a pneumatic system to determine that it is performing correctly
   6. Types of cylinder and motor mounting methods and their applications
8. Installing, Testing the Operation of Components in a Basic Pneumatic Circuit That Uses Vacuum Generators (Given a Schematic)
   1. Interpreting vacuum units of measurement
   2. Pascal’s law (in relation to vacuum)
   3. Calculating lifting force of a vacuum cup (given vacuum level and manufacturer’s data)
   4. Common hose types, fittings, and sealants used in vacuum applications
   5. Identification of vacuum system and safeguards
   6. Installing/connecting a vacuum generator and vacuum cups
9. Troubleshooting a Basic Pneumatic Linear or Rotary Actuator Circuit
   1. Basic components in a pneumatic circuit using in-circuit tests troubleshooting
   2. Flow and pressure instruments (to take pneumatic circuit readings during in-circuit testing)
   3. Flow vs. pressure drop characteristics of pneumatic components and conductors, and their impact on system operation
   4. Systematic methodologies to troubleshoot basic pneumatic circuits with linear and rotary actuators
   5. Types of failures of basic pneumatic components