published s eptember 12, 20 maintenance tips - flui
TRANSCRIPT
Published S
© Valmet
MaiExecutPneumatipulp, papefluids con
There are thousandsmachine rcontrol cabuilding l
This whitetips and e
September 12, 20
intentive Summic and hydrauer, board or ti
ntrol devices.
hundreds of s of pneumatiroom. They aabinets and paocation.
e paper presextensive trou
014
ance mary ulic controls pissue machin
different fluidic and hydraure housed in fanels. In some
nts safety andbleshooting c
Mainten
Tips
perform a vitae. Improved p
ds control cirulic control defloor mountee cases, they a
d general remcharts.
nance Tips - Flui
– Flu
al role in literaprocess efficie
rcuits on a typevices. The co
ed control benare also surfac
minders for flu
ds
uids
ally every opeency results fr
pical paper montrol devicesnchboards, frace mounted t
uids maintena
erational contfrom proper m
achine, usings are located eame mountedto nearby fram
ance, as well a
P
trol function omaintenance o
g literally everywhere ind and auxiliarming or a suit
as some practi
age | 1
of a of
n the ry table
ical
Published S
© Valmet
SafetyOnly trainthe machiapplicableprocedure
• As a gstartin
• Never
• Befor
• Beforsecure
• Alway
Next, repair
After starteare nofuses.
• Alwaythe m
• Verifypipeli
• Use a
• Avoid
• Befor
- Ifac
- C
• Use arequir
• Do noimpur
September 12, 20
y and genned personneine being wore sections in tes.
general rule, bng maintenan
r by-pass safe
e shutting do
e depressurized.
ys begin a hyd
close the appr).
stopping the rs for the eleco lockable moNever remov
ys begin pneumill air supply.
y that there isines, or actuat
ppropriate to
d spilling oil o
e removing a
f a valve has mctuator. Bleed
Close the shut-
ppropriate gared.
ot use cotton rities out. Alw
014
eral pracl should perfo
rked on (safethe relevant eq
both hydraulince or repair w
ty features, su
wn the system
zing circuits, m
draulic system
plicable isolati
pumps, and bctric motors sotor starters, rve someone el
umatic system. Next, bleed t
s no pressure tors which ne
ools and meth
on the floor. C
valve:
manual overrid off pressure
-off valve to t
askets or suita
rags or other ways pay atten
Mainten
tice remiorm maintenaty issues, desigquipment ope
c and pneumwork on any f
uch as guards
m, familiarize
make sure tha
m shutdown b
ion valves in t
before startinso that there isremove the mlse's lock-out
m shutdown bytrapped air fr
in the systemeed to be depr
hods for repair
Clean up any
ide controls, rrepeatedly in
he valve pane
able sealing co
lint cloth. Wntion to clean
nance Tips - Flui
nders ance or add ngn and operaterating and m
atic systems mfluid system.
or interlocks
yourself with
at all loads are
by stopping th
the system (b
ng any maintes no chance o
motor fuses. Putags.
y closing the om the circui
m, such as in pressurized.
r and mainten
oil spills imm
release any remn both directio
el.
ompound to s
hen changingnliness when s
ds
new devices. Ttion, and con
maintenance m
must be locke
s.
h the mill's loc
e in the lower
he pumps.
before perform
enance or repaof anyone acciut your name
hand valve wit.
ressure accum
nance work.
mediately.
maining presons.
seal threaded
g a cylinder, pservicing hyd
This includes ntrol circuits).manuals as we
ed out and de
ck out proced
red position o
ming the main
air work, lockidentally start
e on secured l
which isolates
mulators, air r
ssure between
connections
plug hose endraulic or pneu
P
familiarity w. Refer to ell as mill
pressurized b
dures.
or are mechan
ntenance or
k the motor ting them. If tocks and rem
the system fro
receivers,
n the valve and
in the system
ds to keep umatic system
age | 2
with
before
nically
there moved
om
d
m, as
ms.
Published S
© Valmet
• Re-tigfinishtight.
• Beforother pump
• BeforSystem
• Once systempressu
WARNI
• Makeand cl
• Keep
Genera
FamiliaWhen troand the restudy the
Once youmalfuncti
PressurAlways ch
If a specifthe system
September 12, 20
ghten disconnhing the maint
Re-tighten as
e energizing tmaintenance
ps, maintain a
e opening isom pressurizat
the system ism may need toure.
NG:
Hydrfor h(i.e., or ai
e sure that all lean.
instrument b
al trouble
rity with Coubleshootingelationships bcircuit diagra
have a full union by checkin
re Settingsheck the opera
fication is unam, without exc
014
nected pipe antenance works necessary.
the system, me work is in pra safe distance
olation valves,tion may caus
s pressurized, o be depressu
raulic and phydraulic or
wood, cardir under the
signs and not
boxes and cab
eshooting
Circuits g fluid circuitsbetween themams and the fl
nderstandingng the perform
s ating pressure
available, set tceeding the m
Mainten
nd hose couplk, verify that a
make sure thatrogress. Nevee from the are
, make sure thse machine co
test the repaiurized again to
pneumatic sr pneumaticdboard, etc.e skin. Seek
tices attached
inets closed.
g principl
s, it is importa. Therefore, t
fluid section o
g of a malfuncmance of each
es first. Some
the pressure tmaximum rati
nance Tips - Flui
lings immediall connection
t no one else ier remove anyeas where mai
hat no one is womponents to
ired componeo repair them
systems arec leaks with.) to avoid r
k emergency
to the machi
es
ant to have a fhe first step in
of the equipm
ctioning circuh component
pressure sett
o the lowest ling of the com
ds
iately after mans that have b
is in the viciniyone else's locintenance or
working betwo move unexp
ent. Check form. Do not tigh
e under high your handrisk of injecy help for a
ine or instrum
full understann troubleshoo
ment's mainten
uit, you can bet.
tings are speci
level that will mponents.
aintenance woeen serviced o
ity of the macck-out tags. Wrepair work t
ween the machpectedly.
r leaks. If anyhten leaky fitti
h pressure.s. Use anot
ction of hydany injuries.
ment compon
nding of all cioting any circnance manual
egin to isolate
ified on the c
allow adequa
P
ork. Prior to or repaired ar
chine, and noWhen starting took place.
hine compon
y are found, things under
. Do not testher materiaraulic fluid .
nents are in pl
ircuit componcuit should bel.
e the cause of
ircuit diagram
ate performan
age | 3
re
o the
ents.
he
st al
lace
nents e to
the
ms.
nce of
Published S
© Valmet
ElectricMost fluidmode reqtext assocde-energideterminehave not bcheck the
TroubleTrouble ishow to recguidelines
• Excesoperaintern
• Typicfault itempe
• Excescause viscos
Compon• If the
comp
If the actuwork towa
• New v
• On cohydra
HydrauA hydrauldirectiona
If there arnot drift, y
September 12, 20
al Controlsd circuits havuires that theiated with eaczed. This infoe whether all tbeen met, or ofluid compon
e Indications indicated whcognize troubs for recogniz
ssive heat meaation at relief vnal leakage of
cally, if oil temis found, locaeratures of dif
ssive noise coua relief valve
sity, low reser
nent Replaactuator has
ponents.
uator does notard the actuat
valves must b
omputerized saulic operatin
ulic drift tlic cylinder isal valve is leak
re shutoff valvyou might ass
014
s e at least two solenoid valvch circuit diagormation, comthe conditionother controlsnents themsel
ns henever circuble is to becomzing trouble in
ans trouble. Avalve setting.
f components
mperature excte and replacefferent device
uld mean weato stick or ch
rvoir level, or
acement Nofailed, start tr
t receive suffitor.
be adjusted an
systems, use tg problems.
troublesh experiencing
king. How can
ves on the cylisume that the
Mainten
operating moves in the circgram explains
mbined with tns have been ms are malfunclves.
uit performanme familiar wndications are
A warmer thanHydraulic fluand increase
ceeds 140 °F (6e any devices es to detect m
ar, misalignmhatter. These n
leaking suctio
otes roubleshootin
icient oil flow
nd locked or tu
the help and m
hooting tg drifting undn you tell whi
inder, you coe piston seals
nance Tips - Flui
odes (i.e.: extecuit be in a sps which valvethe applicablemet for a partctioning, corre
ce deviates frwith the norma
e as follows:
n normal tankuids which hathe heat rise.
60 °C), checkshowing redu
major leaks.
ment, cavitationoises may beon or pressur
ng from the ac
w or pressure,
uned to the se
maintenance
tips der load. You ich one is the
uld shut bothare OK.
ds
end/retract orpecific state (ees should be ee electrical draticular operatiect that probl
rom normal. Aal operation o
k return line oave too low a v.
k the cooling suced volumet
on, or air in the the result ofre lines.
ctuator and w
start troubles
ettings given
screens to loc
suspect the pproblem?
h of them. If y
r raise/lower)energized or denergized andawings shoulding mode. If tlem first, and
As a result, thof each circuit
on a relief valviscosity will
system. If no ctric efficiency
he fluid. Contf contaminati
work toward t
shooting at th
for the positi
cate and ident
piston seal and
you observe th
P
). Each operatde-energized)d which shouldd help you the condition then proceed
he best way tot. Some gener
lve indicates increase the
cooling systemy. Monitor the
aminated fluiion, excessive
the power uni
he power unit
on concerned
tify possible
d/or the
hat the load d
age | 4
ting . The d be
ns d to
learn ral
m e
id can
it
and
d.
does
Published S
© Valmet
However,fluid flowsupply preforce that
Another tpressure darea or oil
CC hydThese tipslatest train
Controllepumps to pumps to return oil The follow
The pumThe pumpthe rotatio
The driveRepair as
Intake pipproper vis
Figure 1. lead to pproductio
September 12, 20
even if the piws from the hig
essure was. Eqholds the loa
thing to checkdrop with no l lines for war
draulic uns are excerptening offerings
d Crown roll control shell lubricate sheto the hydrau
wing are troub
mp is not dp may be drivon of the pum
e shaft is broknecessary.
pe is blockedscosity. Filter
Hydraulic unit foor quality and on.
014
iston seals wegh to low prequal pressure
ad in place. So
k if the cylindwork taking prm oil.
nit troubleed from Valms, contact Ric
hydraulic undeflection th
ell load shoes, ulic unit. Pumbleshooting ti
delivering fven in the wr
mp as indicate
ken or the sha
d or the oil visthe oil as reco
failures lost
Mainten
ere totally gonssure side of t
es on unequal o the cylinder
der is suspect iplace, heat is g
eshootingmet training se
k Heitke at ri
nits (Figure 1)rough hydrodrotating bear
mp failures wiips to keep yo
fluid properong directioned by the arro
aft key is she
scosity is too ommended. C
in the reserv
Intake has a
The pump ithe air until
Fluid level iopening of tsure that it i
The hydraRelief valvevalve.
Worn pumthe rotor setexamination
nance Tips - Flui
ne, the load wthe piston andareas (cap encould still be
is temperaturgenerated. Th
g tips essions for opeichard.heitke@
) have pumpsdynamic or hrings and to cill lead to prodour CC roll hy
erly. n of rotationw on the pum
ared. Remove
heavy to primCheck the filtvoir.
air leaks. Che
is not priminl hydraulic flu
is too low. Ththe intake pipis filled to the
aulic systee is set too low
mp parts are cats and take thn of the pump
ds
would still not d equalizes at
nd greater thae the problem
re of the cylinherefore, you
erators and [email protected]
s for three mahydrostatic loacontrol tempeduct quality dydraulic units
n. Stop the pummp body.
e the pump fr
me. Drain theter for cleanlin
eck the intake
ng. Loose conuid flows.
he reservoir flpe. Check thee proper level
em pressurw. Use a press
ausing extremhe required cop parts.
drift. The reat some pressuan rod end are
m.
nder. Wherevecan feel the c
maintenance pm.
ain functions: ad shoe bearinerature; and scdefects and prs running reli
mp to preven
rom its moun
e system. Addness. Check th
e connections
nnection in th
fluid level muse system on st.
re is too lowsure gauge to
me internal leorrective steps
P
ason for this iure higher thaea), results in
er there is a lecylinder pisto
personnel. Fo
high-pressurngs; lubricatiocavenger pumroduction losiably.
nt seizure. Che
nting and insp
d clean fluid ohe oil temper
s. Tighten sec
he outlet line.
st be above thart up to mak
w. o adjust the re
eakage. Replas after
age | 5
is an the n a
eak or n
r the
re on
mps to s.
eck
pect.
of the rature
urely.
Bleed
he ke
elief
ace
Published S
© Valmet
The pumThe intakoccurs. Dproperly.
The pump
Air leaks listening ffor scorin
Drive for
The coupshafts. All
The pumThe seal i
There is edrained ppressure.
The pumToo muchwith the m
The fluidinlet line a
Notice: Mto a great
The hydThe reservand makecover platinspectingon keepinthe cover
The reservthe oil conthe roll beand inspefrequently
September 12, 20
mp is makike strainer/pirain the syste
p has defectiv
at the pump for a change i
ng at the seals
the pump is
pling is misalilowable misal
mp shaft seis worn or da
excessive presumps. Intern
mp has exch thrust on thmotor shaft. T
temperatureand reservoir
Maintenance oextent on the
draulic unitvoir (Figure 2
es up part of thte, which shoug or refilling.
ng contaminatplate remove
voir for the untained in thee completely dcted for corroy as needed.
014
ng excessiipe is cloggedm, clean the p
ve bearings. R
intake pipe jin sound. Tighand replace a
wrong. Make
igned. Check lignment is .0
eal is leakiamaged. Repla
ssure on the snal drain pum
cessive heahe pump bea
The shaft end
e is too high. temperature
on the hydraue timely attent
t reservoir 2) is usually thhe frameworkuld be kept inThe life of antes out of the
ed.
nit must be lae roll if there idrained. The osion and oth
Mainten
ive noise.d or restrictedpipes and clea
Replace the b
joints or shafhten the jointas necessary.
e sure that the
the bearing o005 inch.
ing. ace the seals.
seals. Check fps should be
at (> 400 °Farings. The pu
gap should b
The pump shs. If the pump
lic system andtion that the f
he largest itemk. The reservo
n place exceptny hydraulic sy
oil. This is ha
arge enough tis a situation reservoir sho
her damage ye
nance Tips - Flui
d. The pump an or replace
earings and in
ft seal. Pour flts and replace
e motor is run
or bushings an
for restrictiondrained to th
F, 205 °C) ump shaft mue 1/8-inch mi
hould be shut p is excessivel
d roll dependfilters receive
m on the unitoir contains at when ystem dependard to do with
to handle all othat requires uld be cleane
early, or more
ds
must receive the strainer. A
nspect the pu
fluid on the pie seals as nece
nning at the c
nd seals. Repl
ns or excessivhe inlet side w
compared ust not be out inimum.
down immedly hot, it shou
d e.
t a
ds h
of
ed e
Figurese
intake fluid fAdd new flui
ump shaft.
ipe joints andessary. Check
correct speed.
lace as necess
ve length of linwith no more t
with the hof line more
diately after culd be overhau
ure 2. Clean andervoir for corrosi
P
freely or cavitd and strain
d shaft seal whthe shaft jour
.
sary and align
ne on externathan 10-psi
hydraulic lithan .005 inc
comparing puuled.
d inspect hydrauion annually.
age | 6
tation
hile rnal
n the
ally
ines. ch
ump,
ulic
Published S
© Valmet
ElevatHydraulicdevelop p
Most hydtemperatuoil. Thesefilters. Whincrease inhours to 1
Some sou
• prco
• w• la• pl• to• le• pl• ai
Oil shouldkeep the o
Case Sand eliThe hydranorthern that the m
The mill cpath forwonly werepress loadwas of thehelped to other presconsidere
A Valmetand relatepress and upgrade n
September 12, 20
ed tempecs are used throblems. One
raulic systemure exceeds 14 deposits can hen this occun oil tempera10,000 hours -
rces of high o
ressure drop ontrol valve, l
worn out pumack of coolinglugged heat eoo many bendeaking cylindelugged filters ir in oil
d be tested peoil clean, cool
Study - Coiminates aulic press loaUSA were du
model they nee
called in Valmward. It was noe the valves ofding control sye same vintageraise the next
ss loading comd for upgrade
engineer exped controls ca
help to deternecessary for t
014
erature trroughout thee such problem
s (except hot 40-160 °F (60get stuck in trs over an ext
ature, oxidatio- an order of m
oil temperatur
that is not peleaking directp
g capacity xchanger
ds in piping er piston seals
eriodically to dl and dry to ge
ontrols upobsolesc
ading valves iue for replacemeded was now
met to help deoted in discusf 1970's vintagystem for thee (Figure 3). t logical questmponents thae?
perienced in pame to the milrmine the scopthe machine's
Mainten
roublesho papermakingm is elevated
oil calenders0-70 °C), oxidthe small orifitended periodon rate doublemagnitude dr
re include:
rforming anytional valve)
s
determine theet the longest
pgrade imcence
n the manifolment. But whw obsolete and
etermine a goossions that noge, but the ente paper machiThat realizatition, were the
at should be
press sections ll to examine pe of the s press loadin
nance Tips - Flui
ooting tipg operation. Toil temperatu
) should run ation and varices of propord, the oil will nes and the serrop in oil lifet
y work (pressu
e condition ooil life possib
mproves p
ld located in then mill storesd no longer av
od t tire ine ion ere
the
ng
Figand
ds
ps They are veryure.
at about 120 °rnishing occurtional valvesneed to be reprvice life of thtime.
ure relief valv
f the oil. The ble.
performan
the basements went to purcvailable. Now
gure 3. The pressd malfunctionin
y reliable but o
°F (50 °C). Wur with resultis, directional vplaced. For ev
hat oil can go
ve, pressure co
goal of hydra
nce and r
t below a papechase new val
w what?
s section at the ng 1970's era co
P
occasionally
When the oil ng deposits invalves and oilvery 18 degrefrom 100,000
ontrol valve, f
aulic systems
reliability
er machine inlves, they fou
mill included obntrols.
age | 7
n the l es
0
flow
is to
y,
n the nd
bsolete
Published S
© Valmet
hydraulicvalves, the
Machine ohydraulic hydraulic
Due to limobtained. loading tosheet breaset point wcapabilitie
The soluAfter furthcompletinand troubthe latest
The mill hscreens ofsystem wa
The mill cup to 4 horeadily donow easy loop contr
Overall, mthe mainthappy ope
Figure 4. (right) pa
September 12, 20
s. The mill me mill would o
operators wercontrol systecontrol syste
mitations of thAlso, during
o the presses, aks. The operawould not remes.
ution – a hher analysis a
ng the upgradbleshooting mcontrol techn
has a new Huffering operatas also installe
changed out aours or more, one and reliabto troubleshorol and the m
mill personneltenance manaerators and m
The original (lefanel.
014
aintenance monly "be doin
re having a nuem. Not only wem was quite o
he existing comachine starthe former stators were formain steady. I
hydraulic coand discussionde, a new customuch easier. Anology and saf
man/Machintors enhanceded for the ma
a sticky propotook less than
ble. Breaks duoot, thus redu
mill has set a p
l are very hapager, the equipmaintenance p
ft) valve panel w
Mainten
manager expreg half the job
umber of probwere the valveobsolete as we
ontrol system,rt-up, when thretcher pressurced to make In addition, th
ontrols upgn with the miom valve rack
All obsolete cofety features.
e Interface cod and simplifinifold supply
ortional valve n 40 minutes
ue to stretcherucing down tim
roduction rec
ppy with the repment is easiepersonnel!
was replaced wi
nance Tips - Flui
essed concern."
blems that coes obsolete (Fell.
, proper and rhe operators hure would decontinuous ahe 1970's era
grade ill, Valmet upk (Figure 4, riomponents ha
ontrol featurinied control of y oil to ensure
after the upg. Nip impress
r unloading hame. Press loadcord after the
esults of the uer to access, o
ith a modern
ds
n that by simp
ould be directlFigure 4, left)
reliable nip imhad the formecrease causin
adjustments tocontrol system
graded the hyight) is in pla
ave been upgr
ng first-out lof the system (Fe a good clean
grade and the sions of the vaave been elimding is now st
e upgrade was
upgrade to thoperate and m
Figure 5.include aand monthe right
ply replacing t
ly linked to th) but the exist
mpressions coer running an
ng instability io the press lom had no tro
ydraulic contrace that makeraded to curre
ogic and user Figure 5). A d
n supply of oil
procedure wharious press n
minated and thteadily runnins installed.
eir press sectimaintain – and
. The new HMI ca comprehensivnitoring screens t.
P
the hydraulic
he 1970's era pting original
ould not be nd then appliein the system adings becauubleshooting
rol system. Aes maintenancent models wi
friendly contduplex filter l.
hich used to tnips are now he entire systeng with close
ion. Accordind that makes f
control panels (lve set of machine
such as that sh
age | 8
press
ed and se the
g
fter ce ith
trol
take
em is d
ng to for
left) e control own on
Published S
© Valmet
HydrauThe followlisted for eassociated
AbnormSource/S
Pump
Motor
Mechanivibration
Relief va
September 12, 20
ulic Troubwing troubleseach type of t
d cause.
mal/ExcessSymptom
ical ns
alve
014
bleshootihooting guid
trouble. Cause
ive Noise Possible P
• Cavita
• Air in
• Coupl
• Pump • Coupl
loose • Motor • Misali
• Vibrat
• Impro
• Valve
Mainten
ing Chartes cover five ces are listed in
Problem
ation
n fluid
ling
p worn or dam
ling misaligne
r worn or dam
igned, loose c
tion of pipes
oper setting
worn or dam
nance Tips - Flui
ts categories of tn order of pro
R
••••
••••
••
maged •
ed or ••
maged •
coupling •
•
•
maged •
ds
trouble. Possiobability; rem
Recommende
Replace di Clean clog Clean rese Change to
speed.
Tighten le Fill reserv Bleed air f Replace pu
Tighten co Check con
Repair or
Re-align c Check con
Repair or
Re-align cunnecessa
Tighten piclamps wh
Install precorrect valsetting is npressure o
Repair or
ible causes anmedies are liste
d Action
irty strainers.gged inlet lineervoir breatheo proper pum
eaky inlet convoir to proper from system. ump shaft sea
oupling. ndition of sea
replace.
coupling. ndition.
replace.
coupling and rary clearancesipe clamps anhere necessary
essure gauge alve setting prnot too close tor to another v
replace.
P
nd remedies aed adjacent to
e. er vent. p drive moto
nnection. level.
al.
als and bearing
remove any s. nd add more y.
and adjust to essure. Make to operating valve setting.
age | 9
are o the
r
gs.
sure
Published S
© Valmet
ExcessivSource/S
Pump Relief
Flow lospressuresides Insuffici
Tank He
Viscosity
IncorrecSource/S
No flow
September 12, 20
ve Heat Symptom
ses between and return
ent cooling
eater
y too low
ct Flow Symptom
014
Possible P
• Pump • Incorr
• Pressu• Defec
damag • Coolin
unava• Depos
system • Heate
• Oil da• Water • Impro
Possible P
• Pump
• Pump • Pump
• Pump
incorr
Mainten
Problem
p worn or dam
rect setting
ure set improptive valve funged seals
ng water systeailable sits in cooling
m
er on too muc
amaged r contaminati
oper oil
Problem
p not receiving
p motor not o
p-to-drive
p motor rotatirect
nance Tips - Flui
R
maged •
•
perly •nction or •
em •
g water •
ch ••
ion ••
•
R
g fluid •••
perating •
••
ion •
ds
Recommende
Repair or
Install precorrect set
Set pressu Repair or
Make cool
Clean cooequipmen
Check pro Check disc
Drain and Find and r
and refill w Drain and
Recommende
Replace di Clean clog Clean rese
Repair or
Check for Replace an
Reverse ro
d Action
replace.
essure gauge atting pressure
ure to the diagreplace.
ling water ava
oling water strnt.
ogram for proconnect for p
d refill with frerepair water swith fresh oil
d refill with fre
d Action
irty strainers.gged inlet lineervoir breathe
replace.
damaged pumnd align shear
otation.
Pag
and adjust to e.
gram rating.
ailable.
rainer and
oper commanproper operati
esh oil source then d. esh oil.
e. er vent.
mp or drive.red coupling.
ge | 10
nd. ion.
rain
Published S
© Valmet
Incorrec
Source/S
Low flow
Excess fl
Flow lospressuresides
September 12, 20
ct Flow (cont.
Symptom
w
low
ses between and return
014
):
Possible P
• Directpositio
• Entire • Dama
• Flow c • Relief
valve s • Variab
mecha • Flow c • Maxim
high • Pressu
due topartic
• Cylind
seal da • Seal d
incom
Mainten
Problem
tional valve inon
e flow passing
aged pump
control set to
f valve or unloset too low
ble displacemanism malfun
control set to
mum pressure
ure valve canno dirt or foreigles
der tube, pistoamaged
damaged due tmpatible mate
nance Tips - Flui
R
n wrong •
•
g •
••
o low •
oading •
ment nctioning
••
o high •
e set too •
not close gn
••
on, or •
to rials
•
ds
Recommende
Check posvalves.
Check elecoperated v
Adjust rel
Check for Replace an
Adjust.
Adjust.
Check pum Repair or
Adjust.
Re-adjust
Clean syst Repair or
Repair or
Replace sethe hydrau
d Action
sition of man
ctrical circuitvalves.
ief valve over
damaged pumnd align coup
mp compensareplace.
pressure setti
tem. replace parts.
replace dama
eals that fit thulic fluids to f
Pag
ually-operate
t for solenoid-
r relief valve s
mp or drive.pling.
ator.
ing per diagra
.
aged part.
e system or chfit the seals.
ge | 11
ed
-
etting.
am.
hange
Published S
© Valmet
IncorrecSource/S
No press
Low Pre
September 12, 20
ct PressureSymptom
sure
ssure
014
e Possible P
• Dirty
• Pump • Pump
sheare • Pump
incorr • Direct
positio
• Entire
relief v • Dama
• Reduc • Reduc
damag • Relief
valve s • Variab
mecha • Pump
cylindcompo
• Water
Mainten
Problem
pump straine
p motor not o
p-to-drive coued
p motor rotatirect
tional valve inon
e flow passingvalves
aged pump
cing valve set
cing valve woged
f valve or unloset too low
ble displacemanism malfun
p, valve, motoder, or other onent worn/d
r contaminati
nance Tips - Flui
R
ers ••
perating •
upling •
ion •
n wrong •
•
g over •
••
too low •
rn or •
oading •
ment nctioning
••
r,
damaged
•
ion •
ds
Recommende
Replace. Clean clog
Repair or
Replace an
Reverse ro
Check posvalves.
Check elecoperated v
Adjust rel
Check for Replace an
Adjust.
Repair or
Adjust.
Check pum Repair or
Repair or
Drain, flus
d Action
gged inlet line
replace.
nd align coup
otation.
sition of man
ctrical circuitvalves.
ief valve settin
damaged pumnd align coup
replace.
mp compensareplace.
replace.
sh and refill.
Pag
e.
pling.
ually-operate
t for solenoid-
ng.
mp or drive.pling.
ator.
ge | 12
ed
-
Published S
© Valmet
Incorrec
Source/S
Erratic
Excess p
Faulty O
Source/S
No move
Slow mo
September 12, 20
ct Pressure (co
Symptom
ressure
Operation Symptom
ement
ovement
014
ont.):
Possible P
• Air in
• Reduc
unload • Variab
mecha
Possible P
• No pr
• Limit
deviceimpro
• Mecha
operat • Cylind • Low fl
• Fluid
• Insuff
• Lack o • Cylind
Mainten
Problem
n fluid
cing valve or ding valve set
ble displacemanism
Problem
ressure or flow
device / seque inoperative operly set.
anical bind nting
der or motor
flow
viscosity too
ficient pressur
of lubricant
der or motor
nance Tips - Flui
R
•••
t too high •
ment ••
R
w •
uence or
•
•
ot •
damaged •
•
high •••
re •
•
damaged •
ds
Recommende
Tighten le Fill reserv Bleed air f
Adjust.
Check pum Repair or
Recommende
See troublflow and i
Check mehydraulic
Adjust, rep
Locate and
Repair or
See troublflow.
Fluid may Check hea Change to
See troublpressure.
Lubricate
Repair or
d Action
eaky connectivoir to proper from system.
mp compensareplace malfu
d Action
leshooting guincorrect pre
echanical, eleclimits and seqpair, or replac
d repair bind.
replace.
leshooting gu
y be too cold oating/cooling o clean fluid o
leshooting gu
machine way
replace.
Pag
ons. level.
ator. unctioning un
uides for incoressure.
ctrical and/or quence devicece.
.
uide for incorr
or dirty. system.
of correct visc
uide for incorr
ys or linkage.
ge | 13
nit.
rrect
es.
rect
cosity.
rect
Published S
© Valmet
Faulty O
Source/S
Erratic m
FoaminSource/S
Tank Suction Impropedegraded
DirectioSource/S
Coil not
Valve sp
September 12, 20
Operation (con
Symptom
movements
g Oil Symptom
line
er or d oil
onal ControSymptom
picking up
ool stuck
014
nt.):
Possible P
• Errati
• Air in • Impro
Possible P
• Oil lev • Crack
line • Inade
agent
ol Valve PoPossible P
• Electr
• Impur
and bo
• Throt
betwevalve osoleno
Mainten
Problem
c flow
n oil
oper pressure
Problem
vel in tank too
ked or leaking
quate anti-fo
osition notProblem
ric failure
rities betweenore
ttle set too tigheen the main aof the two coioid valve
nance Tips - Flui
R
•
•
•
R
o low •
g suction •
aming •
t ChangingR
•
n spool •
ht and pilot il
•
ds
Recommende
See troublflow.
See troubl
See troublpressure.
Recommende
• Add oil as
• Repair or
• Replace w
Recommende
Fix electrispool mot
Replace va
Set the thr
d Action
leshooting gu
leshooting gu
leshooting gu
d Action
s required.
replace.
with proper oil
d Action
c failure and tion.
alve if necessa
rottle at the co
Pag
uide for incorr
uide for air in
uide for incorr
l.
check mecha
ary.
orrect rating
ge | 14
rect
oil.
rect
nical
Published S
© Valmet
Directio
Source/S
Proportinot respo
ComputComputertable lists
ALARM M
Pressure F Pressure F CirculatioCirculatio Return Fil Hydraulic
HydraulicHydraulic
Pump Fauby pump)
September 12, 20
nal Control V
Symptom
ional valve onding
ter Alarm Mrized control some recomm
MESSAGE
Filter Blocked
Filter Blocked
n/Filter Pumn/Filter Pum
lter Blocked
c Unit Temper
c Oil Level Lowc Oil Level Low
ult MCC or St
014
Valve Position
Possible P
• Valve value
• Set va
not re
Messages systems usua
mended actio
d (identified by
d for Circulati
p Fault MCCp Stopped &
rature High
w w - Pumps St
tandby Pump
Mainten
n Not Changi
Problem
not receivingfrom program
alue received besponding
ally have alarmns to take to r
y pump)
on Pump
C Main Pumps
topping
Fault MCC (
nance Tips - Flui
ing (cont.):
R
g set m
•
but valve •
m screens whiresolve comm
R
•
•
Running •
•
••••
•
(identified •
ds
Recommende
Locate and
Replace th
ich record alamon hydraulic
RECOMMEN
• Replace o
• Replace o
• Motor ouif that pum
• Replace o
• Check coo• Check the• Check wa• Check tha
valves wercorrect th
• Determinoil level. Astop automthe shutdo
• Motor ouif that pum
d Action
d fix electric f
he proportion
arm messagesc alarms.
NDED ACTIO
old filter with
old filter with
utput gives alamp is not run
old filter with
oling pump oe cooler waterater thermostaat none of there set too low
he setting.
ne what is cauAdd clean oil.matically if thown level.
utput gives alamp is not run
Pag
failure.
nal valve.
s. The followin
ON
new filter ins
new filter ins
arm to contronning.
new filter ins
operation. r strainer. at operation.e pressure reli
w. If required,
sing the drop. The pumps whe level drops
arm to contronning.
ge | 15
ng
sert.
sert.
ol desk
sert.
ief
p in will
s to
ol desk
Published S
© Valmet
PneumThe followintended the followoperation
ActuatoSource/S
Excessiv
Pressure
September 12, 20
matic trouwing charts coas a starting p
wing situationn after checkin
or Moving ASymptom
ve air choke
e too low
014
ubleshootover commonpoint for trous exists, work
ng each sourc
AbnormallPossible P
• Flow cincorr
• Plugg • Air lea • Plugg • Dama • Dama
adjustvalve
• Plugg • System • Direct
open dpilot c
• Cylind
seal da
Mainten
ting Charn problems wubleshooting sk through the e before tryin
y Slow Problem
control valve rectly adjusted
ed air silencer
ak or squeeze
ed filter
aged cylinder
aged or incorrted pressure r
ed filter
m leaks
tional or othedue to dirt orcircuit
der pipe, pistoamaged
nance Tips - Flui
rts ith the actuat
since it is impsource and re
ng another sou
R
d •
r •
ed tube •
•
or seal •
rectly regulator
•
•
•
er valve r failed
•
on, or •
ds
tor or pneumapossible to incemedy lists asurce.
Recommende
Readjust t
Replace or
Repair air
Replace ai
Replace cy
Replace reshown in d
Replace fil
Fix leaks.
Locate damit.
Repair or
atic valves. Thclude all possis possible cau
d Action
the valve.
r clean silence
leak or tube.
ir filter.
ylinder or sea
egulator or redrawing.
lter.
maged part an
renew damag
Pag
hese charts aribilities. If one
uses. Re-check
er.
al.
adjust rating
nd clean or re
ged parts.
ge | 16
re e of
k
as
eplace
Published S
© Valmet
Filter/RSource/S
Air leak
Pressure
Filter Pro
DirectioSource/S
Coil not
Valve sp
September 12, 20
Regulator/Symptom
at regulator
e problems
oblems
onal ControSymptom
picking up
ool stuck
014
LubricatorDiscussion
A continuleaky mainregulator sare availab IMPORTA• Replac
complpneumthems
If the diapwill occur Clean or relement w Drain conair turbulepneumaticdrain. Use filter eother smo
ol Valve noPossible P
• Electr
• Impur
and sl • Valve
Mainten
r Unit n/Recommen
uous air leak fn bonnet or dshould be schble for most s
ANT: ce diaphragmlete failure of
matic system.selves, creatin
phragm is crac. Replace the
replace the filtwill create a pr
ndensate fromence may pickc system. If co
elements withooth surfaces f
ot ChangingProblem
ric failure
rities betweenleeve
pilot not wor
nance Tips - Flui
nded Action
from the smaldiaphragm. Reheduled for retandard regu
m or seals as sof the diaphrag
This may caung a safety haz
cked or brokediaphragm.
ter element reressure drop w
m the filter bowk up the wateondensate req
h the approprfrom harmful
g PositionR
•
n spool •
rking •
ds
ll vent hole inepair parts shepair. Overhauulators.
oon as possibgm might appuse some solezard to person
en, a high velo
egularly. Whewhich may af
wl before it rier and carry itquires frequen
riate rating tol contaminan
Recommende
Fix electrispool mov
Replace va
Replace or
n the regulatorhould be ordeul kits with d
ble after the leply full house enoid valves tonnel and equi
ocity air leak
en over-contaffect system op
ises above thet downstreamnt draining, in
o protect cylinnts.
d Action
c failure and vement.
alve.
r clean pilotin
Pag
r bonnet indired at once an
diaphragm and
ak is discoverpressure to tho shift by ipment.
at the vent ho
aminated, theperation.
e baffle. Otherm into the
nstall an auto
nder barrels an
check mecha
ng part.
ge | 17
icates a nd the d seals
red. A he
ole
e filter
rwise,
omatic
nd
nical
Published S
© Valmet
Directio
Source/S
Proportinot respo
Air ValvSource/S
Low volt
Voltage t
AC hum
Valve sp
September 12, 20
nal Control V
Symptom
ional valve onding
ves Symptom
tage problems
transients
m
ool stuck
014
Valve not Cha
Possible P
• Valve value
• Set va
not re
Discussion
s Applying high inrusmagnetic fhigh resistpowers th Solenoid binsulationwhere soleinductive peaks thatthe solenopractices. If the solenenergized,seating. If moving pa Extremelythis case, r The armatsolenoid w A metal-tothe spool (
Mainten
anging Positio
Problem
not receivingfrom program
alue received besponding
n/Recommen
low voltage tosh current conforce to seat ttance connecte circuit.
burnout may n, causing shoenoids are conloads. Switch
t will be seen boid circuits. UElectrical filte
noid noise lev, operate the m
f the noise decarts and check
y loud AC humreplace the so
ture may be hwill draw high
o-metal spool(and the solen
nance Tips - Flui
on (cont.):
R
g set m
•
but valve •
nded Action
o an AC solenntinuously anthe armature tions; and low
be caused by rt circuits to gnnected to vo
hing such loadby all compon
Use 120 V coner networks m
vel is very higmanual overrcreases, it indk for correct v
m can be causolenoid.
held unseatedh inrush curre
l-type valve mnoid armatur
ds
Recommende
Locate and
Replace th
noid valve wilnd burn out, bof the valve. C
w voltage on t
high transienground. This
oltage sourcesds on and off nents in the c
ntrol circuits amay also be us
gh and occursride to check t
dicates incompvoltage suppl
sed by a brok
d because a valent for too lon
may be varnishre) from shifti
d Action
d fix electric f
he proportion
ll cause the sobecause there Causes of lowthe control tra
nt voltages thaproblem is m
s that supply mcan cause ver
circuit. The reand observe gsed.
s each time thto see that theplete solenoidly.
ken part within
lve spool wonng a time and
hed in place, ing. Repair or
Pag
failure.
nal valve.
olenoid coil towon't be eno
w voltage incluansformer tha
at break downmost commonmotors and ory high voltagemedy is to isgood groundin
he solenoid is e armature is d motion. Cle
n the solenoid
n't shift. The d burn out.
or dirt may pr replace.
ge | 18
o draw ough ude at
n coil n ther
ge olate ng
an all
d. In
prevent
Published S
© Valmet
Air Valv
Source/S
Temperaproblem
Air CylinSource/S
Drift
No move
Erratic m
September 12, 20
ves (cont.):
Symptom
ature ms
nders Symptom
ement
movement
014
Discussion
Solenoid ftemperatuturns of thor using a
Discussion
Piston seathe seal, pside. Virtuseals as ne Other circdirectionaleaks as ne • Pressu
• Piston
• Scored
• Load m • Large
static
Mainten
n/Recommen
failure can be ure. Insulationhe coil. If amb
pilot-actuate
n/Recommen
al leaks can caressurize one
ually no air sheeded.
cuit leaks can al control valveeded.
ure too low
n seal leak
d cylinder bor
misalignment
difference beand dynamic
nance Tips - Flui
nded Action
expected whn may fail, caubient temperaed valve with a
nded Action
ause a cylindere side of the pihould leak pas
cause a cylindve (internally
•
•
•
•
re •
•
t •
etween c friction
•
ds
en a valve is ousing shorts tatures are too a remote pilo
r to drift fromiston and obsst pistons equ
der to drift. Cand externall
Check presmeets circu
Operate val
Observe fluend of cylin
Replace pis
Replace nec
Eliminate c
Re-align cy
Install flowpressure to
operated abovto ground or high, conside
ot valve.
m its normal pserve leakage uipped with so
Check for leakly) and in con
ssure at cylinduit requiremen
lve to cycle cy
uid flow at valnder stroke.
ston seals if flo
cessary parts.
contaminants
ylinder and lo
w control valveo control strok
Pag
ve its rated shorts betweeer moving the
position. To cfrom the oppoft seals. Repl
ks through thennecting lines
der to make sunts.
ylinder.
lve exhaust po
ow is excessiv
.
s from air sup
oad.
es to provide ke.
ge | 19
en e valve
check posite lace
e s. Fix
ure it
orts at
ve.
pply.
back
Published S
© Valmet
Air Cylin
Source/S
Cylinderleak
Rod glan
September 12, 20
nders (cont.):
Symptom
r body seal
nd seal leak
014
:
Discussion
• Loose
• Excess • Pinch • Seal d
gumm • Seal d
brittletempe
• Seal d • Torn o
• Pinch • Seal d
gumm
• Seal d
brittletempe
• Seal d
Mainten
n/Recommen
e tie rod
sive pressure
ed or extrude
deterioration-smy
deterioration-he. Usually dueerature extrem
deterioration-w
or worn seal
ed or extrude
deterioration-smy
deterioration-he. Usually dueerature extrem
deterioration-w
nance Tips - Flui
nded Action
•
•
ed seal •
soft, •
hard, e to mes.
•
wear •
•
•
ed seal •
soft, •
•
hard, e to mes.
•
wear •
ds
Repair or r
Repair or r
Repair or r
Repair or r
Repair or r
Repair or r
Examine piscore markCheck glanreplace.
Replace gla
Check com
Replace wit
Replace seatemperatur
Replace sea
eplace.
eplace.
eplace.
eplace.
eplace.
eplace.
iston rod for ks. Repair or rnd bearing for
and seal.
mpatibility of s
th new seals.
als and shield re extremes.
als.
Pag
dents, gougesreplace. r wear. Repair
seals with lub
cylinder from
ge | 20
s or
r or
ricant.
m
Published S
© Valmet
Air Cylin
Source/S
Contamicircuit
This white technical m
Valmet proand power fabrics. Ouservices.
We are com
September 12, 20
nders (cont.):
Symptom
ination in
paper combinemanuals and pa
ovides competitr professionals ur offering and e
mmitted to mov
014
:
Discussion
• Sealinfitting
• Impro
pipes • Burrs
compo
• Seals e
excess
• Gener
circuit
es technical infapers.
tive technologiespecialize in prexperience cov
ving our custom
Mainten
n/Recommen
ng compound gs
operly filtered
inside pipingonents
extruding frosive pressure
rally excessivet
formation obtai
es and servicerocesses, macver the entire p
mers' performa
nance Tips - Flui
nded Action
inside •••
d feed •
g •
•
m •
•
e dirt in •
ined from Valm
s to the pulp, echinery, equipmprocess life cyc
nce forward.
ds
Protect fittiFollow proDisconnectattempt to aggressive a
Evaluate cirpre-filters.
Componenduring repaDisconnectremove burlines with a
Troubleshoand make cRe-set sealsre-seal.
Wipers or bwhere needconsider adcylinders.
met personnel a
energy and papment, services, cle including ne
ings during stper sealing prt cylinder fromclear debris frair blast.
rcuit design, c
nts and/or pipairs and/or stt cylinder fromrrs. Clear remaggressive air
oot cause for echanges to pres if possible, o
boots were noded. Evaluate dding wipers
and published V
per industries. paper machine
ew production li
Pag
torage. rocedures. m circuit andfrom lines by
consider addi
ping not proteorage. m pipes and
maining debrisblast.
excessive presevent.
otherwise clea
ot used on cylcircuit designor boots to
Valmet articles
Valmet's pulp, e clothing and lines, rebuilds a
ge | 21
d
ing
ected
s from
ssure
an and
linders n,
,
paper filter and