Troubleshooting of Rack & Pinion Pneumatic Actuators

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Mechanical Problems

Problem	Possible Error	Solution
Feedback position and actual position are not the same	Actuator and valve are mounted 90�rotated in relation to each other	Remove actuator from valve. Check assembly code of actuator. Put both valve and actuator in �Closed� position. Mount actuator on valve
Valve is in �Closed� position, actuator is in �Open� position and will not move anymore
Valve does not reach the completely �Closed� or �Open� position	Limit stop screws are not set correctly	Readjust the limit stop screws
	Insert is not mounted properly	Mount the insert in the right position. Remark: Rotate insert to one cam = 22.5�
	Pressure too low	Apply pressure as per sizing
	Sizing is wrong	Check valve torque data with actuator torque data
	Pinion is mounted in the wrong position	Reassemble actuator
Actuator rotates, valve does not	No coupling between actuator shaft and valve spindle	Install a coupling between actuator shaft and valve spindle

Pneumatic Problems

Problem	Possible Error	Solution
Actuator does not react to electrical control signal	There is no supply pressure at the actuator	Supply the right pressure to the actuator
Actuator does not react good to electrical control signal	There is sufficient supply air pressure but insufficient supply air capacity	Take care the supply air tubing has the right dimensions
	Supply pressure too low, causing pilot operated solenoid valve to fail	Check that supply pressure at the actuator and solenoid is sufficient to operate the actuator
	Solenoid valve is not mounted properly	Check the solenoid valve mounting
	Speed control throttle (if present) blocks air flow	Turn the speed control more open
	Manual override (if present) on the Solenoid Valve is locked	Unlock manual override on the solenoid valve
Air leakage between actuator and solenoid valve	Sealing between solenoid valve and actuator is not mounted air tight	Reassemble solenoid valve taking care, that all seals are in place
Double-acting actuator will only move to �open� position	Actuator has wrong Solenoid valve configuration	Mount a solenoid valve suitable for double acting Actuators (4/2 or 5/2 function)
Double-acting actuator will only move to �open� position	Actuator has wrong Solenoid valve configuration	Check that conversion plate on solenoids, that have both 3/2 and 5/2 functions, is in the right position

Electrical Problems

Problem	Possible Error	Solution
Actuator does not react to control signals	Control wiring. Power supply wiring or feedback wiring are not right connected	Connect all wiring in the right way
Actuator does not react to control signals	The power supply voltage is not is not the same as the voltage of the applicable solenoid valve	Connect the right power supply voltage
There are problems with position feedback after sending the actuator to either the �Open� or �Closed� position	The wiring of the feedback signals may be switched	Connect the feedback wiring in the right way