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We went from a major contender to losing the semi-finals for our alliance when our robot ran out of air due to increasing severe air leaks through-out the day this past weekend. We have one more chance next weekend but obviously our robot is in quarantine . We had already seriously tightened all brass fittings to the point soapy water did not find any leaks. We have yet to see any "push in" air hose fittings leak. We had tightened all the pilot valve screws and the manifold screws. Our best guess is we had joint seal leaks and or internal valve air leaks. But that was hard to confirm with soapy water as the valves were vertically mounted immediately above the spikes which could not get wet.

We had a number of people at the regional say that they had suffered from (more than one )"blown" solenoids (implying seals) and or leaking porous castings.

What is everyone elses experiences ? Since we are operating these values close to 1/2 their rated pressure and they are largely brand new and have only an hour of use (ie pressured), I am surprised we are in this position.

Anyone know how waterproof the pilot values are ? We would love to be able to dunk the complete solenoids for 10 seconds in a water tank under pressure with capped output tubes and tubes on the exhaust valve in a way that water can run up them but leaks from them would be obvious. That way all possible leaks will clearly be visible.

Anyone have any experience with the Festo valves ?

Our plan is to come in with tested spares, a standalone test compressor (with no reserve tanks: shows leaks much faster), replacement gasket kits.

Any other suggestions ?

There is another thread on leaks but for some reason its closed.