Basic Electrically Controlled Pneumatic Circuits
Basic Electrically Controlled Pneumatic Circuits
EXERCISE OBJECTIVE
DISCUSSION
Cylinder Reciprocation
Note: In the ladder diagram of Figure 2-13, magnetic proximity switch PX1 is
shown in the activated mode. The side arrow on NO contact PX1 indicates
that it is being held in the closed condition before the cycle starts. Magnetic
proximity switch PX1 is used to confirm the retracted position of the cylinder
rod.
Before the operator presses the START pushbutton PB1, the cylinder rod is
retracted, as shown in Figure 2-13. Relay coil CR1 is deactivated because an
open circuit condition exists in rung 1.
When pushbutton PB1 is depressed, the current flows from the () terminal of
the DC power supply, through contacts PB1, PX1 and PX2, to energize relay
coil CR1. This closes relay contacts CR1-A and CR1-B. Contact CR1-B causes
solenoid SOL-A and pilot lamp L1 to energize. This causes the directional valve
to shift and the cylinder rod to extend.
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Basic Electrically Controlled Pneumatic Circuits
When pushbutton PB1 is released, the current continues to flow to relay coil CR1
through the alternate path provided by the holding contact CR1-A being closed.
The holding action is obtained by holding current on the coil. Therefore,
solenoid SOL-A stays energized and the cylinder rod continues to extend.
When the cylinder rod is extended, magnetic proximity switch PX2 is activated
by the magnetic piston inside the cylinder. This opens NC contact PX2,
deenergizing relay coil CR1. This causes relay contact CR1-B to open,
deenergizing solenoid SOL-A and pilot lamp L1, causing the directional valve to
shift and the cylinder rod to retract. When the cylinder rod is retracted, it stops
and waits for the operator to start another cycle.
DV1
PNEUMATIC DIAGRAM
(+) (−)
START
PB1 PX1, NO PX2, NC
1 CR1
HOLDING
CONTACT
CR1-A
CR1-B SOL-A
2
L1
LADDER DIAGRAM
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Basic Electrically Controlled Pneumatic Circuits
In the circuit of Figure 2-13, automatic reversal of the cylinder is achieved by using
the electrical signal provided by a magnetic proximity switch when the cylinder rod
becomes extended. Magnetic proximity switches are widely used in industrial
pneumatic systems to sense the position of a cylinder piston. They can be mounted
anywhere within the piston travel range.
The Magnetic Proximity Switches supplied with your trainer are of the Reed type.
As Figure 2-14 shows, each switch consists of an internal relay coil controlling a set
of NO and NC contacts of the single-pole, double-throw (SPDT) type, and two
mechanical reeds (contact point). The () and ( ) terminals are to be connected to
the DC Power Supply.
REED
CONTACTS COIL
OPEN DEENERGIZED
+
CR
NO
CONTACTS
COM DEACTIVATED
PNEUMATIC DIAGRAM SYMBOL
NC
REED
CONTACTS COIL NO TERMINAL
CLOSED ENERGIZED
+
COMMON
CR TERMINAL
NC TERMINAL
MAGNETIC NO
PISTON CONTACTS LADDER DIAGRAM SYMBOL
COM ACTIVATED
NC
When the magnetic piston located in the cylinder comes within proximity of the
switch, the magnetic field pulls the reed switch contacts together, allowing the
current to flow from the () terminal to energize the relay coil. This causes the
switch SPDT contacts to activate. The NO contact goes closed while the NC contact
goes open.
When the magnetic piston moves away from the switch, the reed switch contacts
separate, deenergizing the relay coil and the switch contacts return to their normal,
deactivated state.
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Basic Electrically Controlled Pneumatic Circuits
Solenoid-operated valves have distinct advantages over pilot and manually operated
valves that make them an efficient means of actuating directional valves. Solenoid
operated valves react almost instantly to the electrical switching signal, while the
response time of pilot-operated valves depends on pilot pressure, tubing size, and
tubing length.
The solenoid operated valves supplied with your trainer are of the solenoid-pilot
operated type. In this type of valve, the electric current flowing through the solenoid
coil produces a magnetic field that moves a plunger. Moving the plunger opens a
flow path and allows the pilot pressure to act on the valve spool. Note that the spool
of the valve will not move if compressed air is not supplied to the valve even though
an electric current flows through the solenoid.
As shown in Figure 2-15, the solenoids are equipped with an indicator light and a
manual override that allows opening of the flow path without energizing the solenoid.
VALVE
VALVE
SOLENOID SOLENOID
MANUAL
OVERRIDE
SOLENOID-PILOT OPERATED VALVE
SYMBOLS
A quick exhaust valve is a special-purpose 3-way valve that increases the exhaust
capacity of pneumatic devices, such as cylinders, by exhausting air directly to
atmosphere instead of through the components downstream from the cylinder. To
be most effective, a quick exhaust valve must be connected to, or near the exhaust
port of the cylinder.
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Basic Electrically Controlled Pneumatic Circuits
INLET
PORT
RESILIENT
DISC
TO FROM
CYLINDER CYLINDER
SYMBOL
TO ATMOSPHERE
EXHAUST
PORT
Procedure Summary
In this exercise, you will test the one-cycle reciprocation system described in the
DISCUSSION section of the exercise.
In the first part of the exercise, you will assemble the circuit.
In the second part of the exercise, you will verify that the electrical control circuit
operates properly. The purpose of this verification is to isolate problems such as
wiring errors in a systematic, controlled manner before applying compressed air in
the circuit. Verification of the electrical control circuit is particularly important when
working on electrically controlled systems because the functions being performed
by this circuit may not be readily apparent to the operator, and unpredictable
cylinder motion may occur at any time.
In the third part of the exercise, you will test the operation of the circuit.
In the fourth part of the exercise you will measure the retraction time of the cylinder
rod with and without a quick exhaust valve.
In the last part of the exercise, you will test an interlocking circuit that prevents two
solenoids from being energized at the same time.
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Basic Electrically Controlled Pneumatic Circuits
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart, in Appendix A of this manual, to obtain the
list of equipment required to perform this exercise.
PROCEDURE
Note: The Flow Control Valves are used to control the extension
and retraction speeds of the cylinder rod.
DV1
FCV 1
(+) (−)
START
PB1 PX0 PX1
1 CR1
CR1-A
CR1-B DV1-SOL-A
2
L1
LADDER DIAGRAM
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Basic Electrically Controlled Pneumatic Circuits
loosen the set screw on the Magnetic Proximity Switch until the clamp
is loose enough to slip over the cylinder tie rod. Position the switch at
the rod end of the cylinder, then tighten the set screw.
* 3. Turn on the DC Power Supply. Do not open the shutoff valves on the
Conditioning Unit at this time.
* Yes * No
* 6. With your hand, pull the cylinder rod until it is fully extended. If your circuit
is operational, the pilot lamp L1 and the pilot lamp of SOL-A should turn off.
Explain why.
* 7. Retract the cylinder rod and connect the tubes at the cylinder ports.
* 8. Close the Flow Control Valves by turning the control knobs fully clockwise.
Then open each valve by turning the knobs two turns counterclockwise.
Refer to the mark on the knobs to help you set the correct position.
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Basic Electrically Controlled Pneumatic Circuits
* 10. Open the shutoff valve and the branch shutoff valve at the manifold and set
the pressure regulator at 400 kPa (or 60 psi) on the regulated pressure
gauge.
* 11. Start the cylinder cycle by momentarily depressing the START push-
button PB1. Record what the cylinder rod does.
* 12. Does the cylinder rod cycle more than one time or does it stop after one
cycle?
* 14. Start another cycle by momentarily depressing PB1. Does the cylinder
continue to extend when you release PB1? Explain why, by referring to the
ladder diagram in Figure 2-17.
* 15. Loosen the set screw on Magnetic Proximity Switch PX1 until the clamp is
loose enough to slip over the cylinder tie rod. Position the switch
approximately at the middle of the cylinder, then tighten the set screw.
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Basic Electrically Controlled Pneumatic Circuits
* 16. Start the cylinder cycle by momentarily depressing PB1 while observing the
extension of the rod. From your observations, what can you conclude about
the position of the magnetic switch?
* 17. What would happen to circuit operation if relay contact CR1-A in rung 1
were removed? Would you still be able to fully extend the cylinder rod?
Explain.
* 18. Turn off the DC Power Supply. Use a pointed object to operate the manual
override on the directional valve, referring to Figure 2-15 if necessary.
Depress carefully the override button while observing the operation of the
cylinder. Does the cylinder extend showing that the override can be used
to operate the cylinder without electrical power?
* Yes * No
* 19. Reposition Magnetic Proximity Switch PX1 at the rod end of the cylinder
and turn on DC Power Supply.
* 20. Start the cylinder cycle by momentarily depressing the START push-
button PB1 and measure the retraction time of the piston rod. Enter your
results in the appropriate cell in Table 2-2. Repeat your measurement to
validate your result.
Without With
Quick exhaust valve Quick exhaust valve
* 21. Close the shutoff valves on the Conditioning Unit and insert the Quick
Exhaust Valve between the Flow Control Valve FCV1 and the cylinder as
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Basic Electrically Controlled Pneumatic Circuits
shown in Figure 2-18. Use a tube as short as possible between the Quick
Exhaust Valve and the cylinder. Ensure that the IN port of the Quick
Exhaust Valve is connected to the Flow Control Valve.
PX0 PX1
SOL-A
DV1
FCV 1
FCV 2
PNEUMATIC DIAGRAM
(+) (−)
START
PB1 PX0 PX1
1 CR1
CR1-A
CR1-B DV1-SOL-A
2
L1
LADDER DIAGRAM
* 23. Do the results indicated in Table 2-2 confirm that the quick exhaust valve
increases the exhaust capacity of the pneumatic cylinder?
* Yes * No
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Basic Electrically Controlled Pneumatic Circuits
* 25. On the Conditioning Unit, close the shutoff valves, turn the regulator
adjusting knob completely counterclockwise, and disconnect your circuit.
Interlock Circuit
* 26. Connect the interlock circuit shown in Figure 2-19. Retract the cylinder rod.
* 28. On the Conditioning Unit, open the shutoff valves and set the pressure
regulator at 200 kPa (or 30 psi).
* 29. Momentarily depress pushbutton PB1. If the electric circuit is working, pilot
lamp L1 should turn on. Does pilot lamp L1 continue to light when you
release PB1? Explain why.
* 30. Momentarily depress pushbutton PB2. Does the pilot lamp L2 turn on?
* Yes * No
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Basic Electrically Controlled Pneumatic Circuits
SOL-A
DV1
SOL-B
PNEUMATIC DIAGRAM
(+) (−)
PB1, NO
STOP CR2-B, NC
1 CR1
CR1-A, NO DV1-SOL-A
L1
PB2, NO
CR1-B, NC
CR2
CR2-A, NO DV1-SOL-B
L2
LADDER DIAGRAM
* 31. Depress the STOP pushbutton, then depress momentarily pushbutton PB2.
Does pilot lamp L2 turn on?
* Yes * No
* 32. Depress simultaneously pushbuttons PB1 and PB2. Do pilot lamps L1 and
L2 turn on?
* Yes * No
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Basic Electrically Controlled Pneumatic Circuits
* 33. Does the operation of the interlock circuit confirm that the circuit prevents
the solenoids from being energized simultaneously?
* Yes * No
* 34. On the Conditioning Unit, close the shutoff valves, and turn the regulator
adjusting knob completely counterclockwise.
CONCLUSION
In this exercise, you tested the operation of a one-cycle reciprocation system. You
saw that a cylinder can be made to reciprocate automatically by using sensing
devices that detect the position of the cylinder rod.
You learned that a relay contact can be used to maintain a closed circuit to the
output load, allowing a pushbutton to act as a maintained contact switch.
You also learned that it is a good practice to test the electrical control circuit before
putting the whole system into operation. This is particularly important when working
on electrically controlled pneumatic systems because the functions being performed
by a control circuit may not be readily apparent to the operator, and unpredictable
motion may occur at any time.
In the last part of the exercise, you tested an interlock circuit that prevents two
solenoids from being energized simultaneously.
REVIEW QUESTIONS
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Basic Electrically Controlled Pneumatic Circuits
3. In the ladder diagram of Figure 2-17, what is the purpose of holding con-
tact CR1-A in rung 1? Explain.
4. What will the cylinder rod do in the system of Figure 2-17 if NC contact PX1 in
rung 1 is changed for an NO contact? Explain.
5. What will the cylinder rod do in the system of Figure 2-17 if NO contact CR1-B
in rung 2 is changed for an NC contact? Explain.
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