Fluid Power

1-800-Lab-Volt Electrical Control of Hydraulic Systems

www.labvolt.com

31228-00
Student Manual
|3031228000000&~
Fluid Power

Electrical Control
of Hydraulic Systems

Student Manual
31228-00

A
 FLUID POWER

ELECTRICAL CONTROL
OF HYDRAULIC SYSTEMS

by
the Staff
of
Lab-Volt Ltd.

Copyright © 1997 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced,

in any form or by any means, without the prior written permission
of Lab-Volt Ltd.

Legal Deposit – Third trimester 1997

ISBN 978-2-89289-370-0

FIRST EDITION, SEPTEMBER 1997

Printed in Canada
September 2009
 Foreword

The Lab-Volt Hydraulics Training System is a modularized presentation of the

principles of hydraulic energy and its controlled application. The Hydraulics Training
System consists of an introductory and an advanced training program.

The introductory program is based on two manuals: Volume 1, Hydraulics

Fundamentals, covers the basic principles of hydraulics; Volume 2,
Hydraulics - Electrical Control of Hydraulic Systems, covers electrical circuits and
ladder diagrams for hydraulics applications. Both manuals are intended to be used
with the Lab-Volt Hydraulics Trainer.

The advanced training program expands upon the introductory course with
hydraulics applications demonstrating pneumatic controls, programmable controllers,
sensors, proportional controls, and servo controls. The covered applications are
based on those encountered in the industry. The introductory program is a
prerequisite for the advanced program.

This manual, Volume 2 of the Hydraulics series, introduces students to electrical

control of hydraulic systems. Subjects covered are basic electricity, ladder diagrams,
limit switches, standard industrial relays, and solenoid-operated directional valves.
Functional electrically controlled hydraulic systems are studied, assembled, and
tested. Students then use the acquired knowledge to design their own systems and
to simulate the operation of typical industrial systems. Finally, a methodical approach
to troubleshooting electrically controlled hydraulic systems is outlined, based on the
first principles of hydraulics and electricity.

The Lab-Volt Instructor’s Guide for Hydraulics (P/N 30794-10) provides answers to
all procedure steps and review questions found in each exercise in this manual.

III
 Acknowledgements
We wish to thank Mr. Patrick Quirion, Mech. Eng., CEFP, MGI, for
his participation in the elaboration of the hydraulics courseware. Mr.
Quirion teaches fluid power classes in Montreal, Canada.

IV
 Table of Contents
Introduction

Unit 1 Introduction to Electrical Control of Hydraulic Systems . . . . . . . . 1-1

An introduction to electrically controlled hydraulic systems. Description of

the function of each part of an electrical control circuit.

Exercise 1-1 Familiarization with the Equipment . . . . . . . . . . . . . 1-5

Identification of the components used for electrical control of

the Lab-Volt Hydraulics Trainer. Classifying these
components as input element, controller element, or
actuating mechanism.

Unit 2 Electrical Control Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Basic concepts of electricity. How to read, draw, and connect simple ladder
diagrams.

Exercise 2-1 Basic Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Measurement of the voltage, resistance, and current in an

electrical control circuit. Connection and operation of an
electrical control circuit. Safety rules to follow when using the
Lab-Volt Hydraulics Trainer.

Exercise 2-2 Ladder Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Definition of a ladder diagram. Description of how a ladder

diagram operates and how it relates to the hydraulic
equipment. Rules for drawing ladder diagrams. Connection
and operation of basic ladder diagrams using series (AND)
logic, parallel (OR) logic, and control relays.

Exercise 2-3 Basic Electrically Controlled Hydraulic System . . 2-29

Description and operation of a magnetic proximity switch.

Connection and operation of a one-cycle reciprocation
system. Utilization of a holding relay contact to maintain the
current to a directional valve solenoid after the START
pushbutton is released.

Unit 3 Functional Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Connection and operation of functional electrically controlled hydraulic

systems.

Exercise 3-1 Hydraulic Sequencing of Cylinders . . . . . . . . . . . . . 3-3

Description and operation of a sequence valve. Connection

and operation of a clamp and work system sequenced by a
sequence valve. Description and operation of a mechanical
limit switch.

V
 Table of Contents (cont'd)

Exercise 3-2 Electrical Sequencing of Cylinders . . . . . . . . . . . . 3-19

Description and operation of a hydraulic pressure switch.

Connection and operation of a clamp and work system
controlled by electrical means.

Exercise 3-3 Speed Regulation and Braking

of Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Description and operation of a pressure-compensated flow

control valve. Connection and operation of a speed
regulation system that uses a pressure-compensated flow
control valve to maintain a constant motor speed as the
system pressure changes. Connection and operation of a
motor braking system that uses a sequence valve to slow
down a motor before stopping it.

Exercise 3-4 Continuous Reciprocation with Dwell Period . . . 3-45

Description and operation of a time-delay relay. Connection

and operation of a continuous reciprocation system that
uses a time-delay relay to hold (dwell) a cylinder in a pre-
determined position for some period of time.

Unit 4 Industrial Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Connection, design, and operation of industrial electrically controlled

hydraulic systems.

Exercise 4-1 Drilling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Description and operation of a photoelectric switch. Steps

that make up an industrial drilling process. Connection and
operation of an electrically controlled hydraulic system
simulating the operation of an industrial drilling machine.

Exercise 4-2 Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

The purpose and use of safety circuits in electrically

controlled hydraulic systems. Two-hand safety circuits.
Connection and operation of a basic two-hand safety circuit
and a two-hand, non-tie-down safety circuit.

Exercise 4-3 Counting of Actuator Cycles . . . . . . . . . . . . . . . . . 4-23

Description and operation of a time-delay relay. Extension

and retraction of a cylinder a definite number of times using
an electrical counter. Measurement of the rotation speed of
a hydraulic motor using an electrical counter.

VI
 Table of Contents (cont'd)

Exercise 4-4 Multi-Pressure System . . . . . . . . . . . . . . . . . . . . . . 4-37

Utilization of a solenoid-operated directional valve as a

pressure selector valve to select between two or more
operating pressures. Designing a three-pressure level
system simulating a spring testing bench.

Exercise 4-5 Rapid Traverse-Slow Feed System . . . . . . . . . . . . 4-43

Extension of a cylinder at two different speeds in different

parts of its stroke. Designing a two-speed system simulating
a rapid traverse-slow feed system.

Unit 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Basic techniques used in troubleshooting the electrically controlled hydraulic

systems.

Exercise 5-1 Troubleshooting Electrical Control Circuits . . . . . . 5-3

Description of the voltmeter and ohmmeter methods of

troubleshooting an electrical control circuit. Location of
instructor-inserted faults in the electrical section of an
electrically controlled hydraulic drilling system.

Exercise 5-2 Troubleshooting Electrically Controlled

Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Learning an efficient troubleshooting method for locating

faults in an electrically controlled hydraulic system. Location
of instructor-inserted faults in the hydraulic and electrical
sections of an electrically controlled clamp and grind system.

Appendix A Equipment Utilization Chart

B Care of the Hydraulics Trainer
C Conversion Factors
D Hydraulics and Pneumatics Graphic Symbols
E Time-Delay Relay / Counter Specifications

Bibliography

We Value Your Opinion!

VII
VIII
 Introduction

The growing use of electrically controlled hydraulic systems in industry comes from
the need for fast, low cost means of production with better quality, less waste, and
increased power. Electrically controlled hydraulic systems provide many other
advantages. A few of these are spark- and burnout-resistance, fine control, and
compact size.

This manual is divided into five units:

– Units 1 and 2 present the basic concepts of an electrically controlled hydraulic

system. Unit 1 describes each part of an electrical control system. Unit 2
presents the basic principles of electricity and ladder diagrams, and introduces
a basic electrically controlled hydraulic system.

– Units 3 and 4 present functional and industrial systems demonstrating electrical

sequencing, speed regulation, continuous reciprocation, safety circuits, counting
of actuator cycles, multi-pressure control, and two-speed control.

– Unit 5 presents the basic troubleshooting techniques used in troubleshooting the

electrically controlled hydraulic systems.

The exercises in this manual provide a systematic and realistic means of learning the
subject matter. Each exercise contains:

– A clearly defined Exercise Objective.

– A Discussion of the theory involved.
– A Procedure Summary which provides a bridge between the theoretical
discussion and the laboratory procedure.
– A detailed step-by-step laboratory Procedure in which the student observes and
measures important phenomena. Block diagrams facilitate connecting the
electrical and hydraulic components and guide the student’s observations.
Questions direct the student’s thinking process and help in understanding the
principles involved.
– A Conclusion to confirm that the objective has been reached.
– Review Questions which verify that the material has been well assimilated.

IX
 Unit 1
Introduction to Electrical Control
of Hydraulic Systems

UNIT OBJECTIVE

When you have completed this unit, you will be able to identify the components used
for electrical control of the Hydraulics Trainer and to safely operate the trainer.

DISCUSSION OF FUNDAMENTALS

In a hydraulic system, fluid power provides the “muscles” or power to do work,

while a control part provides the “brain” to command system operation. Control of
a hydraulic system may range from the simple starting and stopping of the system
to controlling extension and retraction of several cylinders in a completely automated
factory.

A hydraulic system can be controlled either manually or automatically:

C Manual control: system operation is sequenced and commanded by an operator

that decides each action to take.

C Automatic control: system operation is sequenced and commanded by a

controller that decides each action to take. Automatic control can be
accomplished by means of:

a. electrical signals (electrical control);

b. compressed air (pneumatic control);

c. mechanical link (mechanical control).

Manual control is good for system operations which do not require constant
repetition. An earth-moving truck such as those used in construction, farming, and
mining is a common example of a machine requiring manual control. Since the
operator must constantly change the position to where the shovel digs and the depth
at which the shovel digs, automatic control could not be used because the sequence
of operations is not repetitive.

In systems requiring the repetition of a series of operations, however, it would be

inefficient to manually shift the hydraulic valves each time the direction of oil flow
needs to be changed. As an example, Figure 1-1 shows manual and automatic
(electrical) operation of a hydraulic drilling system.

1-1
Introduction to Electrical Control
of Hydraulic System

Figure 1-1. Manual and automatic (electrical) controls of a hydraulic drilling system.

1-2
Introduction to Electrical Control
of Hydraulic System
In Figure 1-1 (a), the part to drill is positioned by hand on the drilling machine. A
directional control valve is then shifted manually to extend the drill cylinder. When
the part is drilled, the directional control valve is shifted in the opposite direction to
retract the drill cylinder. Then the drilled part is removed and a new part is positioned
on the machine. Each step of the drilling sequence must be initiated by the operator,
based on a visual observation that the previous step has been completed.

In Figure 1-1 (b), the only thing the operator has to do is to start the system by
pressing the START pushbutton. This causes the controller to activate the solenoid
of directional valve 1 to extend the feed cylinder and push a part under the drill.
When the feed cylinder is extended, it activates a photoelectric switch, PE1. PE1
sends a signal to the controller that the part has been pushed into position. This
causes the controller to deactivate the solenoid of directional valve 1 to retract the
feed cylinder. Once this cylinder is retracted, it activates photoelectric switch PE2.
This sends a signal to the controller causing it to energize the solenoid of directional
valve 2 to extend the drill cylinder. When the drill cylinder has extended far enough
to drill the part, it activates photoelectric switch PE3. This sends a signal to the
controller, causing it to deactivate the solenoid of directional valve 2 to retract the drill
cylinder. Once this cylinder is retracted, it activates photoelectric switch PE4. This
causes the controller to commence a new sequence of operations by activating the
solenoid of directional valve 1 to extend the feed cylinder. The sequence of
operations will repeat until the system is manually stopped or a malfunction occurs.

As you can see, electrical control adds flexibility, enhanced performance, and safety
to systems involving a series of interrelated operations.

1-3
1-4
 Exercise 1-1

Familiarization with the Equipment

EXERCISE OBJECTIVE

C To identify the components used for electrical control of the Lab-Volt Hydraulics
Trainer;
C To describe the function of each of the following parts of an electrical control
circuit: input element, controller, and actuating mechanism.

DISCUSSION

Basic principles of electrical control

Electrical control is by far the most popular type of automatic control used for
industrial hydraulic applications. As Figure 1-2 shows, an electrical control circuit
consists of the following parts:

1) Input element(s)
2) Controller
3) Actuating mechanism(s)

Figure 1-2. Breakdown of an electrical control circuit.

An input element is a device that provides an electrical signal to indicate that a

hydraulic actuator (cylinder or motor) has reached a specific position, or that it is time
to start the sequence of operations. Examples of input elements are limit switches,
pushbutton switches, and relay contacts. The signal issued from an input element
is called input signal because it is sent to the input of a controller.

1-5
Familiarization with the Equipment

A controller is a device that decides what action to take based on the signals sent
to it from the input element(s). The controller may be a set of electromechanical
relays, a programmable logic controller (PLC), or a computer. The signal issued from
the controller is called control signal because it is used to control the motion of a
hydraulic actuator through an actuating mechanism.

An actuating mechanism is a device that provides oil flow to a hydraulic actuator

according to the control signal sent to it from the controller. Examples of actuating
mechanisms are hydraulic solenoid-operated valves and electro-hydraulic servo
valves.

Indicating devices such as pilot lamps and meters do not make part of the control
circuit because they have no effect on the control process.

Electrical control offers a high flexibility because operation of the hydraulic system
can be changed only by modifying the logic of the controller instead of modifying the
hydraulic circuitry itself. On high-pressure applications, however, electrical control
may become complex and costly because the actuating mechanisms
(solenoid-operated hydraulic valves) must be pilot-operated.

This course will show you how to control the Lab-Volt Hydraulics Trainer with a type
of electrical control called electromechanical relay control. With this type of
control, the controller is a series of relay contacts achieving the proper logic to move
the actuators in a specific sequence.

Procedure summary

In this exercise, you will identify the components used for electrical control of the
Lab-Volt Hydraulics Trainer. You will then classify these components as input
element, controller element, or actuating mechanism.

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

Identifying the components used for electrical control

G 1. Figure 1-3 shows the components used for electrical control of the
Hydraulics Trainer. Get these components from their storage location and
identify each component by writing its part number (P/N) in Figure 1-3.

1-6
Familiarization with the Equipment

Figure 1-3. Components used for electrical control of the Hydraulics Trainer.

1-7
Familiarization with the Equipment

G 2. Examine the 24-V DC Power Supply. When turned on, this device converts
the 120-V AC line voltage into a 24-V DC voltage that is used to power the
electrical control circuit. The 24-V DC voltage is supplied between the red
and black terminals (also called banana jacks) located on top of the DC
Power Supply.

Look at the information silkscreened next to the jacks. What color is the jack
corresponding to the positive (+) terminal of the DC Power Supply? To the
negative (!) terminal?

G 3. Examine the Dual-Pushbutton Stations. Pushbuttons allow an operator to

manually start and stop a sequence of operations. Each pushbutton has an
internal pair of conducting parts called contact. Pressing a pushbutton
causes its contact to close or open, which sends an electrical signal to the
controller.

Below each pushbutton is a silkscreened symbol indicating the state (open

or closed) of the pushbutton contact when the pushbutton is not pressed, or
in the NORMAL (deactivated) state. Based on the silkscreened symbols,
what color are the normally open pushbuttons? The normally closed
pushbuttons?

G 4. Draw in Figure 1-4 the symbols for normally open (N.O.) and normally
closed (N.C.) pushbutton contacts, as silkscreened on a Pushbutton Station.

Figure 1-4. Symbols for pushbutton contacts.

G 5. Examine the Limit-Switch Assembly. This device consists of two mechanical

limit switches that are used to sense the position of a cylinder rod. As the
cylinder rod travels across a switch, it pushes against the roller, depressing
the lever arm. This activates the switch, which sends an electrical signal to
the controller.

1-8
Familiarization with the Equipment

Activate one of the switches by depressing the roller lever with a finger.
Does the switch make a clicking noise as it activates?

G Yes G No

G 6. Look at the symbol silkscreened on a mechanical limit switch. The switch

has a pair of N.O. and N.C. contacts that are controlled by a common arm.
When the switch is deactivated, the arm contacts the N.C. (red) terminal,
forming a N.C. contact. When the switch is activated, the arm switches to
the N.O. (black) terminal and closes the N.O. contact which was open in the
deactivated (normal) condition. Upon deactivation of the switch, the arm is
returned to its initial position by an internal spring. The switch is called a
single-pole double-throw (SPDT) switch because a single armature
switches back and forth between a N.O. and a N.C. terminal.

In Figure 1-5, draw the symbol for the SPDT contacts of a mechanical limit
switch, as silkscreened on the switch. Identify the COMMON, N.O., and
N.C. terminals on your drawing.

Figure 1-5. Symbol for the SPDT contacts of a mechanical limit switch.

G 7. Examine the Magnetic Proximity Switches. This type of switch is used to

sense the position of the piston inside a cylinder. It is designed to clamp
onto a cylinder equipped with a special magnetic piston, as is the case of
the cylinders supplied with your Hydraulics Trainer. When the magnetic
piston moves within proximity of the switch, its magnetic field activates the
Magnetic Proximity Switch, which sends an electrical signal to the controller.

The + and ! terminals on top of the switch are used to power the sensing
cell inside the switch. The three other terminals provide access to a pair of
N.O. and N.C. contacts. The switch is of SPDT type because a single switch
arm switches back and forth between a N.O. and a N.C. terminal.

In Figure 1-6, draw the symbol for the SPDT contacts of a Magnetic
Proximity Switch, as silkscreened on the switch. Identify the COMMON,
N.O., and N.C. terminals on your drawing.

1-9
Familiarization with the Equipment

Figure 1-6. Symbols for the SPDT contacts of the Magnetic Proximity Switch.

G 8. Mount a Magnetic Proximity Switch on one of the trainer Cylinders. To do

so, loosen the set screw on the proximity switch until the clamp is loose
enough to slip over the cylinder tie rod. Position the switch at the cap end
or at the rod end of the cylinder. Then tighten the set screw until the clamp
is attached firmly to the cylinder tie rod. Could the Magnetic Proximity
Switch be positioned to indicate when the piston passes virtually any point
in its stroke?

G Yes G No

G 9. Examine the Diffuse Reflective Photoelectric Switch. This switch is used to

sense the position of a cylinder rod. It consists of a light source, a receiver,
and a pair of N.O. and N.C. contacts. When powered by a 24-V DC voltage,
the light source projects a beam of infrared light. When the cylinder rod
enters the beam, light reflects off the rod back to the receiver, causing the
switch contacts to turn on.

The + and ! terminals on top of the switch are used to power the infrared
light source. The three other terminals provide access to the switch N.O.
and N.C. contacts. The switch is of SPDT type because a single switch arm
switches back and forth between the N.O. and N.C. terminals.

In Figure 1-7, draw the symbol for the SPDT contacts of the Diffuse
Reflective Photoelectric Switch, as silkscreened on the switch. Identify the
COMMON, N.O., and N.C. terminals on your drawing.

1-10
Familiarization with the Equipment

Figure 1-7. Symbols for the SPDT contacts of the Diffuse Reflective Photoelectric Switch.

G 10. Examine the Pressure Switch. This switch is used to sense the pressure in
a hydraulic circuit. It has a hydraulic port which is to be connected into the
hydraulic circuit like a pressure gage. When the circuit pressure reaches a
preset level, the Pressure Switch is activated, which sends an electrical
signal to the controller.

Look at the symbol silkscreened on top of the switch. The Pressure Switch
is of SPDT type because a single switch arm switches back and forth
between a N.O. and a N.C. terminal. In Figure 1-8, draw the symbol for the
SPDT contacts of the Pressure Switch. Identify the COMMON, N.O., and
N.C. terminals on your drawing.

Figure 1-8. Symbols for the SPDT contacts of the Pressure Switch.

G 11. Examine the Pilot-Lamp Stations. These devices indicate the condition
(activated or deactivated) of an associated device. Each lamp is connected
to a pair of banana jacks allowing connection of that lamp into a circuit. In
Figure 1-9, draw the symbol for a pilot lamp as silkscreened between a pair
of jacks.

1-11
Familiarization with the Equipment

Figure 1-9. Pilot lamp symbol.

G 12. Examine the Relay and Time-Delay Relay / Counter. A relay is an

electromechanical component used in electrical control circuits as a
controller element. It sends control signals to an actuating mechanism to
control the motion of an actuator, based on the signals sent to it from an
input element. One or more relays can be connected in various
combinations to achieve proper logic to move several actuators in a specific
sequence.

G 13. Look at the symbols silkscreened on the Relays. Each Relay consists of a
coil, CR, controlling three sets of N.O. and N.C. contacts. Coil CR is to be
connected to an input element such as a limit switch. The N.O. and
N.C. contacts can be connected to actuating mechanism(s) such as valve
solenoids, or to other relay coils to perform various logic functions.

When the input element applies a 24-V DC voltage across coil CR, the coil
energizes and shifts its associated contacts to their opposite state.
N.O. contacts close and N.C. contacts open. When the 24-V DC voltage is
removed from coil CR, the coil de-energizes and its associated contacts are
returned to their normal state by a spring.

Based on the silkscreened symbols, what type of relay contact (N.O./N.C.)

is connected between the following pairs of terminals: 1-2, 4-5, and 7-8?
Between the following pairs: 2-3, 5-6, and 8-9?

G 14. Examine the symbols silkscreened on the Time-Delay Relay / Counter. This
device can be programmed for either timing or counting function by
configuring the thumbwheel switches on top of the unit accordingly. When
the preset time or count set on the thumbwheel switches is reached, the
Time-Delay Relay / Counter shifts its two sets of contacts to the activated
state.

1-12
Familiarization with the Equipment

Based on the silkscreened information, are the symbols for N.C. and N.O.
contacts of the Time-Delay Relay / Counter similar to those for N.O. and
N.C contacts of the Relays?

G Yes G No

G 15. Examine the single-solenoid operated, 4-way, 2-position, spring-return

Directional Valve. This valve is an actuating mechanism providing fluid flow
to a hydraulic actuator such as a cylinder or motor. It is operated by an
electrical solenoid. This solenoid must be connected to a controller
output—usually a relay contact.

When the solenoid is energized by the controller, it pushes the valve spool
to the straight-arrows condition, causing the actuator to move in one
direction. When the solenoid is de-energized, an internal spring returns the
valve spool to the normal, crossed-arrows condition, causing the actuator
to move in the other direction.

In Figure 1-10, draw the symbol for the single-solenoid operated,

4-way, 2-position, spring-return Directional Valve, as engraved on the
manufacturer name plate located on top of the valve.

Figure 1-10. Symbol for the single-solenoid operated, 4-way, 2-position, spring-return Directional
Valve.

G 16. Examine the double-solenoid operated, 4-way, 3 position, spring-centered,

tandem-center Directional Valve. This valve is operated by two separate
solenoids that shift the spool to the straight-arrows and crossed-arrows
conditions. Each solenoid must be connected to a controller output—usually
a relay contact.

When neither solenoid is energized by the controller, the spool is kept in the
center position by centering springs. The valve has a tandem center
condition, which means that the pressure (P) and return (T) ports are
connected when the valve is centered.

In Figure 1-11, draw the symbol for the double-solenoid operated, 4-way,
3-position, spring-centered, tandem-center Directional Valve, as engraved
on the manufacturer name plate located on top of the valve.

1-13
Familiarization with the Equipment

Figure 1-11. Symbol for a double-solenoid operated, 4-way, 3-position, spring-centered, tandem-
center Directional Valve.

G 17. Examine the electrical leads. These wires are used to carry electrical signals
from one component of the electrical control circuit to another. They can be
connected to any of the banana jacks on the electrical components of the
Hydraulics Trainer. The leads can be stack connected.

Practice connecting and disconnecting the leads and stack connect the lead
ends as shown in Figure 1-12. Then, disconnect and store the electrical
leads.

Figure 1-12. Connecting and stacking leads.

G 18. Based on what you have learned in this exercise, classify the components
used for electrical control of the Hydraulics Trainer as input element,
controller element, or actuating mechanism by checking the appropriate box
in Table 1-1.

1-14
Familiarization with the Equipment

INPUT CONTROL ACTUATING

COMPONENT
ELEMENT ELEMENT MECHANISM

Double-solenoid operated, 4-way,

3-position, tandem-center
Directional Valve

Time-Delay Relay / Counter

Limit Switch

Magnetic Proximity Switch

Relays

Pressure Switch

Single-solenoid operated,
4-way, 2-position, Directional
Valve

Diffuse Reflective Photo-

electric Switch

Pushbutton

Table 1-1. Classifying the components used for electrical control of the Hydraulics Trainer.

CONCLUSION

In this exercise, you were introduced to the components used for electrical control
of the Hydraulics Trainer. You classified these components as input element,
controller element, or actuating mechanism.

REVIEW QUESTIONS

1. Name the three parts of an electrical control circuit.

2. What is the function of an input element?

3. Name the two types of relays used as controller elements in the Hydraulics
Trainer.

1-15
Familiarization with the Equipment

4. Name the part of an electrical control circuit that provides oil flow to the
actuator(s) according to the control signals received from the controller.

5. What is meant by “contact” when speaking of an input switch or a control relay?

6. What device provides the 24-V DC voltage required to power the electrical
components of the Hydraulics Trainer?

1-16
 Unit Test

1. Which one of the following is not a part of an electrical control circuit?

a. Input element;
b. Controller;
c. Meter;
d. Actuating mechanism.

2. An input element is a device that

a. decides what action to take based on the signals sent to it from the actuating
mechanisms.
b. decides what action to take based on the signals sent to it from the
controller.
c. provides an electrical signal to indicate that a hydraulic actuator has reached
a specific position or that it is time to start an operation.
d. provides oil flow to a hydraulic actuator according to the control signals sent
to it from the controller.

3. Which one of the following is not an input element?

a. Relay contact;
b. Pushbutton;
c. Pilot lamp;
d. Mechanical limit switch.

4. What type of controller element is used for electrical control of the Lab-Volt
Hydraulics Trainer?

a. Set of electromechanical relays;

b. Programmable logic controller (PLC);
c. Computer;
d. Multimeter.

5. Which part of an electrical control circuit provides oil flow to a hydraulic actuator
according to the control signals sent to it from the controller?

a. Input element;
b. Actuating mechanism;
c. Electromechanical relay;
d. Metering device.

6. Which one of the following is an actuating mechanism?

a. Single-solenoid operated directional valve;

b. Double-solenoid operated directional valve;
c. Flow control valve;
d. Both a. and b.

1-17
 Unit Test (cont'd)

7. Switch and relay contacts are symbolized

a. as normally open.
b. as normally closed.
c. in their normal (deactivated) position.
d. in their activated position.

8. A normally open (N.O.) switch contact is a contact that

a. opens when the switch is activated.

b. closes when the switch is activated.
c. closes when the switch is deactivated.
d. Both a. and c.

9. A normally closed (N.C.) relay contact is a contact that

a. opens when the relay coil is activated.

b. closes when the relay coil is deactivated.
c. opens when the relay coil is deactivated.
d. Both a. and b.

10. Which one of the following converts the 120-V AC line voltage into a 24-V DC
voltage that is used to power the electrical components of the Lab-Volt
Hydraulics Trainer?

a. Limit-Switch Assembly;
b. Relay;
c. Electrical lead;
d. 24-V DC Power Supply.

1-18
 Unit 2

Electrical Control Principles

UNIT OBJECTIVE

When you have completed this unit, you will be able to measure the voltage,
resistance, and current in an electrical circuit. You will also be able to read and draw
simple ladder diagrams. A simple electrically controlled hydraulic system will be
assembled and operated.

DISCUSSION OF FUNDAMENTALS

In order to understand how electrical control circuits work, it is important that you first
become familiar with the three parameters associated with basic electricity: voltage,
resistance, and current. Exercise 2-1 defines these parameters and describes the
relationship between them. It also shows how to measure each parameter in an
electrical DC circuit.

Electrical control circuits are represented on paper by ladder diagrams. Ladder

diagrams use a different set of symbols and rules than hydraulic schematics, but
their function is the same: to show how components are connected and how the
circuit operates. Exercise 2-2 explains how a ladder diagram works and how it
relates to the hydraulic circuitry. It also lists the rules for drawing ladder diagrams.

Exercise 2-3 introduces students to a basic electrically controlled hydraulic system

called one-cycle reciprocation system. One-cycle reciprocation systems extend
and retract a cylinder one time after an operator presses a START pushbutton. They
are often used on machines where an operator must position the workpiece by hand
before actuating the work cylinder.

2-1
2-2
 Exercise 2-1

Basic Electricity

EXERCISE OBJECTIVE

• To measure voltage, resistance, and current in an electrical control circuit;

• To test the operation of an electrical control circuit;
• To be aware of the safety rules to follow when using electrical equipment to
control a hydraulic system.

DISCUSSION

Fundamentals

Electricity is a form of energy used for lighting, heating, or providing control and
power for machines. It is produced by the flow of tiny particles of matter called
electrons through a conducting material. Examples of conducting materials are iron,
copper, and aluminium.

Electrical components such as wires, lamps, and solenoids are made of conducting
material and so allow electrons to pass through them. To produce a flow of electrons,
the electrical component must be connected to a source of electromotive force that
pushes the electrons through the component. This source may be either a generator
or a battery. As an example, Figure 2-1 shows a battery pushing electrons through
electrical wires to energize a solenoid. As a result, a magnetic field is created around
the solenoid.

Figure 2-1. Simple electrical circuit.

The electromotive force exerted by a source is called voltage. The magnitude of the
voltage is measured in volts (V). The instrument used to measure voltage is called
a voltmeter.

There is always an opposition to the flow of electrons through an electrical

component. This opposition to electron flow is called resistance. Resistance is
measured in ohms (Ω). The instrument used to measure resistance is called an
ohmmeter.

2-3
Basic Electricity

The result of electrons flowing through an electrical component is called current.

The magnitude of the current is measured in amperes (A). One ampere is equal to
the motion of 6.24 x 1018 electrons past a cross section in 1 second. The instrument
used to measure current is called an ammeter.

Ohm’s law

The magnitude of the current flowing through an electrical component is equal to the
voltage drop across the component, in volts, divided by the resistance of the
component, in ohms. This is called the Ohm’s law. Written as an equation, it
becomes:

If, for example, the voltage drop across the solenoid in Figure 2-1 is 20 V and the
resistance of the solenoid is 10 Ω, then the magnitude of the current flowing through
the solenoid is 2 A.

The Ohm’s law can be reformulated to calculate either voltage drop, resistance, or
current when the other two variables are known.

Electrical power

The capability of an electrical source to move electrons through a circuit is called

electrical power. Electrical power is measured in watts (W). The amount of power
generated by an electrical source is equal to the voltage supplied by this source
multiplied by the current flowing through the circuit. In equation form:

Some of the electrical power generated by the source is dissipated as heat by each
component in the circuit due to the resistance, or opposition to the current flow, of
the components. The rest of the power is consumed by an electrical device called
a load to perform a useful work such as producing light (lamp), providing rotary
motion (motor), or moving a plunger (solenoid).

The amount of power consumed by a load is equal to the voltage drop across this
load multiplied by the current flowing through it. It is also equal to the square of the
current flowing through the load multiplied by the resistance of the load. In equation
form:

If, for example, the current flowing through the solenoid in Figure 2-1 is 2 A and the
resistance of the solenoid is 5 Ω, then the power consumed by the solenoid is 20 W.

2-4
Basic Electricity

Types of electric current

Current flow through an electrical circuit may be one of two types: direct current or
alternating current.

• Direct current (DC) is the type of current produced by batteries and DC power
supplies. This type of current flows in only one direction: from the positive (+)
terminal of the battery or power supply towards the negative (!) terminal. The
DC Power Supply provided with your Hydraulics Trainer, for example, produces
a DC current.

Note: In DC circuits, the convention used for current flow says that current
flows from the positive (+) terminal of the DC source towards the negative
(!) terminal, even though the electrons actually flow from the negative
terminal towards the positive terminal.

• Alternating current (AC) is the type of current supplied to most houses and
plants. This type of current changes direction (polarity) many times each second.
Examples of devices that produce AC current are alternators and AC generators.

Figure 2-2 shows the symbols used to represent DC and AC power sources in
electrical diagrams.

Figure 2-2. Symbols used to represent DC and AC power sources in electrical diagrams.

Closed and open circuits

Figure 2-3 shows a simple DC circuit. This circuit includes a 24-V DC power supply,
a normally open (N.O.) pushbutton, and a directional valve solenoid. The pushbutton
allows an operator to control the flow of current through the circuit.

2-5
Basic Electricity

Figure 2-3. A pushbutton controls the flow of current through the circuit.

When the operator presses the pushbutton, the contact in the pushbutton goes from
open to closed, which creates a complete conducting path, starting at the
positive (+) terminal of the power supply, through the pushbutton contact, the
solenoid, and back to the negative (!) terminal of the power supply, as Figure 2-3 a)
shows. This permits the current to flow through the circuit. The circuit is said to be
closed. As a result, solenoid SOL-A is energized.

When the operator releases the pushbutton, the pushbutton contact goes from
closed to open, which breaks the continuity of the conducting path and stops the flow
of current, as Figure 2-3 b) shows. The circuit is said to be open. As a result,
solenoid SOL-A is de-energized.

Measuring voltage drop, resistance, and current

As previously mentioned, voltage is measured with a voltmeter, resistance is

measured with an ohmmeter, and current is measured with an ammeter. These
meters are available as separate units, but they are usually found combined in a
single enclosure called multimeter.

Figure 2-4 shows how to measure voltage drop, resistance, and current in a
DC circuit. Either a multimeter or a separate meter may be used.

• To measure the voltage drop across a component, connect a voltmeter or

multimeter placed in voltmeter mode across the component terminals, as
Figure 2-4 a) shows. Then turn on the power supply.

• To measure the resistance of a component, make sure the power supply is

turned off, then disconnect the component from the circuit. This may require you
to open one or more circuit connections. Connect an ohmmeter or multimeter
placed in ohmmeter mode across the component terminals, as Figure 2-4 b)
shows. The ohmmeter has its own internal power source (battery) that supplies
a current used to test the resistance of the component.

2-6
Basic Electricity

• To measure the current flowing through a component, make sure the power
supply is turned off, then connect an ammeter or multimeter placed in ammeter
mode in series with the component, as Figure 2-4 c) shows. Then, turn on the
power supply.

Note: Series means that all the current will flow through the component
and the rest of the circuit when the power supply is turned on.

Figure 2-4. Measuring voltage, resistance, and current in a DC circuit.

When using meters in DC circuits, it is essential to hook them up to the circuit

according to the proper polarity, since they will not read properly if connected
backwards and may be damaged. This means that the positive terminal (red probe)
of the meter must be connected to the positive side of the component under test, and
the negative terminal (black probe) of the meter to the negative side of the
component. The positive side of a component is the side that is nearest to the
positive terminal of the power supply on the electrical diagram of the circuit. The
voltage on the positive side of a component is always higher than the voltage on its
negative side.

Safety rules

Observe the following safety rules when using electrical equipment to control a
hydraulic system:

a. Always make sure that the electrical power supply is OFF when connecting or
disconnecting electrical leads or components.

b. Never leave any electrical lead unconnected. This could cause you to receive an
electrical shock when you touch the unconnected end of a lead while the
electrical power supply is on. This could also cause a short circuit to occur when
the unconnected end of a lead touches a metal surface.

c. Make sure the power switch on the electrical power supply is set to the OFF
position before connecting the power supply line cord.

d. When connecting an electrical circuit, make sure the contact terminals are free
of dirt, oil, and water. Dirt and oil are insulators and do not allow a good

2-7
Basic Electricity

connection to be made. Water is a conductor and might make a connection

where it is not wanted.

It is also a good idea to review the safety rules regarding manual control of a
hydraulic system, as these rules still apply. These rules are located in the
DISCUSSION section of Exercise 1-1 in the Hydraulics, Fundamentals manual.

Procedure summary

In the first part of the exercise, you will measure voltage, resistance, and current in
an electrical control circuit. You will use the measured values to calculate the power
consumed by a solenoid.

In the second part of the exercise, you will test the operation of the electrical control
circuit connected in the first part of the exercise.

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

Measuring voltage, current, and resistance in an electrical control circuit

G 1. Connect the electrical control circuit shown in Figure 2-5.

G 2. Make sure the power switch on the 24-V DC Power Supply is set to the
OFF position. Plug the line cord of the 24-V DC Power Supply into
AC outlet.

G 3. Turn on the 24-V DC Power Supply by setting its power switch to the
I position. The red indicator lamp inside the power switch should light to
indicate that a 24-V DC voltage is now supplied between the red (+) and
black (!) banana jacks of the DC Power Supply.

2-8
Basic Electricity

Figure 2-5. Electrical control circuit to connect.

G 4. Get the multimeter from its storage location. Connect the black probe of the
multimeter to the common terminal of the multimeter, and the red probe to
the multi-purpose (V@Ω@mA) terminal.

G 5. Measure the voltage supplied by the DC Power Supply. To do so, set the
multimeter selector to read DC volts. Then, connect the red probe of the
multimeter to the + terminal of the DC Power Supply and the black probe to
the ! terminal, as Figure 2-6 shows. Record below the voltage reading in
volts on your multimeter.

Note: If the multimeter displays a negative (!) voltage, it is wired

incorrectly. Check polarity and switch the multimeter probes.

Supply voltage = V

2-9
Basic Electricity

Figure 2-6. Measuring the supply voltage.

G 6. Measure the voltage drop across solenoid SOL-A of the Directional Valve
by performing the following steps:

– Connect the red probe of the multimeter to the positive (+) side of the
solenoid, and the black probe to the negative (!) side. The + side of the
solenoid is the side that is nearest to the + side of the DC Power Supply
on the electrical diagram of the circuit (see Figure 2-5).

– Press pushbutton PB1 on the Pushbutton Station to allow the current to

flow through the circuit and observe the voltage reading in volts on the
multimeter. Record this voltage in Table 2-1 under “VOLTAGE DROP”.

VOLTAGE DROP (V) RESISTANCE (Ω) CURRENT (A)

Table 2-1. Solenoid data.

G 7. Disconnect the multimeter probes from the solenoid of the Directional Valve.

G 8. Measure the resistance of the solenoid of the Directional Valve by

performing the following steps:

– Turn off the 24-V DC Power Supply by setting its power switch to the
O position.

– Disconnect the solenoid of the Directional Valve from the electrical

circuit. To do so, remove the lead connecting the + side of the solenoid
to the ! side of pushbutton PB1, and the lead connecting the ! side of
the solenoid to the ! terminal of the 24-V DC Power Supply.

2-10
Basic Electricity

– Set the multimeter to read ohms. Then, connect the red probe of the
multimeter to a terminal of the solenoid of the Directional Valve and the
black probe to the other terminal. Observe the resistance reading in
ohms on the multimeter. Record this resistance in Table 2-1 under
“RESISTANCE”.

Note: Never connect an ohmmeter or multimeter in ohmmeter

mode into a circuit while the DC Power Supply is on. To do so
could permanently damage the meter.

G 9. Disconnect the multimeter probes from the solenoid of the Directional Valve.

G 10. Measure the current flowing through the solenoid of the Directional Valve by
performing the following steps:

– Reconnect the ! side of the solenoid of the Directional Valve to the

! terminal of the 24-V DC Power Supply, using an electrical lead.

– Set the multimeter to read a DC current. Then, connect the red probe
of the multimeter to the ! side of pushbutton PB1, and the black probe
to the + side of the solenoid of the Directional Valve.

– Turn on the 24-V DC Power Supply. Press pushbutton PB1 to allow the
current to flow through the solenoid of the Directional Valve and observe
the current reading in milliamperes (mA) on the multimeter. Record this
current in Table 2-1 under “CURRENT”.

G 11. Release pushbutton PB1. According to the current reading on the multi-
meter, does the current flow through the solenoid when the pushbutton is
in its normal (released) condition? Why?

G 12. Turn off the 24-V DC Power Supply and the multimeter. Reconnect the
! side of pushbutton PB1 to the + side of the solenoid of the Directional
Valve using an electrical lead.

G 13. Based on the voltage drop and resistance recorded in Table 2-1, calculate
the current flowing through the solenoid of the Directional Valve using the
Ohm’s law.

2-11
Basic Electricity

G 14. Compare the current value calculated in step 13 with the current value
recorded in Table 2-1. Can the Ohm’s law be used to determine the current
through a component when the voltage drop and resistance of this
component are known?

G Yes G No

G 15. How would the current flow through the solenoid change if the voltage drop
across the solenoid were doubled and the solenoid resistance held the
same?

G 16. Calculate the amount of power consumed by the solenoid of the Directional
Valve, based on the voltage drop and current recorded in Table 2-1.

G 17. Calculate the amount of power consumed by the solenoid of the Directional
Valve, based on the current and resistance recorded in Table 2-1.

G 18. Compare the power value calculated in step 17 with the power value
calculated in step 16. Can the consumed power be calculated using two
different methods?

G Yes G No

Testing the operation of an electrical control circuit

G 19. Connect the electrically controlled hydraulic system shown in Figure 2-7.
This will allow you to test the operation of the electrical control circuit used
in the first part of the exercise.

Note: To identify the ports on the solenoid-operated Directional

Valve, refer to the letters silkscreened on the valve subplate next
to the ports.

2-12
Basic Electricity

Figure 2-7. Electrically controlled hydraulic system.

G 20. Turn on the 24-V DC Power Supply.

2-13
Basic Electricity

G 21. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the Power Unit reservoir. Oil should cover,
but not be over, the black line above the temperature/oil level indicator
on the Power Unit. Add oil if required.
c. Put on safety glasses.
d. Make sure the power switch on the Power Unit is set to the OFF pos-
ition.
e. Plug the Power Unit line cord into an AC outlet.
f. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

G 22. Turn on the Power Unit by setting its power switch to ON. With the solenoid
of the Directional Valve in the deenergized condition, the Directional Valve
is in the normal, crossed-arrows condition and the pumped oil is blocked at
port B of this valve. As a result, the pumped oil is now being forced through
the Relief Valve. Pressure Gauge A now reads the minimum pressure
setting of the Relief Valve.

Increase the pressure setting of the Relief Valve to 2000 kPa (290 psi). To
do so, turn this valve adjustment knob clockwise until Pressure Gauge A
reads 2000 kPa (290 psi).

G 23. While observing the reading of Pressure Gauge A, press pushbutton PB1
to energize the solenoid of the Directional Valve and shift this valve to the
straight-arrows position. What happens to the reading of Pressure
Gauge A? Why?

G 24. Release pushbutton PB1 to de-energize the solenoid of the Directional

Valve. What happens to the reading of Pressure Gauge A? Why?

G 25. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise.

G 26. Turn off the 24-V DC Power Supply.

2-14
Basic Electricity

G 27. Disconnect all hoses and electrical leads and wipe off any hydraulic oil
residue. Return all hoses and leads to their storage rack.

G 28. Remove all electrical and hydraulic components from the Work Surface and
wipe off any hydraulic oil residue. Return all components to their storage
location.

G 29. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you learned how to measure voltage, resistance and current in an
electrical circuit.

You measured the voltage drop across a component by connecting a multimeter in

voltmeter mode across the component terminals, with the power supply turned on.

You measured the resistance of a component by disconnecting it from the circuit and
by connecting a multimeter in ohmmeter mode across the component terminals.

Finally, you measured the current flow through a component by connecting a

multimeter in ammeter mode in series with the component. You learned that when
the voltage drop and resistance of a component are known, the Ohm’s law can be
used to calculate the current through this component.

You also learned two methods of calculating the power consumed by a load.

REVIEW QUESTIONS

1. What is the difference between direct current (DC) and alternating current (AC)?

2. What are the units of measurement for voltage, resistance, current, and power?

3. What is the mathematical relationship between current, voltage drop, and

resistance?

2-15
Basic Electricity

4. In a DC circuit, what is meant by the “positive (+) side” of a component?

5. Describe the method used to measure the current flowing through a component.

6. What are the two formulas for calculating the power consumed by an electrical
component?

7. Can an ohmmeter or multimeter in ohmmeter mode be used to measure the

resistance of an energized solenoid? Why?

2-16
 Exercise 2-2

Ladder Diagrams

EXERCISE OBJECTIVE

• To explain how a ladder diagram relates to the hydraulic circuitry;

• To assemble and operate basic ladder diagrams;
• To learn the rules for drawing ladder diagrams;
• To describe the operation of an electromechanical control relay.

DISCUSSION

The electrical control circuits you have seen until now were represented by pictorial-
type schematic diagrams. There are other methods of drawing schematic diagrams,
but ladder diagrams is the most popular method and probably the simplest and
easiest.

Ladder diagrams graphically show which switches must be closed or open to allow
the current to flow to an output load. Figure 2-8 shows the general appearance of a
ladder diagram. The vertical lines on the left and right sides of the diagram represent
the terminals of the power supply. The left line is the “hot” (+) terminal, and the right
line, the “ground” (!) terminal.

The horizontal lines are called rungs. Each rung basically consists of an input
element, an output load, and electrical wires joining these two devices. Input
elements, as pushbuttons, switches, and relay contacts, are located on the left side
of the rung. Output loads, as lamps, valve solenoids, and relay coils, are located on
the right side of the rung.

2-17
Ladder Diagrams

Figure 2-8. Basic ladder diagram.

When the input element on a rung is closed, it forms a continuous path, or closed
circuit, to the output load, allowing the current to flow from the positive (+) terminal
of the power supply to energize the output load. In Figure 2-8, for example,

• pressing pushbutton PB-1 causes normally open (N.O.) switch contact PB1 in
rung 1 to go closed and lamp L1 to turn on. When the pushbutton is released,
contact PB1 returns to its normal state, which is open, causing lamp L1 to turn
off;

• pressing pushbutton PB2 causes normally closed (N.C.) switch contact PB2 in
rung 2 to go open and lamp L2 to turn off. When pushbutton PB2 is released,
contact PB2 returns to its normal state, which is closed, causing lamp L2 to turn
on.

Series and parallel logic

Two or more input elements can be connected on a rung in series or parallel to form
AND and OR logic, as Figure 2-9 shows.

• Rung 1 of the ladder diagram is an example of series (AND) logic. Both switch
contacts must close in order for lamp L1 to turn on.

• Rung 2 of the ladder diagram is an example of parallel (OR) logic. Only one of
the switch contacts has to close in order for lamp L2 to turn on.

2-18
Ladder Diagrams

Figure 2-9. Series (AND) and parallel (OR) logic.

Several input elements can be connected in various combinations of series (AND)

and parallel (OR) to perform additional logic functions.

Rules for drawing ladder diagrams

1. The ladder diagram must show only electrical control devices such as switches,
relay coils, and solenoids. Directional valves, cylinders, and other hydraulic
devices never appear on a ladder diagram. These devices are drawn on a
hydraulic diagram.

2. Output loads such as lamps, relay coils, and valve solenoids must be drawn on
the right side of the ladder diagram, with one terminal connected directly to the
! terminal of the power supply. Load devices should never be connected directly
to the + terminal of the power supply.

There may be two or more output loads on the same rung. In that case, the loads
must be connected in parallel. Loads must never be connected in series on the
same rung.

Insofar as possible, output loads used to perform the control logic such as relay
coils should be drawn in the upper rungs of the ladder. Output loads used for
hydraulic control such as valve solenoids should be drawn in the lower rungs of
the ladder. This will make it easier for another person to understand how the
ladder works.

3. Input elements such as pushbuttons, switches, and relay contacts must be drawn
on the left side of the ladder diagram. They should never be connected directly
to the ! terminal of the power supply. There must be at least one input element
per rung.

4. All ladder rungs must be numbered.

2-19
Ladder Diagrams

5. Each device in the ladder diagram must be identified with a representative

abbreviation. For example, PB is an abbreviation for pushbutton, and CR is an
abbreviation for relay coil.

Contacts operated by a relay coil must be identified with the same abbreviation
as the coil which operates them. For example, contacts operated by relay
coil CR1 are labelled CR1-A, CR1-B, CR1-C, etc.

6. All components must be drawn on horizontal lines (rungs). They must not be
connected on the vertical lines, which represent the power supply terminals.

Electromechanical control relays

Electromechanical control relays are widely used in ladder diagrams to perform

complex logic functions. An electromechanical control relay consists of a solenoid
coil, a magnetic core, an armature, and one or more sets of normally open (N.O.)
and normally closed (N.C.) contacts. When a current flows through the relay coil, the
magnetic core and the armature are both magnetized and attract each other, causing
the armature to move towards the core. This switches the relay contacts to their
activated state. N.O. contacts go closed, while N.C. contacts go open. When the
current is removed from the relay coil, the armature is moved back to its original
position by a spring, which returns the relay contacts to their normal state.

Figure 2-10 shows the Relay supplied with your Hydraulics Trainer. It contains a
solenoid coil and three sets of N.O. and N.C. contacts. The Relay is of the triple-pole,
double-throw (3PDT) type, because it simultaneously switches three conducting
parts back and forth between two positions.

2-20
Ladder Diagrams

Figure 2-10. 3PDT Relay.

Procedure summary

In the first part of the exercise, you will test a basic ladder diagram.

In the second part of the exercise, you will test ladder diagrams using series (AND)
and parallel (OR) logic.

In the third part of the exercise, you will test a ladder diagram using a control relay.

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.

2-21
Ladder Diagrams

PROCEDURE

Basic ladder diagram

G 1. Make sure the power switch of the 24-V DC Power Supply is set to the
OFF position. Connect the circuit shown in Figure 2-11.

Figure 2-11. Testing the operation of a basic ladder diagram.

G 2. Turn on the 24-V DC Power Supply by setting its power switch to the
I position.

G 3. Does lamp L1 light?

G Yes G No

G 4. Press pushbutton PB1. What happens to lamp L1? Why? Explain by

referring to the ladder diagram in Figure 2-11.

2-22
Ladder Diagrams

G 5. Does lamp L2 light?

G Yes G No

G 6. Press pushbutton PB2. What happens to lamp L2? Why? Explain by

referring to the ladder diagram in Figure 2-11.

G 7. Turn off the 24-V DC Power Supply by setting its switch to the O position.

Ladder diagrams using series (AND) and parallel (OR) logic

G 8. Connect the series (AND) logic circuit shown in Figure 2-12.

Figure 2-12. Testing a ladder diagram using series (AND) logic.

G 9. Turn on the 24-V DC Power Supply.

G 10. Press pushbutton PB1. Does lamp L1 turn on?

G Yes G No

2-23
Ladder Diagrams

G 11. Press pushbutton PB2. Does lamp L1 turn on?

G Yes G No

G 12. Press both pushbuttons PB1 and PB2. Does lamp L1 turn on? Why?
Explain by referring to the ladder diagram in Figure 2-12.

G 13. In a ladder rung containing two switch contacts in series, what is the
condition required for the output load to energize?

G 14. Turn off the 24-V DC Power Supply. Connect the parallel (OR) logic circuit
shown in Figure 2-13.

Figure 2-13. Testing a ladder diagram using parallel (OR) logic.

G 15. Turn on the 24-V DC Power Supply. Press pushbutton PB1. Does lamp L1
turn on?

G Yes G No

2-24
Ladder Diagrams

G 16. Release pushbutton PB1. Press pushbutton PB2. Does lamp L1 turn on?

G Yes G No

G 17. In a ladder rung containing two switch contacts in parallel, what is the
condition required for the output load to energize?

G 18. Turn off the 24-V DC Power Supply.

Ladder diagram using a control relay

G 19. Connect the circuit shown in Figure 2-14. Notice that coil CR of the Relay
is not polarized, which means that it does not matter which coil terminal is
connected to pushbutton PB1 and which coil terminal is connected to the
! terminal of the 24-V DC Power Supply. Either way, the coil will still
energize and shift the relay contacts to their opposite state.

Figure 2-14. Testing a ladder diagram using a control relay.

G 20. Turn on the 24-V DC Power Supply. Since pushbutton PB1 is not pressed,
N.O. contact PB1 in rung 1 should be open and relay coil CR1 should be
deenergized. Therefore, N.C. relay contact CR1-B in rung 3 should be
closed and lamp L2 should be on. Is lamp L2 now on?

G Yes G No

2-25
Ladder Diagrams

G 21. Press pushbutton PB1. What happens to lamps L1 and L2? Why? Explain
by referring to the ladder diagram in Figure 2-14.

G 22. Release pushbutton PB1. What happens to the lamps? Why?

G 23. From your observations, does a relay provide more than one contact,
allowing one relay to control more than one electrical component?

G Yes G No

G 24. Turn off the 24-V DC Power Supply.

G 25. Disconnect all electrical leads. Remove all electrical components from the
Work Surface. Return all leads and components to their storage location.

CONCLUSION

In the first part of the exercise, you tested the operation of a basic ladder diagram.
You learned that a complete conducting path (closed circuit) must occur on a rung
in order for the output load on this rung to energize. You saw that a N.O. contact
keeps the circuit open until closed, and that a N.C. contact keeps the circuit closed
until open.

In the second part of the exercise, you tested the operation of ladder diagrams using
series (AND) and parallel (OR) logic. In a ladder diagram using several input
switches in series, all switch contacts must close in order for the output load to
energize. In a ladder diagram using several input switches in parallel, only one of the
switch contacts has to close in order for the output load to energize.

In the third part of the exercise, you tested the operation of a ladder diagram using
a control relay. You learned that when a relay coil is energized, the relay contacts
shift to their opposite condition. Normally open (N.O.) relay contacts close and
normally closed (N.C.) contacts open. When the relay coil is de-energized, the relay
contacts revert to their normal condition.

2-26
Ladder Diagrams

REVIEW QUESTIONS

1. What do the vertical lines on the left and right sides of a ladder diagram
represent?

2. Where should input switches and relay contacts be drawn on a ladder diagram?

3. Where should relay coils and valve solenoids be drawn on a ladder diagram?

4. Should a solenoid-operated directional valve appear in a ladder diagram or a

hydraulic diagram?

5. Should the solenoid of a solenoid-operated directional valve appear in a ladder

diagram or a hydraulic diagram?

6. In Figure 2-15, draw a ladder diagram of a circuit that operates as follows:

A. Pressing pushbutton PB1 will cause relay coil CR1 to energize and lamp L1
to turn on.

2-27
Ladder Diagrams

B. Pressing pushbutton PB2 at any time will de-energize lamp L1.

Figure 2-15. Ladder diagram for review question 6.

2-28
 Exercise 2-3

Basic Electrically Controlled Hydraulic System

EXERCISE OBJECTIVE

• To describe the function and operation of a magnetic proximity switch;

• To describe the purpose of a holding relay contact;
• To assemble and test a one-cycle reciprocation system.

DISCUSSION

Reciprocation of cylinders

Many industrial applications require that a hydraulic cylinder be extended and

retracted automatically after an operator presses a START pushbutton. This is called
reciprocation of a cylinder, and an electrical control circuit can be used to perform
this sequence. While the cylinder provides the muscles, or power, to do work, the
electrical control circuit provides fast and accurate control of a directional valve to
reciprocate the cylinder.

Reciprocation involves a change in the direction of the cylinder. Automatic reversal

is achieved by using the electrical signal provided by a sensing device, such as a
magnetic proximity switch, mechanical limit switch, or photoelectric switch, to shift
the directional valve when the cylinder becomes fully extended or retracted.

One-cycle reciprocation system

As an example, Figure 2-16 shows a ladder diagram providing one-cycle

reciprocation of a hydraulic cylinder. One-cycle reciprocation means that when
started by an operator, the cylinder rod extends fully, automatically retracts without
attention of the operator, and stops, which makes a complete cycle.

Automatic retraction is achieved with a solenoid-operated directional valve activated

by a magnetic proximity switch, PX1, placed at the end of the extension stroke. The
switch contact is normally closed (N.C.) in the deactivated condition.

a. In the normal condition of the system, the cylinder rod is retracted, as illustrated
in Figure 2-16 a). Relay coil CR1 is deactivated because an open circuit
condition exists on ladder rung 1 by the open condition of N.O. contacts PB1 and
CR1-A. Therefore, directional valve solenoid SOL-A is deenergized and the
valve is in the crossed-arrows condition.

2-29
Basic Electrically Controlled Hydraulic System

Figure 2-16. One-cycle reciprocation of a cylinder.

b. When pushbutton PB1 is pressed, as illustrated in Figure 2-16 b), the current
flows from the + terminal of the power supply, through contacts PB1 and PX1 in
rung 1, to energize relay coil CR1. This closes relay contacts CR1-A and CR1-B.

2-30
Basic Electrically Controlled Hydraulic System

Contact CR1-B in rung 2 causes solenoid SOL-A and lamp L1 to energize. This
causes the directional valve to shift to the straight-arrows position and extend the
cylinder rod. Contact CR1-A in rung 1 provides another path in parallel with
contact PB1 for the current to flow to relay coil CR1, and is called a holding, or
seal-in contact.

c. When pushbutton PB1 is released, as illustrated in Figure 2-16 c), the current
continues to flow to relay coil CR1 through the alternate path provided by holding
contact CR1-A being closed. Therefore, solenoid SOL-A stays energized and the
cylinder rod continues to extend to full stroke.

d. When the cylinder rod becomes fully extended, magnetic proximity switch LS1
is activated by the magnetic piston inside the cylinder. This is illustrated in
Figure 2-16 d). This opens N.C. contact PX1 in rung 1, de-energizing relay
coil CR1. This causes relay contact CR1-B in rung 2 to open, de-energizing
solenoid SOL-A and lamp L1. This causes the directional valve to return to the
crossed-arrows condition and retract the cylinder. When the cylinder rod is fully
retracted, it stops and waits for the operator to start another cycle.

Magnetic proximity switches

In the circuit described above, automatic reversal of the cylinder is achieved by using
the electrical signal provided by a magnetic proximity switch to shift a directional
valve when the cylinder rod becomes fully extended. Magnetic proximity switches are
widely used in industrial hydraulic systems to sense the position of a cylinder piston.
They can be easily and quickly mounted anywhere within the piston travel range.

Your Hydraulics Trainer comes with two magnetic proximity switches of the Reed
type. As Figure 2-17 shows, each switch consists of two mechanical reeds (contact
points that open and close by touching and separating), and of an internal relay coil
controlling a set of N.O. and N.C. contacts of the single-pole, double-throw
(SPDT) type. The + and ! terminals on top of the switch are to be connected to a
24-V DC power supply. The three other terminals provide access to the SPDT
contacts.

2-31
Basic Electrically Controlled Hydraulic System

Figure 2-17. Magnetic proximity switch of the Reed type with SPDT contacts.

When the magnetic piston of a cylinder comes within proximity of the switch, the
magnetic field pulls the switch reeds together, allowing the current to flow from the
+ terminal of the switch to energize the internal relay coil. This causes the switch
SPDT contacts to activate. The N.O. contact goes closed while the N.C. contact
goes open.

When the magnetic piston moves away from the switch, the switch reeds separate
again, de-energizing the relay coil. This causes the switch contacts to return to their
normal, deactivated state.

Procedure summary

In this exercise, you will assemble and test the one-cycle reciprocation system
described in the DISCUSSION section of the exercise.

– In the first part of the exercise, you will clamp the 3.8-cm (1.5-in) bore cylinder
to the Work Surface and mount a magnetic proximity switch at the end of its
extension stroke. Then 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 turning on the Power Unit.
Verification of the electrical control circuit is particularly important when working
on electrically controlled hydraulic systems because the functions being

2-32
Basic Electrically Controlled Hydraulic System

performed by this circuit may not be readily apparent to the operator, and
unpredictable cylinder motion may occur at anytime.

– In the third part of the exercise, you will test system operation.

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

Setting up the system

G 1. Get the 3.8-cm (1.5-in) bore cylinder from your storage location. Clamp the
cylinder to the Work Surface. Connect the two ports of the cylinder to the
Power Unit return line port through a manifold.

G 2. Get a Magnetic Proximity Switch from your storage location. Mount the
switch on the 3.8-cm (1.5-in) bore cylinder so that the switch is activated
when the cylinder rod is fully extended. To so do, perform the following
steps:

– Manually retract the cylinder rod completely.

– 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.

– Connect the circuit shown in Figure 2-18. Notice that the Magnetic
Proximity Switch, PX1, is to be wired normally open. Also, notice that
the switch + and ! terminals are to be connected to the corresponding
terminals of the 24-V DC Power Supply.

– Turn on the 24-V DC Power Supply. Pilot lamp L1 should be off,

indicating that the Magnetic Proximity Switch is deactivated.

– Manually extend the cylinder rod completely. Pilot lamp L1 should now
be on, indicating that the Magnetic Proximity Switch is activated. If L1
is off, loosen the set screw on the switch and reposition the switch until
L1 turns on. Then, tighten the set screw.

– When you have finished, retract the cylinder rod completely. Turn off the
24-V DC Power Supply.

2-33
Basic Electrically Controlled Hydraulic System

Note: If the cylinder rod is too hard to extend and retract manually, you
will have to actuate the cylinder rod hydraulically. To do this, disconnect
the two cylinder ports from the Power Unit return line port, then connect a
simple cylinder reciprocation circuit using the lever-operated Directional
Valve (P/N 6320) and the Relief Valve (P/N 6322). With the pressure
setting of the Relief Valve at minimum (knob turned fully
counterclockwise), turn on the Power Unit. Perform the above steps in
order to position the limit switch, using the Directional Valve lever to
extend and retract the rod. When the switch is correctly positioned, turn off
the Power Unit and disconnect the hoses, then proceed with the exercise.

Figure 2-18. Mounting a Magnetic Proximity Switch at the rod end of the 3.8-cm (1.5-in) bore
cylinder.

G 3. Disconnect the circuit and store all hoses and electrical leads.

2-34
Basic Electrically Controlled Hydraulic System

Figure 2-19. Schematic diagram of a one-cycle reciprocation system.

2-35
Basic Electrically Controlled Hydraulic System

G 4. Connect the one-cycle reciprocation system shown in Figure 2-19. As you

do this, be careful not to modify the mounting of the cylinder and Magnetic
Proximity Switch (PX1). Notice that PX1 is now to be wired normally closed.
The + and ! terminals of this switch are to be connected to the
corresponding terminals of the 24-V DC Power Supply.

Note: The solenoid of the Directional Valve is not polarized,

which means that it does not matter which solenoid terminal is
connected to relay contact CR1-B and which solenoid terminal is
connected to the ! terminal of the 24-V DC Power Supply. Either
way, the solenoid will still energize and shift the valve spool.

Testing the electrical control circuit

G 5. Turn on the 24-V DC Power Supply. Do not turn on the hydraulic Power
Unit yet.

G 6. Momentarily press pushbutton PB1. If the circuit is working, pilot lamp L1

should turn on to indicate that solenoid SOL-A of the Directional Valve is
energized. Is this your observation?

G Yes G No

G 7. Verify that solenoid SOL-A of the Directional Valve is energized. Get your
multimeter from its storage location and set it to read DC volts. Connect the
multimeter probes across the + and! terminals of the solenoid. The voltage
reading on the multimeter should be about 24 V, indicating that the solenoid
is energized. Does the multimeter read 24?

G Yes G No

G 8. Leave the multimeter probes connected across the solenoid. Turn off the
24-V DC Power Supply. Remove the electrical wire connecting N.C. switch
contact PX1 to the + side of relay coil CR1. This will simulate activation of
Magnetic Proximity Switch PX1. Turn on the DC Power Supply. You should
observe that lamp L1 is off and that the voltage across the solenoid is about
0 V. Is lamp L1 off and does voltage reading 0 V?

G Yes G No

G 9. When all the above conditions are met, the electrical control circuit is
operational. Turn off the 24-V DC Power Supply. Reconnect N.C. switch
contact PX1 to the + side of relay coil CR1, as Figure 2-19 shows. Turn on
the 24-V DC Power Supply, then proceed to the next part of the exercise.

2-36
Basic Electrically Controlled Hydraulic System

CAUTION!

Do not proceed with the exercise if any of the above

requirements are not met. Instead turn off the 24-V DC Power
Supply and check the circuit connections. Modify the circuit
connections as required, then turn on the DC Power Supply
and test circuit operation.

Testing the one-cycle reciprocation system

G 10. Before starting the Power Unit perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the Power Unit reservoir. Oil should cover,
but not be over, the black line above the temperature/oil level indicator
on the Power Unit. Add oil if required.
c. Put on safety glasses.
d. Make sure the power switch on the Power Unit is set to the OFF pos-
ition. Plug the Power Unit line cord into an AC outlet.
e. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

CAUTION!

Ensure that the electrical leads and components are not

placed in a position where they may become wedged or
confined between rigid parts of the trainer when the cylinder
rod extends. Otherwise, damage to the operator and the
trainer could result.

G 11. Turn on the hydraulic Power Unit.

G 12. With the solenoid of the Directional Valve deenergized, the valve is in the
crossed-arrows condition and the oil from the pump is directed to the rod
end of the cylinder. Since, however, the cylinder rod is fully retracted, the
pumped oil is blocked at the cylinder piston and is now being forced through
the Relief Valve. Adjust the adjustment knob of the Relief Valve so that the
system pressure at Pressure Gauge A is 1400 kPa (200 psi).

G 13. Start the cylinder cycle by momentarily pressing pushbutton PB1. Record
below what the cylinder rod does.

2-37
Basic Electrically Controlled Hydraulic System

G 14. Does the cylinder rod cycle more than one time or does it stop after one
cycle?

G 15. Start another cycle by momentarily pressing PB1. Is retraction automatic

when the cylinder rod becomes fully extended? Why? Explain by referring
to the ladder diagram in the electrical section of Figure 2-19.

G 16. Start another cycle by momentarily pressing PB1. Does the cylinder
continue to extend when you release PB1? Why? Explain by referring to the
ladder diagram in the electrical section of Figure 2-19.

G 17. What would happen to circuit operation if relay contact CR1-A in rung 1
were removed? Would you still be able to extend the cylinder? Explain.

G 18. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise.

G 19. Turn off the 24-V DC Power Supply and the multimeter.

G 20. Disconnect and store all hoses and electrical leads. Wipe off any hydraulic
oil residue.

G 21. Remove and store all electrical and hydraulic components. Wipe off any
hydraulic oil residue.

G 22. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

2-38
Basic Electrically Controlled Hydraulic System

CONCLUSION

In this exercise, you tested the operation of a one-cycle reciprocation system. You
saw that a cylinder can be made to retract automatically by using a magnetic
proximity switch. You learned that a relay contact can be used to maintain a closed
circuit to an 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 hydraulic 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.

REVIEW QUESTIONS

1. What is meant by «one-cycle reciprocation»?

2. What is the purpose of a magnetic proximity switch in a one-cycle reciprocation

system?

3. In the ladder diagram of Figure 2-19, what is the purpose of holding

contact CR1-A in ladder rung 1? Explain.

4. What will the cylinder rod do in the system of Figure 2-19 if N.C. contact PX1 in
ladder rung 1 is changed for a N.O. contact? Explain.

5. What will the cylinder rod do in the system of Figure 2-19 if N.O. contact CR1-B
in ladder rung 2 is changed for a N.C. contact? Explain.

2-39
2-40
 Unit Test

1. According to Ohm’s Law,

a. voltage drop is equal to current multiplied by resistance;

b. current is equal to voltage drop divided by resistance;
c. resistance is equal to voltage drop divided by current;
d. All of the above.

2. If the current flowing through the solenoid of a directional valve is 2 A and the
voltage drop across the solenoid is 10 V, then the power consumed by the
solenoid is

a. 40 W
b. 200 W
c. 20 W
d. 5W

3. Which one of the following is the correct way to measure the current flowing
through a component?

a. Connecting a voltmeter or multimeter placed in voltmeter mode across the

component terminals and then turning on the DC Power Supply.
b. Connecting an ohmmeter or multimeter placed in ohmmeter mode in series
with the component with the DC Power Supply turned off.
c. Connecting an ammeter or multimeter placed in ammeter mode in series
with the component and then turning off the DC Power Supply.
d. Connecting an ammeter or multimeter in ammeter mode in series with the
component and then turning on the DC Power Supply.

4. If the voltage across a component is 12 V and the current flowing through the
component is 2 A, then the resistance of the component is

a. 24 Ω
b. 6Ω
c. 48 Ω
d. 4Ω

5. Which one of the following is a general rule for drawing ladder diagrams?

a. The vertical lines on the left and right sides of the diagram represent the +
and ! terminals of the power supply.
b. Output loads are drawn on the right side of the ladder diagram.
c. Each device in the ladder diagram must be identified with a representative
abbreviation.
d. All of the above.

6. What happens when the coil of a control relay is energized?

a. N.O. relay contacts go open, while N.C. relay contacts go closed;

b. The relay contacts are returned to their normal state by a spring;
c. The coil burns out;
d. N.O. contacts close, while N.C. contacts open.

2-41
 Unit Test (cont’d)

7. In a ladder rung containing two N.C. switch contacts in series, what is the
condition required for the output load to energize?

a. Both switches must be deactivated.

b. One of the switches must be activated.
c. One of the switches must be deactivated.
d. Both switches must be activated.

8. Creating a holding circuit with a relay contact

a. maintains a closed circuit to the output load before the START pushbutton
is pressed.
b. maintains a closed circuit to the output load after the START pushbutton is
released.
c. maintains an open circuit to the output load after the START pushbutton is
released.
d. maintains an open circuit to the output load before the START pushbutton
is pressed.

9. One-cycle reciprocation means that when started by an operator, the cylinder

rod

a. extends fully and then stops.

b. extends and retracts two times.
c. extends and retracts once.
d. extends and retracts indefinitely.

10. Automatic reversal of a cylinder can be achieved by using the electrical signal
provided by a sensing device such as a

a. Mechanical limit switch;

b. Magnetic proximity switch;
c. Photoelectric switch;
d. All of the above.

2-42
 Unit 3

Functional Systems

UNIT OBJECTIVE

When you have completed this unit, you will be able to construct and operate
functional hydraulic systems that are electrically controlled.

DISCUSSION OF FUNDAMENTALS

When one hydraulic cylinder must reach a certain stage before another cylinder can
operate, these two cylinders are said to be sequenced. Sequencing of cylinders can
be achieved by means of a hydraulic sequence valve, as discussed in
Exercise 3-1, or by electrical means, as discussed in Exercise 3-2.

The speed of a hydraulic motor is usually controlled through the use of a flow control
valve. If a non-compensated flow control valve is used, any change in system
pressure will modify the flow rate through the valve, resulting in a change of motor
speed. When a precise motor speed is required, a pressure-compensated flow
control valve must be used. Exercise 3-3 explains how to operate a hydraulic motor
at constant speed under varying system pressures using a pressure-compensated
flow control valve. Exercise 3-3 also explains how to brake a hydraulic motor
gradually and smoothly using a sequence valve.

Many automated processes require that a cylinder be extended and retracted

indefinitely after a START pushbutton is pressed. This is called continuous
reciprocation. Exercise 3-4 introduces students to a continuous reciprocation
system that includes a dwell function to hold the cylinder in the extended position
before it retracts.

3-1
3-2
 Exercise 3-1

Hydraulic Sequencing of Cylinders

EXERCISE OBJECTIVE

C To describe the design and operation of a sequence valve;

C To describe the function and operation of a mechanical limit switch;
C To assemble and test a clamp and work system sequenced by a hydraulic
sequence valve.

DISCUSSION

Hydraulic sequencing of cylinders

In many industrial systems, there is a need for two or more actuators to move in a
certain programmed order, cycle after cycle. An example might be a cutting machine
which first clamps the workpiece and then starts the cut. The cutting operation must
begin only after the clamp operation is finished. This is called sequential operation
and a sequence valve might be used to perform this sequence.

Sequence valves

Figure 3-1 shows the Sequence Valve of the Hydraulics Trainer. The valve body has
three ports: an inlet pressure (P) port, a sequence (S) port, and a drain (D) port
which is to be connected to the reservoir. Similar to the Relief Valve, the Sequence
Valve is normally closed and it senses the pressure upstream. Unlike the Relief
Valve, however, the Sequence Valve is externally drained to the reservoir through
its drain port.

3-3
Hydraulic Sequencing of Cylinders

Figure 3-1. Pilot-operated sequence valve.

3-4
Hydraulic Sequencing of Cylinders

An internal spool controls the oil flow through the valve by acting on a large spring.
The pressure level where the spool begins to open to allow some oil to flow through
the valve is called cracking pressure. The pressure level where the spool is
completely open is called operating pressure. The operating pressure can be
adjusted by using the adjustment knob on the valve body. Turning the knob
clockwise increases the valve operating pressure. Once the operating pressure is
set, tightening a locking nut on the adjustment screw will prevent vibrations and
shocks from modifying the adjustment.

As long as the pressure upstream of the valve is lower than the valve cracking
pressure, the spool will remain closed and oil will not be allowed to flow through the
valve. When the upstream pressure becomes higher than the valve cracking
pressure, the spool will move up towards its open position to allow oil to flow through
the valve. When the valve becomes fully open, the pressure at the sequence port of
the valve will rise to the level demanded by the load. This means that the full system
pressure ( pressure setting of the Relief Valve) will be available downstream.

In order for the Sequence Valve to be able to hold its spool open against this
downstream pressure, the valve spring chamber must be drained to the reservoir.
If the reservoir connection is missing or blocked, the downstream oil will back up into
the spring chamber and cause the valve to close completely.

Sequence valves will not allow the oil to flow very well in the reverse direction,
because they will try to close, resulting in a restricted flow rate. When reverse flow
is required, as in a circuit containing an extending and retracting cylinder, a
sequence valve with a built-in check valve may be used, or an external check valve
may be connected across the valve inlet pressure (P) and sequence (S) ports. The
Sequence Valve of the Hydraulics Trainer does not have a built-in check valve, so
an external check valve must be connected across it when reverse flow is required.

Figure 3-2 shows the Check Valve of the Hydraulics Trainer. The valve consists of
inlet and outlet ports, a ball, and a light spring. When the pressure of the oil at the
inlet port is high enough to overcome the spring force, the ball is lifted off the valve
seat and oil flows through the valve. This is known as the free flow direction. When
the direction of the oil is reversed, however, the ball is pushed against the valve seat,
and oil cannot flow through the valve. This is known as the blocked flow direction.

Figure 3-2 also shows the symbol for the Check Valve. The valve blocks the oil
flowing in the direction of the arrow, but allows the oil to flow freely in the opposite
direction.

3-5
Hydraulic Sequencing of Cylinders

Figure 3-2. Check valve.

Application example

The most common application of sequence valves is for “clamp and work” circuits.
Clamp and work circuits usually consist of two cylinders. The clamp cylinder, which
is a small-bore cylinder, advances until it stalls against the workpiece. The work
cylinder, which is a larger-bore cylinder, performs a particular task on the clamped
workpiece, such as bending, pressing, drilling, cutting, or grinding. The clamp
cylinder must always extend first, and the workpiece must be clamped with sufficient
force at the moment when the work cylinder starts to extend. Full clamping force
must continue during extension of the work cylinder. Sequence valves are a good
way to achieve this action.

As an example, Figure 3-3 shows a clamp and press system sequenced by a

sequence valve. The clamp operation is performed by a small-bore cylinder to limit
the clamping force and prevent distortion or damage to the workpiece. The press
operation is performed by a large-bore cylinder to press the workpiece with full force.
A sequence valve connected upstream will not open unless the system pressure
reaches the valve pressure setting of 2000 kPa (290 psi). Therefore, the oil flow to
the press cylinder is blocked until the workpiece is clamped with sufficient force.

3-6
Hydraulic Sequencing of Cylinders

Figure 3-3. Clamp and press system sequenced by a hydraulic sequence valve.

C In the normal condition of the circuit, both cylinders are retracted, so the operator
can load a workpiece into the machine, as Figure 3-3 a) shows. Solenoids A and
B of the directional valve are deenergized, so the valve is in its center position.

3-7
Hydraulic Sequencing of Cylinders

Since this valve is of the tandem-center type, the pumped oil is allowed to return
to the reservoir at low pressure. This unloads the pump and saves energy.

C When the operator presses a START pushbutton, the directional valve is shifted
to the straight-arrows condition, as illustrated in Figure 3-3 b). The clamp cylinder
starts to extend. Since this cylinder extends under no load, it requires a pressure
that is less than the 2000 kPa (290 psi) setting of the sequence valve. Therefore,
the sequence valve stays closed and the flow is blocked to the press cylinder.

C Once the clamp cylinder is extended, the pumped oil becomes deadheaded and
the system pressure rises quickly. When it reaches 2000 kPa (290 psi) upstream
of the sequence valve, the valve opens and the press cylinder extends. When
the cylinder contacts the workpiece, the system pressure rises to its maximum
level (setting of the relief valve) to press the workpiece with full force. This is
illustrated in Figure 3-3 c).

Notice that this pressure is also applied to the cap end of the clamp cylinder. This
means that a sequence valve cannot be used as a relieving device to limit
pressure in the other circuit branches. For that reason, a pressure reducing valve
is often used to limit the pressure in the branch of the clamp cylinder.

C Once the press cylinder is extended, it activates mechanical limit switch LS1.
This causes the directional valve to shift to the crossed-arrows condition to
retract the cylinders, as illustrated in Figure 3-3 d). The clamp cylinder completes
its stroke first because it requires the lowest pressure to move. The press
cylinder then completes its stroke, which activates mechanical limit switch LS2
and stops the cycle.

Mechanical limit switches

In the circuit of Figure 3-3, automatic reversal and stopping of the cylinders is
achieved by using the electrical signals provided by mechanical limit switches to shift
the directional valve when the cylinders become fully extended or retracted.
Mechanical limit switches are used extensively on industrial hydraulic equipment.
They are reliable, small in size, simple to use, and generally cheaper than the other
types of switches.

A mechanical limit switch basically consists of an actuator and one or more sets of
N.O. and N.C. contacts. It is activated when a moving part, such as a cylinder rod
or machine member, strikes the actuating mechanism, shifting the contacts to their
activated state.

Figure 3-4 shows the Limit-Switch Assembly supplied with your Hydraulics Trainer.
Also shown are the hydraulic and ladder diagram symbols of a mechanical limit
switch. Each switch has a roller-type actuator and a set of SPDT contacts of the
single-pole, double-throw (SPDT) type. When the cylinder tip travels across one of
the switches, it pushes against the roller, depressing the lever arm. The lever arm
acts on an internal plunger, causing the SPDT contacts to activate. The N.O. contact
goes closed while the N.C. contact goes open. When the cylinder tip moves away
from the switch, a spring returns the lever arm and SPDT contacts to their normal
condition.

3-8
Hydraulic Sequencing of Cylinders

Figure 3-4. Mechanical limit switch with roller arm actuator and SPDT contacts.

Mechanical limit switches are often available as multiple-switch assembly with two
or more limit switches mounted on the same supporting frame. The two mechanical
limit switches supplied with your Hydraulics Trainer, for example, are mounted on the
same supporting frame. This design is ideal for situations which require two switches
mounted side by side.

Procedure summary

In the first part of the exercise, you will test the operation of a sequence valve.

In the second part of the exercise, you will connect and test the hydraulically-
sequenced clamp and press system described in the DISCUSSION section of the
exercise.

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

Operation of a sequence valve

G 1. Connect the circuit shown in Figure 3-5. In this circuit, the Flow Control
Valve will be used to simulate a varying load downstream of the Sequence
Valve. The lever-operated Directional Valve will be used to simulate a clamp
cylinder extending to a workpiece.

Note: If required, refer to Figure 3-1 to locate ports P, S, and D

on the Sequence Valve .

3-9
Hydraulic Sequencing of Cylinders

Figure 3-5. Testing the operation of a sequence valve.

G 2. Open the Flow Control Valve completely by turning its adjustment knob fully
counterclockwise.

G 3. Close the Sequence Valve completely. To do so, first loosen the locking nut
on the adjustment screw by turning this nut fully counterclockwise. Then,
turn the valve adjustment knob fully clockwise. The operating pressure of
the Sequence Valve is now set at the highest possible pressure.

G 4. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the Power Unit reservoir. Oil should cover,
but not be over, the black line above the temperature/oil level indicator
on the Power Unit. Add oil if required.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

G 5. Turn on the Power Unit.

G 6. With the Sequence Valve fully closed and the Directional Valve in its center
condition, the pumped oil is now being forced through the Relief Valve. Turn

3-10
Hydraulic Sequencing of Cylinders

the adjustment knob of the Relief Valve clockwise until the system pressure
at Pressure Gauge A is 3000 kPa (440 psi).

G 7. Observe the Flowmeter reading. Since the Sequence Valve is closed, no oil
flows downstream of the Sequence Valve.

Decrease the operating pressure of the Sequence Valve by turning its

adjustment knob counterclockwise until the reading of Pressure Gauge A
starts to decrease. As indicated by the Flowmeter reading, the Sequence
Valve is now open because its operating pressure is lower than the pressure
setting of the Relief Valve. The operating pressure of the Sequence Valve
is indicated by Pressure Gauge A.

Note: The adjustment knob of the Sequence Valve can be turned

over approximately six turns. You may have to turn the valve
knob four or five turns counterclockwise before the reading of
Pressure Gauge A starts to decrease.

G 8. Open the Sequence Valve completely by turning its adjustment knob fully
counterclockwise. Observe the reading of Pressure Gauge A. This is the
minimum operating pressure of the Sequence Valve. Record this pressure
below.

Minimum operating pressure: kPa or psi

G 9. Set the operating pressure of the Sequence Valve to 2000 kPa (290 psi). To
do so, turn the valve adjustment knob clockwise until the reading of
Pressure Gauge A is 2000 kPa (290 psi).

G 10. Decrease the Flow Control Valve opening (turn knob clockwise) until the
reading of Pressure Gauge B is 1000 kPa (150 psi). This creates a down-
stream load that is lower than the operating pressure of the Sequence
Valve. What happens to the condition (open/closed) of the Sequence Valve
and reading of Pressure Gauge A? Explain.

G 11. Further decrease the Flow Control Valve opening (turn knob clockwise) until
the reading of Pressure Gauge B is 2500 kPa (360 psi). This creates a
downstream load that is higher than the operating pressure of the Sequence
Valve. What happens to the condition (open/closed) of the Sequence Valve
and reading of Pressure Gauge A? Why?

3-11
Hydraulic Sequencing of Cylinders

G 12. Move the lever of the Directional Valve toward the valve body to simulate a
clamp cylinder extending under no load to a workpiece. What happens to
the reading of Pressure Gauge A and condition (open/closed) of the
Sequence Valve? Explain.

G 13. Release the lever of the Directional Valve to simulate the clamp cylinder
stalling against the workpiece. What happens to the condition (open/closed)
of the Sequence Valve and reading of Pressure Gauge A? Explain why.

G 14. Decrease the pressure setting of the Relief Valve by turning its adjustment
knob counterclockwise until the upstream pressure at Pressure Gauge A is
1000 kPa (150 psi). Is the Sequence Valve still open? Why?

G 15. Increase the pressure setting of the Relief Valve by turning its adjustment
knob until the Sequence Valve re-opens (Flowmeter reads full flow). The
upstream pressure at Pressure Gauge A should now correspond to the
operating pressure (2000 kPa/290 psi) of the Sequence Valve. Is this your
observation?

G Yes G No

G 16. Turn off the Power Unit. Open the Relief Valve completely (turn knob fully
counterclockwise). Do not modify the 2000-kPa (290-psi) pressure setting
of the Sequence Valve. Lock the Sequence Valve to this setting by turning
its locking nut fully clockwise. Then, disconnect and store all hoses and
hydraulic components.

Hydraulically-sequenced clamp and press system

G 17. Get the 3.8-cm (1.5-in) bore cylinder from your storage location. Clamp this
cylinder to the Work Surface. Connect the two cylinder ports to the Power
Unit return line port through a manifold.

3-12
Hydraulic Sequencing of Cylinders

G 18. Mount a mechanical limit switch at the beginning of the 3.8-cm (1-5 in) bore
cylinder stroke, and another mechanical limit switch at the end of the
cylinder stroke. To do so, perform the following steps:

– Screw the cylinder tip (bullet) onto the rod end of the cylinder.

– Manually extend the cylinder rod completely.

– Clamp the Limit-Switch Assembly along the cylinder rod.

– Loosen the positioning screw on each limit switch. Position the switches
side by side at the center of the support bracket, as Figure 3-6 a)
shows. Tighten the limit-switch positioning screws.

– Loosen the support-bracket positioning screws until you are able to slide
the bracket over the mounting base, as Figure 3-6 b) shows. Adjust the
position of the bracket so that the switches are activated when the
cylinder tip pushes against the switch arm and deactivated when the
cylinder tip releases the switch arm. To test this out, manually extend
and retract the cylinder rod, and listen for the “click”. Then, tighten the
support-bracket positioning screws down on the mounting base.

– Loosen the positioning screw on each limit switch. Adjust the positioning
of the switches so that they are activated when the cylinder rod is fully
extended and fully retracted, as Figure 3-6 c) shows. To test this out,
manually extend and retract the cylinder rod, and listen for the click.
Then, tighten the limit-switch positioning screws.

– Retract the cylinder rod completely, as Figure 3-6 d) shows.

Note: If the cylinder rod cannot be extracted and retracted

manually, you will have to actuate the cylinder rod hydraulically.
To do this, disconnect the two cylinder ports from the Power Unit
return line port, then connect a simple cylinder reciprocation
circuit using the lever-operated Directional Valve (P/N 6320) and
the Relief Valve (P/N 6322). With the pressure setting of the
Relief Valve at minimum (knob turn fully counterclockwise), turn
on the Power Unit. Perform the above steps in order to position
the limit switches, using the lever of the Directional Valve to
extend and retract the rod. When the switches are correctly
positioned, turn off the power and disconnect the hoses, then
proceed with the exercise.

3-13
Hydraulic Sequencing of Cylinders

Figure 3-6. Mounting of the mechanical limit switches.

G 19. Connect the system shown in Figure 3-7. As you do this, be careful not to
modify the mounting of the 3.8-cm (1.5-in) bore cylinder and mechanical
limit switches (LS1 and LS2).

Note that these switches are to be wired normally closed. In the ladder
diagram of Figure 3-7 b), the side arrow on N.C. contact LS2 shows that it
is being held in the open condition before the cycle starts. This is because
the press cylinder [3.8-cm (1.5-in) bore], in fully retracted position, is holding
mechanical limit switch LS2 activated.

Note: The Sequence Valve should still be set to 2000 kPa

(290 psi) from the first part of the exercise. Continue to use this
setting.

3-14
Hydraulic Sequencing of Cylinders

Figure 3-7. Schematic diagram of an hydraulically-sequenced clamp and press system.

3-15
Hydraulic Sequencing of Cylinders

G 20. Adjust the maximum system pressure to 3000 kPa (440 psi). To do so,
remove the hose connecting Pressure Gauge A to port P of the Directional
Valve. Turn on the Power Unit. Turn the adjustment knob of the Relief Valve
clockwise until the system pressure at Pressure Gauge A is 3000 kPa
(440 psi), then turn off the Power Unit. Reconnect Pressure Gauge A to
port P of the Directional Valve.

G 21. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 22. Start the system by pressing pushbutton PB1 momentarily. The system
should operate as follows:

– The clamp cylinder (2.5-cm/1-in bore) starts to extend first;

– When the clamp cylinder becomes extended, the press cylinder
(3.8-cm/1.5-in bore) starts to extend;
– When the press cylinder becomes extended, both cylinders automati-
cally retract;
– When both cylinders are fully retracted, they stop and wait for the
operator to start a new cycle.

This cycle simulates a clamp and press system. Do you observe this?

G Yes G No

G 23. Repeat step 22 several times to become familiar with the operation of a
clamp and press system.

What causes the cylinders to extend when pushbutton PB1 is pressed?

Explain by referring to the ladder diagram in Figure 3-7.

G 24. Why does the clamp cylinder start to extend first?

G 25. Does the reading of Pressure Gauge A climb to the 2000-kPa (290-psi)
setting of the Sequence Valve when the clamp cylinder (2.5-cm/1-in bore)
becomes fully extended? Explain why.

3-16
Hydraulic Sequencing of Cylinders

G 26. What causes the cylinders to automatically retract when the press cylinder
becomes fully extended? Explain by referring to the ladder diagram in
Figure 3-7.

G 27. What causes the cycle to automatically stop when the press cylinder
becomes fully retracted? Explain by referring to the ladder diagram in
Figure 3-7.

G 28. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 29. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 30. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you tested the operation of a sequence valve. You
saw that this type of valve remains closed as long as the upstream pressure is lower
than the valve operating pressure. When the upstream pressure becomes higher
than the operating pressure, the valve opens and the full system pressure (relief
valve setting) is allowed to build downstream. This means that a sequence valve
cannot be used to limit the maximum circuit pressure.

In the second part of the exercise, you tested a clamp and press system sequenced
by a hydraulic sequence valve. You observed that the press cylinder only extended
when the clamp cylinder had extended and the system pressure had increased
enough to “crack” the sequence valve. This was not simply a delay between the two
operations. No matter how slowly the clamp cylinder extended, the press cylinder
could not start until the cylinder had finished its full stroke. This feature is important
in clamp and work systems where the actual times involved are not so important, but
where the two operations must take place in a certain order.

3-17
Hydraulic Sequencing of Cylinders

REVIEW QUESTIONS

1. Why are sequence valves used?

2. What is the normal condition of a sequence valve? Explain.

3. How is the sequence valve different from the relief valve?

4. What is the condition required for a sequence valve to open?

5. Why is a bypass check valve required across a sequence valve when reverse
flow is required?

3-18
 Exercise 3-2

Electrical Sequencing of Cylinders

EXERCISE OBJECTIVE

C To describe the design and operation of a pressure switch;

C To assemble and test an electrically sequenced clamp and work system.

DISCUSSION

Hydraulic sequencing compared to electrical sequencing

The clamp and press system tested in Exercise 3-1 was hydraulically sequenced
because a hydraulic sequence valve was used to move the cylinders in a definite
order. The problem with hydraulic sequencing is that the operation of the system
depends on the system pressure, so anything which interferes with the extension of
the clamp cylinder can open the sequence valve and start the press cylinder
prematurely. If, for example, the clamp cylinder were to jam, the press operation
could start insecurely held because the jammed cylinder would load the sequence
valve to open anyway.

A solution to this problem is to sequence the cylinders by electrical means, using

solenoid-operated directional valves and sensing devices such as limit switches and
pressure switches. As an example, Figure 3-8 shows an electrically sequenced
clamp and press system. The system is designed so the press cylinder cannot start
until the clamp cylinder has activated a mechanical limit switch, LS1, and the
pressure at the cap end of the clamp cylinder has risen enough to activate a
pressure switch, PS1. The cycling sequence is as follows:

1. Clamp cylinder extends;

2. Press cylinder extends;

3. Press cylinder retracts;

4. Clamp cylinder retracts. The cycle is ended.

As you can see, the two cylinders do not only extend in a definite order, but also
retract in a definite order. This sequence is designed so the clamp cylinder cannot
release its grip on the workpiece until the press cylinder has completely retracted.
This is particularly important for applications such as bending, cutting, and milling
where the workpiece must remain firmly clamped while being worked on and during
retraction of the work cylinder.

3-19
Electrical Sequencing of Cylinders

Figure 3-8. Electrically sequenced clamp and press system.

In the normal condition of the circuit, the clamp and press cylinders are retracted. As
a result, mechanical limit switch LS2 and magnetic proximity switch PX2 are
activated. Therefore, switch contacts LS2 and PX2 in Figure 3-8 b) are shown in their
activated state, as indicated by the side arrows. The dashed line connecting N.O.
and N.C. contacts LS2 indicates that these contacts are operated by the same switch
(LS2).

3-20
Electrical Sequencing of Cylinders

Also, pressure switch PS1 is deactivated because the pressure at its hydraulic port
is lower than its 1790-kPa (260-psi) pressure setting. Therefore, N.O. contact PS1
in Figure 3-8 b) is shown in its deactivated state.

Electrical circuit action is as follows:

1. Momentarily pressing the START pushbutton, PB1, causes relay coil CR1 to
energize. Relay contact CR1-A closes to lock in relay coil CR1. Relay
contact CR1-B closes, causing relay coil CR2 and solenoid A of directional
valve 1 to energize.

2. The clamp cylinder extends and after a short travel releases mechanical limit
switch LS2. This opens N.O. contact LS2 and breaks the current path to the
START pushbutton for the rest of the cycle. The clamp cylinder continues to
extend until it reaches the workpiece. This activates mechanical limit switch LS1.
This also causes the pressure to rise quickly at the cap end of the clamp
cylinder. When it reaches 1790-kPa (260-psi), it activates pressure switch PS1.
This energizes solenoid A of directional valve 2 to start the press cylinder. Due
to the back-pressure created by the flow control valve downstream from the
press cylinder, a substantial pressure is maintained at the cap end of the clamp
cylinder to keep the workpiece firmly clamped while being worked on.

3. The press cylinder extends until it reaches the workpiece. This causes the
system pressure to rise to the 3000-kPa (440-psi) setting of the relief valve to
press the workpiece with full force. When the press cylinder becomes fully
extended, it activates magnetic proximity switch PX1. This opens rung 1 by
causing the holding circuit of relay coil CR1 to drop out. This de-energizes relay
coil CR1 and solenoid A of directional valve 2. Directional valve 2 returns to its
normal condition and the press cylinder starts to retract. When it has released
magnetic proximity switch PX1, solenoid A of directional valve 2 remains de-
energized because holding contact CR1-A is now open.

4. Once fully retracted, the press cylinder activates magnetic proximity switch PX2.
This deenergizes relay coil CR2 and solenoid A of directional valve 1. Relay
contact CR2-A returns in the closed condition, which energizes solenoid B of
directional valve 1, causing the clamp cylinder to retract. Once fully retracted, the
clamp cylinder activates mechanical limit switch LS2, which deenergizes
solenoid B of directional valve 1 and reconnects the START pushbutton for
control so another cycle can be started. The cycle ends with both cylinders fully
retracted.

Hydraulic pressure switches

Hydraulic pressure switches are used in electrically controlled hydraulic systems to

ensure the pressure in a circuit branch is at some minimum acceptable level before
starting a cylinder or motor.

Figure 3-9 shows the Pressure Switch supplied with your Hydraulics Trainer. The
switch basically consists of a hydraulic pressure port and a set of N.O. and N.C.
contacts of the single-pole, double-throw (SPDT) type. The hydraulic pressure port
is to be connected into the hydraulic circuit like a pressure gauge. The pressure at
this port must never exceed the maximum value indicated on the switch scale
[35.9 bar (3590 kPa)/520 psi].

3-21
Electrical Sequencing of Cylinders

When the pressure at the hydraulic pressure port builds to the actuation, or set
pressure of the switch, the switch activates and shifts its contacts to their opposite
state. As long as the pressure remains above the actuation pressure, the switch will
remain activated. When the pressure drops to the reset pressure, the switch returns
to the deactivated state. The difference between the actuation and reset pressures
is called the differential. Differential action prevents minor pressure drops in the
sensing line from deactivating the Pressure Switch after it has activated.

Figure 3-9. Hydraulic pressure switch.

The pressure-switch actuation pressure can be adjusted by using an adjustment

knob on the switch itself. A black band on this knob indicates the actuation pressure
setting on the switch scale. Each calibration on the scale represents 4.5 bar
(450 kPa)/65 psi. Since the thickness of the black band corresponds to
approximately 4.5 bar (450 kPa)/65 psi, the scale is meant to approximate the
actuation pressure setting, not to accurately set the switch.

A smaller knob located besides the actuation pressure adjustment knob allows
adjustment of the differential. Turning this knob clockwise (when viewed from the
hydraulic pressure port of the switch )increases the differential, and so decreases the
reset pressure. The maximum adjustable differential is approximately
480 kPa/70 psi. In the clamp and press circuit of Figure 3-8, for example, the
differential of pressure switch PS1 is set to maximum to prevent the switch from
deactivating while an oil lock is maintained at the cap end of the clamp cylinder
because of oil leakage through directional valve 1 in the center condition.

3-22
Electrical Sequencing of Cylinders

Procedure summary

In the first part of the exercise, you will test the operation of a pressure switch.

In the second part of the exercise, you will connect and test the electrically
sequenced clamp and press system described in the DISCUSSION section of the
exercise. You will first clamp two cylinders to the Work Surface and mount two
switches at the ends of their stroke. Then you will assemble the system and test its
operation.

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

Operation of a pressure switch

G 1. Connect the system shown in Figure 3-10.

G 2. Set the pressure-switch actuation pressure to approximately 3590 kPa

(520 psi). To do so, turn the actuation-pressure adjustment knob until the
black band on the knob reads 35.9 bar (3590 kPa)/520 psi on the switch
scale.

Set the differential of the Pressure Switch to its maximum value. To do so,
turn the differential adjustment knob fully clockwise (when viewed from the
hydraulic pressure port of the switch).

G 3. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

3-23
Electrical Sequencing of Cylinders

Figure 3-10. Testing the operation of a pressure switch.

G 4. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 5. Turn the adjustment knob of the Relief Valve clockwise until the system
pressure at Pressure Gauge A is 1790 kPa (260 psi).

G 6. Is lamp L1 lit? Why?

3-24
Electrical Sequencing of Cylinders

G 7. Decrease the pressure-switch actuation pressure by turning the actuation

pressure adjustment knob clockwise (when viewed from the hydraulic
pressure port of the switch) until lamp L1 turns on. The pressure-switch
actuation pressure is now at 1790 kPa (260 psi).

G 8. Very slowly decrease the pressure setting of the Relief Valve (turn knob
counterclockwise) until lamp L1 turns off. Pressure Gauge A now indicates
the current reset pressure of the Pressure Switch . Record this pressure in
Table 3-1.

ACTUATION PRESSURE RESET PRESSURE DIFFERENTIAL

1790 kPa (260 psi)

Table 3-1. Pressure Switch data.

G 9. Based on the actuation and reset pressures recorded in Table 3-1, calculate
the current differential setting of the Pressure Switch. Record this differential
in Table 3-1.

G 10. Turn off the Power Unit and the 24-V DC Power Supply. Disconnect and
store all hoses and electrical leads. Remove and store all electrical and
hydraulic components. Be careful not to modify the actuation pressure and
differential settings of the Pressure Switch, since you will continue to use
these settings in the next part of the exercise.

Electrically sequenced clamp and press system

G 11. Get the 3.8-cm (1.5-in) and 2.5-cm (1-in) bore cylinders from your storage
location. Clamp these cylinders to the Work Surface. Connect the two ports
of each cylinder to the Power Unit return line port through a manifold.

G 12. Get a Magnetic Proximity Switch from your storage location. Mount the
switch on the 3.8-cm (1.5-in) bore cylinder so that the switch is activated
when the cylinder rod is fully extended.

G 13. Get another Magnetic Proximity Switch from your storage location. Mount
the switch on the 3.8-cm (1.5-in) bore cylinder so that it is activated when
the cylinder rod is fully retracted. Leave the cylinder rod fully retracted.

G 14. Mount a mechanical limit switch at the beginning of the 2.5-cm

(1-in) cylinder stroke, and another mechanical limit switch at the end of the
cylinder stroke. Leave the cylinder rod in the fully retracted position.

3-25
Electrical Sequencing of Cylinders

G 15. Remove and store all hoses and electrical leads.

G 16. Connect the system shown in Figure 3-8. As you do this, be careful not to
modify the mounting of the cylinders and limit switches.

Note: The actuation pressure of the Pressure Switch should still

be set to 1790 kPa (260 psi) from the first part of the exercise.
Continue to use this setting.

Note: The Magnetic Proximity Switches require a 24-V DC

voltage to operate. Therefore, make sure to connect the + and
! terminals of these switches to the 24-V DC Power Supply.

G 17. Adjust the maximum system pressure to 3000 kPa (440 psi) and the Flow
Control Valve. To do so, perform the following steps:

– Remove the hoses connecting port T of Directional Valve 1 to return

manifold.

– Disconnect the end of the hose connected to port T of Directional

Valve 2 and connect it to port T of Directional Valve 1.

– Close the Flow Control Valve completely by turning its adjustment knob
fully clockwise.

– Turn on the Power Unit.

– Adjust the knob of the Relief Valve until the system pressure at
Pressure Gauge A is 3000 kPa (440 psi)

– Open the Flow Control Valve partially in order for Pressure Gauge A to
read 2400 kPa (350 psi).

– Turn off the Power Unit.

– Disconnect the end of the hose connected to port T of Directional

Valve 1 and connect it to port T of Directional Valve 2. Connect port T
of Directional Valve 1 to the return manifold, using a hose. The circuit
should now be like that shown in Figure 3-8.

G 18. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 19. Start the system by pressing pushbutton PB1 momentarily. The system
should operate as follows:

– The clamp cylinder (2.5-cm/1-in bore) starts to extend first;

– When the clamp cylinder becomes fully extended, the press cylinder
(3.8-cm/1.5-in bore) starts to extend;
– When the press cylinder becomes fully extended, it retracts automati-
cally;

3-26
Electrical Sequencing of Cylinders

– When the press cylinder becomes fully retracted, it stops and the clamp
cylinder starts to retract;
– When the clamp cylinder becomes fully retracted, it stops. Both
cylinders are ready for a new cycle.

This cycle simulates an electrically sequenced clamp and press system. Is

this your observation?

G Yes G No

G 20. Repeat step 19 several times to become familiar with the operation of an
electrically sequenced clamp and press system.

What causes the clamp cylinder to extend when pushbutton PB1 is

pressed? Explain by referring to the ladder diagram in Figure 3-8.

G 21. What keeps the press cylinder from extending during the extension of the
clamp cylinder? Explain by referring to the ladder diagram in Figure 3-8.

G 22. What is the condition (shifted/centered) of Directional Valve 1 when the

press cylinder is extending and the clamp cylinder has fully extended? Why?

G 23. What causes the press cylinder to automatically retract when it becomes
fully extended? Explain.

3-27
Electrical Sequencing of Cylinders

G 24. Why is solenoid A of Directional Valve 2 (DV2-SOL-A) not re-energized

when the press cylinder releases Magnetic Proximity Switch PX1 during its
retraction stroke?

G 25. What causes the clamp cylinder to automatically retract when the press
cylinder becomes fully retracted? Explain.

G 26. What causes the cycle to automatically stop when the clamp cylinder
becomes fully retracted? Explain.

G 27. Press pushbutton PB1 momentarily. When the press cylinder is retracting,
but before it is fully retracted, try to restart the cycle by pressing PB1. Can
the cycle be restarted before the clamp cylinder has fully retracted? Explain
why.

G 28. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 29. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 30. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you demonstrated that electrical sensing devices such as limit
switches and pressure switches can be used instead of hydraulic sequence valves
to sequence the operation of clamp and press cylinders. Electrical sequencing,
compared with hydraulic sequencing, is a sure method for obtaining the sequential

3-28
Electrical Sequencing of Cylinders

action between the cylinders because both the position and pressure of the work
cylinder are sensed before starting the press cylinder. Hydraulic sequencing does
not provide complete fail-safe operation because any load on the clamp cylinder can
operate the sequence valve prematurely.

REVIEW QUESTIONS

1. In the ladder diagram of Figure 3-8, what is the purpose of relay contact CR2-A
on rung 2? Explain.

2. What does a dashed line connecting two switch contacts on a ladder diagram
indicate?

3. What is meant by the actuation point of a pressure switch?

4. What is the differential of a pressure switch?

5. Which two sensing devices of the electrical control circuit for a clamp and press
system prevent the press cylinder from starting before the clamp cylinder has
fully extended and the pressure at the cap end of this cylinder has risen enough
to clamp the workpiece with sufficient force?

3-29
3-30
 Exercise 3-3

Speed Regulation and Braking of Hydraulic Motors

EXERCISE OBJECTIVE

C To operate a hydraulic motor at constant speed under varying system pressures

using a pressure-compensated flow control valve;
C To brake a hydraulic motor gradually and smoothly using a sequence valve.

DISCUSSION

Speed regulation of a hydraulic motor

As you have learned from the Lab-Volt course on basic hydraulics, the speed of a
hydraulic motor is dependent on the rate at which the pumped oil fills the hydraulic
motor. This flow rate and, therefore, the motor speed, is usually controlled through
the use of a flow control valve.

If a non-compensated flow control valve is used, any change in pressure upstream

or downstream of the valve will modify the flow rate through the valve, resulting in
a change of motor speed.

When a precise motor speed is required, a pressure-compensated flow control

valve must be used. This type of valve is designed to regulate the flow at a selected
rate and then maintain this flow constant as the upstream and downstream
pressures vary.

Figure 3-11 shows the pressure-compensated flow control valve supplied with your
Hydraulics Trainer, along with its symbol. This valve consists of a needle valve, a
compensator spool acting on a bias spring, and a bypass check valve. The needle
valve is an adjustable orifice restricting the oil flow from the inlet to the outlet ports.
The compensating spool senses the rate of flow across the needle valve and
compresses the spring more or less, as needed, to keep a constant pressure
differential and, therefore, a constant flow rate across the needle valve. The check
valve allows the oil to flow freely from the outlet to the inlet ports, however it keeps
the oil from flowing in the other direction.

3-31
Speed Regulation and Braking of Hydraulic Motors

Figure 3-11. Pressure-compensated flow control valve.

Figure 3-12 shows an example of a system using a pressure-compensated flow

control valve to maintain a constant motor speed as the system pressure varies. This
system could easily be applied to a hydraulic drill unit. The hydraulic motor drives the
drill unit and the cylinder lowers and raises the drill unit. To keep the available motor
torque to a sufficient level when the cylinder extends, a sequence valve connected
upstream of the cylinder prevents the system pressure from dropping below
1700 kPa (250 psi).

The operator first starts the hydraulic motor by pressing the MAIN START
pushbutton, PB1. This energizes solenoid A of directional valve 1 and shifts the valve
to the straight-arrows condition, causing the hydraulic motor to start rotating. A
constant flow rate of 2 l/min [0.53 gal(US)/min] flows through the motor, while the
remainder of the pumped oil flows through the pressure relief valve. Gauge A,
therefore, reads the 3400-kPa (500-psi) pressure setting of the relief valve. Gauge B
reads a pressure of 2300 kPa (330 psi), which approximately corresponds to the
pressure drop created by the pressure-compensated flow control valve.

3-32
Speed Regulation and Braking of Hydraulic Motors

Figure 3-12. Hydraulic motor operated at constant speed.

When the operator presses the START CYLINDER pushbutton, PB3, the cylinder
extends and lowers the drill. This causes the system pressure at gauge A to drop to
about 3000 kPa (440 psi), which corresponds to the level required by the sequence

3-33
Speed Regulation and Braking of Hydraulic Motors

valve and the extending cylinder. This causes the pressure upstream of the
pressure-compensated flow control valve (gauge B) to drop to about 1000 kPa
(150 psi). However, the flow rate through the motor and, therefore, the motor speed
remain constant due to the compensating action of the pressure-compensated flow
control valve. If a non-compensated flow control valve were used, this change in
upstream pressure would cause the flow rate through the motor to decrease and in
turn the motor speed to decrease.

Braking of a hydraulic motor

When a hydraulic motor is suddenly stopped by returning a directional control valve

to neutral with a blocked center or blocked motor port condition, a high back-
pressure called pressure spike may be created in the line connecting the motor
outlet port to the directional valve. This is because during a short stopping period,
the kinetic energy of the motor and its load causes the motor to continue to rotate as
if it were a pump. The oil pumped by this action becomes deadheaded against the
directional valve, which creates a pressure spike. The higher the motor speed and
the heavier its load, the higher the pressure spike.

High pressure spikes can be damaging to the motor, the directional valve, the
pressure gauges, and the hoses. Their magnitude can be minimized by decelerating
the motor gradually while it is coming to a stop. This is called braking of a motor,
and a normally closed pressure control valve, such as a relief valve, brake valve, or
sequence valve, can be used to perform this action. With any of the types of valves
used, the braking action is created by limiting the back pressure produced at the
motor outlet when the motor stops.

As an example, Figure 3-13 shows a braking circuit that uses a sequence valve to
stop a motor gradually without causing high pressure spikes. You will notice that the
circuit drives the motor in only one direction.

C When the directional valve is shifted to the straight-arrows position, the motor
rotates and the oil discharging from it returns freely to the reservoir through the
check valve and path B-T of the directional valve, so the sequence valve stays
fully closed.

C However, when the directional valve is returned to its normal position, the oil
discharging from the motor becomes blocked in the line between the motor outlet
and port B of the directional valve. The kinetic energy of the motor and its load
continues to drive the motor, causing the motor to pump oil from the reservoir
into the blocked line through path T-A of the directional valve. This causes the
pressure to rise quickly in the blocked line. When it reaches the sequence valve
pressure setting, the valve opens to limit the back pressure at the motor outlet
and gradually discharge the entrapped oil to the reservoir. This causes the motor
to stop smoothly and prevents a pressure spike of dangerous level from being
produced.

3-34
Speed Regulation and Braking of Hydraulic Motors

Figure 3-13. Braking of a hydraulic motor by means of a sequence valve.

The amount of time required for the motor to stop and the magnitude of the pressure
spike generated can be adjusted by modifying the sequence valve pressure setting.
High sequence valve pressure settings will cause the motor to stop very rapidly but
will create high pressure spikes. Low sequence valve pressure settings will provide
significant attenuation of the pressure spikes, but will cause the motor to decelerate
very slowly. By experimentally adjusting the valve, a setting can be found which will
decelerate the motor rapidly without creating excessive pressure spikes.

It is important to allow the oil to flow directly from the reservoir into the rotating motor
when it is braking, because a partial vacuum is created at the motor inlet. If an

3-35
Speed Regulation and Braking of Hydraulic Motors

adequate amount of oil is not available at the motor inlet, the motor will cavitate like
a pump. In unidirectional-motor circuits, this requirement can be met by allowing the
motor inlet to be connected to the reservoir through a directional valve of appropriate
center configuration. In bidirectional-motor circuits, supplying oil to the motor inlet
during braking is usually done with check valves connected between the motor ports
and the reservoir. These valves are called make-up check valves.

Procedure summary

In the first part of the exercise, you will connect and test a hydraulic system that uses
a pressure-compensated flow control valve to maintain a constant motor speed when
the system pressure varies.

In the second part of the exercise, you will connect and test a hydraulic system that
uses a sequence valve to gradually stop a hydraulic motor.

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

Operating a hydraulic motor at constant speed

G 1. Connect the system shown in Figure 3-12. Remove the flywheel from the
shaft of the motor. To do so, loosen and remove the flywheel set screw,
using a hexagonal wrench. Set the flywheel aside for now.

G 2. Close the Sequence Valve completely. First loosen the locking nut on the
valve adjustment screw by turning this nut fully counterclockwise. Then, turn
the valve adjustment knob fully clockwise.

G 3. Close the Pressure-Compensated Flow Control Valve completely. To do so,

turn the valve adjustment knob fully clockwise.

G 4. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

3-36
Speed Regulation and Braking of Hydraulic Motors

G 5. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 6. Press the MAIN START pushbutton, PB1, to energize solenoid A of

Directional Valve 1 and shift this valve to the straight-arrows condition.
Since the Sequence Valve and the Flow Control Valve are closed, all the
pumped oil is now being forced through the Relief Valve. Turn the
adjustment knob of the Relief Valve clockwise until the system pressure at
Pressure Gauge A is 3400 kPa (500 psi).

G 7. Set the operating pressure of the Sequence Valve to 1700 kPa (250 psi). To
do so, perform the following steps:

– Turn off the Power Unit.

– Disconnect the hose coming from port S of the Sequence Valve at port
P of Directional Valve 2, then connect it to the return manifold.
– Turn on the Power Unit.
– Decrease the operating pressure of the Sequence Valve (turn knob
counterclockwise) until Pressure Gauge A reads 1700 kPa (250 psi).
– Turn off the Power Unit.
– Disconnect the hose coming from port S of the Sequence Valve at the
return line manifold, then connect it to port P of Directional Valve 2.
– Turn on the Power Unit.

G 8. Turn the Pressure-Compensated Flow Control Valve adjustment knob

counterclockwise to make the motor rotate. Adjust this valve until 2 l/min
[0.53 gal(US)/min] is indicated by the Flowmeter.

G 9. Record the pressure level upstream of the Pressure-Compensated Flow

Control Valve ( Pressure Gauge B) in the “RETRACTED” row of Table 3-2.

CYLINDER CONDITION FLOWMETER READING GAUGE B PRESSURE

RETRACTED 2 l/min
[0.53 gal(US)/min]

EXTENDING

Table 3-2. Circuit data with the Pressure-Compensated Flow Control Valve.

G 10. Now press and hold the START CYLINDER pushbutton, PB3, which will
cause the cylinder to extend and the pressure to drop upstream of the
Pressure-Compensated Flow Control Valve ( Pressure Gauge B). While the
cylinder is extending, observe the Flowmeter reading. A change in flow rate
is a sign that the motor speed is changing. Does the motor speed change
as the cylinder is extending?

G Yes G No

3-37
Speed Regulation and Braking of Hydraulic Motors

G 11. Release pushbutton PB3 to retract the cylinder if you have not already done
this.

G 12. Again press PB3 to extend the cylinder. While the cylinder is extending,
measure the Flowmeter reading and the reading of Pressure Gauge B.
Record these in the “EXTENDING” row of Table 3-2.

G 13. According to Table 3-2, is the flow rate affected across the Pressure-
Compensated Flow Control Valve when the pressure upstream of this valve
(Pressure Gauge B) decreases? Explain why.

G 14. Turn off the Power Unit. Disconnect the Pressure-Compensated Flow
Control Valve from the circuit and connect the Non-Compensated Flow
Control Valve in its place.

G 15. Close the Non-Compensated Flow Control Valve completely (turn knob fully
clockwise). Turn on the Power Unit.

G 16. Turn the Non-Compensated Flow Control Valve adjustment knob

counterclockwise to make the motor rotate. Adjust this valve until 2 l/min
[0.53 gal(US)/min] is indicated by the Flowmeter.

G 17. Record the pressure level upstream of the Non-Compensated Flow Control
Valve (Pressure Gauge B) in the “RETRACTED” row of Table 3-3.

CYLINDER CONDITION FLOWMETER READING GAUGE B PRESSURE

RETRACTED 2 l/min
[0.53 gal(US)/min]

EXTENDING

Table 3-3. Circuit data with the Non-Compensated Flow Control Valve.

3-38
Speed Regulation and Braking of Hydraulic Motors

G 18. Now press and hold the START CYLINDER pushbutton, PB3, which will
cause the cylinder to extend and the pressure to drop upstream of the Non-
Compensated Flow Control Valve (Pressure Gauge B). While the cylinder
is extending, observe the Flowmeter reading. Does the motor speed change
as the cylinder is extending?

G Yes G No

G 19. Release pushbutton PB3 to retract the cylinder. Again press PB3 to extend
the cylinder. While the cylinder is extending, measure the Flowmeter
reading and the reading of Pressure Gauge B. Record these in the
“EXTENDING” row of Table 3-3.

G 20. According to Table 3-3, is the flow rate affected across the Non-Compen-
sated Flow Control Valve when the pressure upstream of this valve
(Pressure Gauge B) decreases? Why?

G 21. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

Braking of a hydraulic motor

G 22. Connect the system shown in Figure 3-13.

G 23. Install the heavyweight flywheel onto the shaft of the motor. To do this,
perform the following steps:

– Slip the flywheel onto the motor shaft, taking care to align the set
screw in the flywheel hub with the notch in the motor shaft.

– Fully tighten the set screw, using the Allen key supplied with your
hydraulic motor.

– Check that the set screw is completely screwed into its hole.

– Ask your instructor to check the flywheel installation in case of doubt.

CAUTION!

Make absolutely certain the flywheel is secured to the motor

shaft.

3-39
Speed Regulation and Braking of Hydraulic Motors

G 24. Close the Sequence Valve completely. First loosen the locking nut on the
valve adjustment screw by turning this nut fully counterclockwise. Then, turn
the valve adjustment knob fully clockwise.

G 25. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 26. With the Directional Valve in the normal, crossed-arrows condition, the
pumped oil is blocked at the Check Valve and Pressure Gauge A indicates
the current pressure setting of the Relief Valve. Turn the adjustment knob
of the Relief Valve clockwise until the system pressure at Pressure Gauge A
is 2100 kPa (300 psi).

G 27. Press the START pushbutton, PB1, to energize solenoid A and start the
motor. After the motor has reached full speed, press the STOP pushbutton,
PB2, and observe the pressure spike at Pressure Gauge B when the motor
stops. Record the magnitude of this spike in the “MAXIMUM” row of
Table 3-4.

SEQUENCE VALVE PRESSURE PRESSURE SPIKE AT

BRAKE TIME
SETTING GAUGE B

MAXIMUM (VALVE CLOSED)

1400 kPa (200 psi)

900 kPa (130 psi)

– 0 kPa (0 psi)

Table 3-4. Pressure spike and brake time versus the pressure setting of the Sequence Valve.

G 28. Press the START pushbutton to start the motor. After the motor has reached
full speed, press the STOP pushbutton and measure the time required for
the motor to stop, using a stopwatch. Record this brake time in the
“MAXIMUM” row of Table 3-4.

Note: After the STOP pushbutton is pressed, the motor will come
to a stop and then start to rotate in the opposite direction for a
brief period due to oil leakage through the motor. Stop your
stopwatch just before the motor starts to rotate in the opposite
direction.

G 29. Adjust the operating pressure of the Sequence Valve to 1400 kPa (200 psi).
To do so, perform the following steps:

– Turn off the Power Unit. Remove the hose connecting the Check Valve
to port B of the Directional Valve. This will block the motor return line so
the oil discharging from the motor outlet will be forced to flow through
the Sequence Valve at whatever pressure this valve is set for. Turn on
the Power Unit.

3-40
Speed Regulation and Braking of Hydraulic Motors

– Press the START pushbutton. Decrease the operating pressure (turn

knob counterclockwise) of the Sequence Valve until the motor begins
to rotate. The operating pressure of the Sequence Valve is now slightly
lower than the 2100-kPa (300-psi) pressure setting of the Relief Valve,
as indicated by Pressure Gauge B. Further decrease the operating
pressure of the Sequence Valve until Pressure Gauge B indicates
1400 kPa (200 psi). Press the STOP pushbutton.

– Turn off the Power Unit. Reconnect the Check Valve to port B of the
Directional Valve. Turn on the Power Unit.

G 30. Repeat steps 27 and 28, recording the requested information in the
“1400 kPa (200 psi)” row of Table 3-4.

G 31. Set the operating pressure of the Sequence Valve to the lowest possible
level (900 kPa/130 psi approximately) by turning its knob fully
counterclockwise.

G 32. Repeat steps 27 and 28, recording the requested information in the
“900 kPa (130 psi)” row of Table 3-4.

G 33. Now bypass the Sequence Valve completely. To do so, turn off the Power
Unit. Disconnect the end of the hose connected to port P of the Sequence
Valve and connect it directly to the return manifold. Turn on the Power Unit.

G 34. Repeat steps 27 and 28, recording the requested information in the “–0 kPa
(0 psi)” row of Table 3-4.

G 35. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 36. According to Table 3-4, how does decreasing the pressure setting of the
Sequence Valve affect the magnitude of the pressure spike? Why?

G 37. How does decreasing the pressure setting of the Sequence Valve affect the
time required to stop the motor? Why?

3-41
Speed Regulation and Braking of Hydraulic Motors

G 38. Was oil from the reservoir allowed to flow directly to the motor inlet when the
motor was braking? Explain.

G 39. Remove the flywheel from the motor shaft.

G 40. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 41. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you learned that a pressure-compensated flow control
valve must be used to operate a hydraulic motor at constant speed when the system
pressure varies. You learned that the pressure-compensated flow control valve
compensates for changes in upstream and downstream pressures to maintain a
constant flow rate across its inlet and outlet ports. The non-compensated flow control
valve, on the other hand, does not compensate for changes in upstream and
downstream pressures, resulting in a varying flow rate across the valve for the same
needle valve setting.

In the second part of the exercise, you learned how a hydraulic motor can be made
to decelerate through the use of a sequence valve. When you stopped the motor with
the sequence valve fully closed, there was a short pressure spike as the motor tried
to keep rotating and pushing the oil into the blocked line. When you partially opened
the sequence valve, this spike simply opened the valve, allowing the motor to slow
down more gently and preventing the spike to rise to a dangerously-high level. You
have noticed that the motor stopped more slowly and the magnitude of the spike
decreased as the sequence valve pressure setting was decreased.

REVIEW QUESTIONS

1. What is the primary difference between a pressure-compensated flow control

valve and a non-compensated flow control valve?

3-42
Speed Regulation and Braking of Hydraulic Motors

2. What is the function of the pressure-compensated flow control valve in the

system shown in Figure 3-12?

3. What is the function of the sequence valve in the motor braking system of
Figure 3-13?

4. Explain the operation of the sequence valve in the motor braking system of
Figure 3-13.

5. In a motor braking system, why is it important to allow the oil to flow directly from
the reservoir into the rotating motor when the motor is braking?

3-43
3-44
 Exercise 3-4

Continuous Reciprocation with Dwell Period

EXERCISE OBJECTIVE

C To describe the operation of a time-delay relay;

C To assemble and test a continuous reciprocation system with dwell period.

DISCUSSION

Time-delay relays

Time-delay relays are designed to create a delay between two operations of a work
cycle. They are commonly used in hydraulic machining operations to delay the start-
up of a cylinder, start a series of cylinders one at a time, or hold a cylinder in a pre-
determined position for some period of time. For example, a metal drilling operation
may require the drill bit to remain in the hole temporarily to clean up the cut after
drilling through the metal. This function, called cylinder dwell, is accomplished
through the use of a time-delay relay that prevents the drill cylinder from retracting
immediately after reaching the end of the extension stroke.

Basic operation of a time-delay relay

The time-delay relay basically consists of a solenoid coil, an internal timer, and one
or more sets of N.O. and N.C. relay contacts. It can be designed for either ON-
DELAY or OFF-DELAY operation:

C The ON-DELAY relay does not shift its contacts to the activated state until a
preset time has passed after the coil has been energized. It returns them to the
normal state immediately when the coil is de-energized.

C The OFF-DELAY relay shifts its contacts to the activated state immediately when
the coil is energized. It returns them to the normal state after a preset time has
passed.

Hydraulics Trainer Time-Delay Relay / Counter

Figure 3-14 shows the Time-Delay Relay / Counter supplied with your Hydraulics
Trainer. This device can be programmed for either timing or counting function by
configuring the thumbwheel switches on top of the unit accordingly. Activation of the
programmable Time-Delay Relay / Counter is through the use of a control (C) input
terminal instead of a solenoid coil.

3-45
Continuous Reciprocation with Dwell Period

Figure 3-14. DPDT Time-Delay Relay / Counter.

To program the Time-Delay Relay / Counter for timing function, three parameters
must be configured, as Figure 3-14 shows:

Î Timer mode switch: selects between the following timer modes:

On-delay (switch set to A): when the CONTROL (C) input is switched to
common (!), an internal timer starts timing. When the preset time has passed,
both sets of relay contacts are activated. Momentarily switching the RESET (R)
input to common or removing the supply voltage at the + power input deactivates
both sets of relay contacts and resets the timer value.

Off-delay (switch set to B): when the CONTROL (C) input is switched to
common (!), both sets of relay contacts are activated and an internal timer starts
timing. When the preset time has passed, both sets of relay contacts are
deactivated. Momentarily switching the RESET input to common or removing the
supply voltage at the + power input deactivates both sets of relay contacts and
resets the timer value.

Ï Preset time switches: specify the value the timer must reach before the relay
contacts are activated (on-delay operation) or deactivated (off-delay operation).
Can be set between 001 and 999.

3-46
Continuous Reciprocation with Dwell Period

Ð Time base switch: the time base is a measure of the interval counted by the
timer. Selectable as 0.1 second (switch set to .1 S), 1 second (S), 0.1 minute
(.1 M), 1 minute (M), 0.1 hour (.1 H), 1 hour (H), or 10 hours (10 H).

Continuous reciprocation of a cylinder

Many automated processes involving machining operations, such as drilling,

pressing, bending, or cutting, require that a cylinder be extended and retracted
indefinitely after the process is started. This is called continuous reciprocation of
a cylinder, and a simple electrical control circuit can be used to perform this action.

Continuous reciprocation systems are usually started manually. The cylinder then
extends and retracts continuously until a signal stops the cycling process. This signal
could come from an operator, a counter, a timer, or an emergency circuit.

Several refinements can be added to the continuous reciprocation system to provide

special control functions. They may include a single-cycle reciprocation function
that will extend and retract the cylinder only one time, allowing initial set-up and
testing of the machine. They may also include a dwell function that will hold the
cylinder in the extended position for a pre-defined period of time. As an example,
Figure 3-15 shows a continuous reciprocation system featuring single-cycle
reciprocation and dwell functions.

This circuit uses a time-delay relay to dwell the cylinder for a short time at the end
of its extension stroke before retracting it. Pressing the START pushbutton will cause
the cylinder to extend and retract one time, allowing initial set-up and testing of the
system. Pressing the START pushbutton and then pressing the CONTINUOUS
MODE pushbutton while the cylinder is retracting or dwelling will cause the cylinder
to reciprocate continuously until the STOP pushbutton is pressed.

3-47
Continuous Reciprocation with Dwell Period

Figure 3-15. Continuous cylinder reciprocation system featuring single-cycle reciprocation and
dwell functions.

3-48
Continuous Reciprocation with Dwell Period

Detailed circuit action is as follows:

1. Pressing the START pushbutton, PB1, causes relay coil CR1 to energize.
Holding relay contact CR1-A closes to lock in relay coil CR1. Relay
contact CR1-B closes to energize directional valve solenoid SOL-A and extend
the cylinder.

2. When the cylinder becomes fully extended, it activates limit switch LS1. This
applies a 24-V DC voltage to the + input of timer TD1. Since the timer control (C)
input is connected to common (!), the timer starts timing. The cylinder remains
extended for the duration of the dwell with full pressure applied behind its piston.
When the preset time has passed, N.C. contact TD1-A on rung 1 opens, de-
energizing relay coil CR1 and causing relay contact CR1-B on rung 2 to open.
This de-energizes solenoid A, causing the cylinder to retract. This also removes
power to timer TD1, resetting the timer value.

3. When the cylinder becomes fully retracted, it activates limit switch LS2. If the
CONTINUOUS mode pushbutton, PB2, has been pressed during cylinder
extension or cylinder dwell, N.O. contact CR2-B on rung 1 will be closed and the
cylinder will reciprocate again. If PB2 has not been pressed, rung 1 will be open
and the cylinder will stop.

You will note in Figure 3-15, that the RESET (R) input of timer TD1 is connected to
the + input of TD1, preventing TD1 from being reset through its RESET input. This
is necessary because leaving the RESET input unconnected (floating) might cause
timer TD1 to be reset inopportunely.

Procedure summary

In the first part of the exercise, you will test the operation of a time-delay relay.

In the second part of the exercise, you will connect and test the continuous
reciprocation system with single-cycle reciprocation and dwell functions described
in the DISCUSSION section of the exercise.

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.

3-49
Continuous Reciprocation with Dwell Period

PROCEDURE

Operation of a time-delay relay

G 1. Connect the circuit shown in Figure 3-16. Use the trainer Time-Delay Relay /
Counter as timer TD1.

Figure 3-16. Testing the operation of a time-delay relay.

G 2. On the Time-Delay Relay / Counter (TD1), set the thumbwheel switches to

"A 0 1 0 S", as Figure 3-14 shows. This will program Time-Delay
Relay / Counter for on-delay operation, and set the preset time to
10 seconds.

G 3. Turn on the 24-V DC Power Supply. With pushbutton PB1 in the normal
(released) condition, the control (C) input of Time-Delay Relay / Counter
TD1 is deactivated and relay contacts TD1-A and TD1-B are in their normal
state, as indicated by lamps L1 and L2. Record the status of these lamps in
the “CONTROL INPUT DEACTIVATED” row of Table 3-5.

3-50
Continuous Reciprocation with Dwell Period

CIRCUIT CONDITION LAMP L1 LAMP L2

CONTROL INPUT DEACTI-

VATED

IMMEDIATELY AFTER THE

CONTROL INPUT IS ACTIVATED

10 s AFTER THE CONTROL

INPUT HAS BEEN ACTIVATED

AFTER RESET

Table 3-5. Lamp status versus coil condition.

G 4. What is the timer value on the display of the Time-Delay Relay / Counter?

G 5. While observing the displayed time and the status of lamps L1 and L2, press
pushbutton PB1 momentarily to activate the CONTROL input of Time-Delay
Relay / Counter TD1. Do the lamps change state immediately after the
CONTROL input is activated? Or do they change state 10 seconds after the
CONTROL input has been activated? Record your observations in
Table 3-5.

G 6. Momentarily press the RESET pushbutton, PB2, which will remove the
supply voltage at the + input of the Time-Delay Relay / Counter and will
reset the timer value. Do the lamps return to their initial state when the timer
value is reset? Record your observations in Table 3-5.

G 7. Based on the data recorded in Table 3-5, explain how the Time-Delay
Relay / Counter operates when placed in the on-delay mode.

G 8. Turn off the 24-V DC Power Supply. Disconnect and store all leads and
components.

Continuous cylinder reciprocation with dwell period

G 9. Get the 3.8-cm (1.5-in) bore cylinder from its storage location. Clamp the
cylinder to the Work Surface. Connect both ports of the cylinder to the
Power Unit return line port through a manifold.

G 10. Mount a mechanical limit switch so that it will activate when the 3.8-cm
(1.5-in) bore cylinder rod is fully retracted. Then, mount a second mechani-

3-51
Continuous Reciprocation with Dwell Period

cal limit switch so that it will activate when the cylinder rod is fully extended.
Manually extend and retract the cylinder rod to test the activation of the
switches. Leave the cylinder rod in the fully retracted position.

Note: If the cylinder rod cannot be extended or retracted

manually, you will have to actuate the cylinder rod hydraulically.
To do this, disconnect the two cylinder ports from the Power Unit
return line port, then connect a simple cylinder reciprocation
circuit using the lever-operated Directional Valve (P/N 6320) and
the Relief Valve (P/N 6322). With the pressure setting of the
Relief Valve at minimum (knob turned fully counterclockwise), turn
on the Power Unit. Perform the above steps in order to position
the limit switches, using the lever of the Directional Valve to
extend and retract the rod. When the switches are correctly
positioned, turn off the Power Unit and disconnect the hoses, then
proceed with the exercise.

G 11. Remove the hoses connecting the cylinder to the Power Unit return line port.

G 12. Connect the system shown in Figure 3-15. Be careful not to modify the
mounting of the cylinder and limit switches.

G 13. On the Time-Delay Relay / Counter, set the thumbwheel switches to

"A 0 0 5 S".

G 14. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

G 15. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 16. With the 3.8-cm (1.5-in) bore cylinder rod in the fully retracted position, all
the pumped oil is blocked at the cylinder piston and is now being forced
through the Relief Valve. Turn the adjustment knob of the Relief Valve
clockwise until the system pressure at Pressure Gauge A is 1700 kPa
(250 psi).

G 17. Start the system by pressing the START pushbutton momentarily. The
system should operate as follows:

– The cylinder rod extends to full stroke;

– When it becomes fully extended, it dwells for approximately 5 seconds;

3-52
Continuous Reciprocation with Dwell Period

– It then retracts to home position and stops.

This cycle simulates one-cycle reciprocation of a drill cylinder that dwells for
a short period before retracting. Record below if you observe this.

G Yes G No

G 18. Repeat step 17 several times to become familiar with the operation of the
system. What causes the cylinder rod to dwell when it becomes fully
extended? Explain by referring to the ladder diagram in Figure 3-15.

G 19. What causes the cylinder rod to retract when the dwell period has passed?
Explain.

G 20. Why does the cylinder rod stop when it becomes fully retracted?

G 21. Press the START pushbutton, then press the CONTINUOUS MODE
pushbutton while the cylinder rod is extending. Observe the operation of the
system in continuous mode. Does the cylinder rod extend and retract
continuously? Explain why.

G 22. Press the STOP pushbutton while the cylinder rod is extending. Does the
rod stop immediately? Explain why.

3-53
Continuous Reciprocation with Dwell Period

G 23. Try to start the cylinder rod by pressing the CONTINUOUS MODE
pushbutton. What happens? Why?

G 24. Press the START pushbutton, then press the CONTINUOUS MODE
pushbutton while the cylinder rod is retracting. Can the system be placed in
continuous mode during retraction of the cylinder rod? Why?

G 25. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 26. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 27. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you tested the operation of a time-delay relay. You
saw that a time-delay relay does not shift its contacts to the activated state until a
preset time has passed after the timer is activated. The contacts are returned to their
normal state immediately when the timer is deactivated.

In the second part of the exercise, you tested the operation of a continuous
reciprocation system. You learned that an electrical control circuit can cause a
hydraulic cylinder to repeat a cycle continuously until the operator stops the cycling
process. You also learned that continuous reciprocation systems can include
enhancements such as a one-cycle reciprocation function to allow initial set-up and
testing of the system, and a dwell function to hold the cylinder in the extended
position for a pre-defined period of time.

REVIEW QUESTIONS

1. What is the difference between an ON-DELAY and an OFF-DELAY relay?

3-54
Continuous Reciprocation with Dwell Period

2. What is meant by "preset time"?

3. What is meant by "cylinder dwell"?

4. In the ladder diagram of Figure 3-15, what purpose is served by N.O. relay
contact CR2-B on rung 1?

5. In the ladder diagram of Figure 3-15, what modification is required on rung 3 to

provide the capability to start the system in continuous reciprocation mode at the
press of PB3 without having to press PB1 first?

3-55
3-56
 Unit Test
1. The main function of a sequencing circuit is

a. operating actuators in a particular order;

b. cycling a cylinder many times;
c. cycling a cylinder one time;
d. monitoring system pressure.

2. Similar to the pressure relief valve, the sequence valve is

a. normally open and it senses the pressure downstream.

b. normally closed and it senses the pressure upstream.
c. normally open and it senses the pressure upstream.
d. normally closed and it senses the pressure downstream.

3. As long as the pressure upstream of a sequence valve is lower than the valve
cracking pressure, the valve will

a. remain wide open and oil will be allowed to flow through the valve.
b. remain closed and oil will be allowed to flow through the valve.
c. remain closed and oil will not be allowed to flow through the valve.
d. remain in some intermediate position to maintain the downstream pressure
at its operating pressure.

4. What is the purpose of a limit switch in an electrically controlled cycling system?

a. Maintaining the position of a cylinder.

b. Monitoring the position of a cylinder.
c. Adjusting the position of a cylinder.
d. Energizing and de-energizing valve solenoids.

5. What is the function of a pressure switch in an electrically sequenced clamp and

work circuit?

a. Preventing the clamp cylinder from over-tightening the workpiece.

b. Maintaining a constant pressure behind the piston of the clamp cylinder.
c. Ensuring that the workpiece is clamped correctly.
d. Allowing the pump to unload to reservoir at minimum pressure.

6. The difference between the actuation pressure and the reset pressure of a
pressure switch is called the

a. proof pressure.
b. pressure differential.
c. ambient pressure.
d. actuation point.

3-57
 Unit Test (cont'd)

7. Pressure-compensated flow control valves maintain a constant flow rate

a. as the upstream pressure varies.

b. as the downstream pressure varies.
c. by keeping a constant pressure drop across their internal needle valve;
d. all the above.

8. What is the function of a sequence valve in a hydraulic motor braking circuit?

a. To immediately stop the motor by creating a back pressure at the motor

inlet.
b. To stop the motor gradually and smoothly by limiting the back pressure
created at the motor outlet.
c. To allow the oil to flow directly from the reservoir into the rotating motor
when it is braking.
d. To decrease the braking time and increase the pressure spikes generated.

9. Cylinder dwell is a function used to

a. allow a cylinder to retract immediately after contacting the workpiece.

b. allow a cylinder to retract immediately after reaching the end of the
extension stroke.
c. prevent a cylinder from extending immediately after reaching the end of the
retraction stroke.
d. prevent a cylinder from retracting immediately after reaching the end of the
extension stroke.

10. Which one of the following describes the operation of a solid-state ON-DELAY
relay?

a. It shifts its contacts to the activated state immediately when the coil is
energized. It returns them to the normal state after a preset time has
passed.
b. It shifts its contacts to the activated state after a preset time has passed
after the coil has been de-energized. It returns them to the activated state
immediately when the coil is re-energized.
c. It does not shift its contacts to the activated state until a preset time has
passed after the coil has been energized. It returns them to the normal state
immediately when the coil is de-energized.
d. It does not shift its contacts to the deactivated state until a preset time has
passed after the coil has been energized. It returns them to the activated
state immediately when the coil is de-energized.

3-58
 Unit 4

Industrial Applications

UNIT OBJECTIVE

When you have completed this unit, you will be able to construct and operate
industrial-type hydraulic systems that are electrically controlled.

DISCUSSION OF FUNDAMENTALS

Some industrial processes include a drilling operation which is accomplished with a

drill attached to a hydraulic cylinder. Boring a hole, tapping and threading the hole,
and countersinking the top edge of the hole are all machining functions that involve
drilling. Exercise 4-1 introduces students to a typical drilling system that includes
a clamp cylinder, a drill cylinder that lowers and raises a hydraulic drill motor, and a
photoelectric switch that senses the position of the drill cylinder rod.

Safety is very important when working with hydraulic systems. On hydraulic

applications where a safety hazard exists, a safety circuit should be designed to
prevent injury to the personnel, and damage to the equipment and the product being
made. Exercise 4-2 introduces students to a basic two-hand safety circuit and a two-
hand, non-tie-down safety circuit.

Counting of actuator cycles is sometimes required in hydraulic systems when a

portion of the system must be activated or deactivated after a definite number of
events have occurred. Exercise 4-3 explains how to use an electrical counter to
count the number of cycles made by a hydraulic cylinder or motor.

Many industrial machines are required to operate at different pressures during

different stages of operation to protect components, to protect the workpiece being
worked on by actuators, and to save energy. Exercise 4-4 explains how to design a
multi-pressure system using a solenoid-operated directional valve.

Many industrial machine tools involve a cylinder that extends up to a workpiece at

a high speed before it performs a work on it. As the rod of a fast-moving cylinder
reaches a workpiece, however, it impacts against it with a great force. This impact
can cause serious damage to either the cylinder or the workpiece. Impacts damages
can be minimized by decelerating the cylinder rod just before it contacts the
workpiece. Exercise 4-5 discusses cylinder deceleration with a method called rapid
traverse-slow feed control.

4-1
4-2
 Exercise 4-1

Drilling System

EXERCISE OBJECTIVE

C To describe the function and operation of a photoelectric switch;

C To assemble and test an industrial-type drilling system.

DISCUSSION

Industrial drilling system

Many industrial processes include some kind of machining operation. Grinding,

shaping, folding, molding, honing, and milling are just a few of these operations.
Machining operations are often controlled by some type of sequencing circuit so that
each machining operation occurs at a specific moment during the work cycle. The
clamp cylinder should always operate first.

A drilling operation is a common machining operation. Many machining functions are

accomplished with a drill attached to a hydraulic cylinder. Boring a hole, tapping and
threading the hole, and countersinking the top edge of the hole are all machining
functions that involve drilling.

Figure 4-1 shows a typical drilling system that includes a clamp cylinder and a drill
cylinder that lowers and raises a hydraulic drill unit. The sequence of operation is as
follows: directional valve 1 is first shifted to extend the clamp cylinder. When the
workpiece is clamped into place, the hydraulic motor of the drill unit starts rotating.
Directional valve 2 is then shifted to extend the drill cylinder, which lowers the drill
unit. When the workpiece is drilled, directional valve 2 is shifted to retract the drill
cylinder, which raises the drill unit. When the drill cylinder is retracted, directional
valve 1 is returned to its normal condition to retract the clamp cylinder and stop the
hydraulic motor of the drill unit.

4-3
Drilling System

Figure 4-1. Industrial drilling system.

You will note in Figure 4-1 that the sequence valve connected upstream of
directional valve 2 allows the pressure to build in the branch of the clamp cylinder
and drill motor when directional valve 1 is shifted. If this valve were not used, all the
pumped oil would be allowed to return freely to the reservoir through directional
valve 2 in the center (tandem) condition, so the clamp cylinder would not extend and
the drill motor would not rotate.

The pressure-compensated flow control valve connected downstream of the

hydraulic motor provides a constant motor speed by compensating for pressure
changes upstream and downstream. It is adjusted so that the pressure at the motor
inlet must build to 2100 kPa (300 psi) before the motor can start rotating.

Detailed system action is as follows:

1. The workpiece to drill is first positioned by hand on the machine. When the
operator presses a START pushbutton, solenoid A of directional valve 1 is
energized. This shifts the valve to the straight-arrows condition to extend the

4-4
Drilling System

clamp cylinder. Since the extending clamp cylinder requires a pressure that is
less than 2100 kPa (300 psi), the hydraulic motor of the drill unit does not rotate.

2. When the clamp cylinder squeezes the workpiece, the pressure rises quickly
behind its piston. When it reaches 2100 kPa (300 psi), the hydraulic motor of the
drill unit starts rotating. Also, pressure switch PS1 is activated, indicating that the
workpiece is correctly clamped. This energizes solenoid A of directional valve 2
and shifts the valve to the straight-arrows condition to extend the drill cylinder.
Since the pressure applied to port P of the sequence valve (2100 kPa/300 psi)
is slightly lower than its 2350-kPa (340 psi) pressure setting, the sequence valve
stays partially closed so that most of the pumped oil goes to the motor, while a
small amount of oil goes through the sequence valve to extend the drill cylinder.
The drill cylinder, therefore, extends at slow speed, which is desirable because
the drill bit will not be damaged by impacting the workpiece.

3. The drill cylinder extends and lowers the drill unit to drill a hole in the workpiece.
When this cylinder becomes fully extended, it activates a photoelectric switch,
PE1. This energizes solenoid B of directional valve 2, shifting the valve to the
crossed-arrows condition to retract the drill cylinder and raise the drill unit. During
retraction of the drill cylinder, solenoid A of directional valve 1 is kept energized
so the drill motor continues to turn and the clamp remains holding.

4. When the drill cylinder becomes fully retracted, it activates magnetic proximity
switch PX2, which de-energizes solenoid B of directional valve 2 and returns the
valve to the center condition. This also de-energizes solenoid A of directional
valve 1, causing the clamp cylinder to retract and the drill motor to stop rotating.

5. When the clamp cylinder becomes fully retracted, it activates magnetic proximity
switch PX1, which stops the cycle. The drilled workpiece can then be removed.

Several refinements can be added to the drilling system to provide special control
functions. They may include, for example, a reset pushbutton as a safety feature to
permit the operator to stop the system at any sequential step and reset it back to the
initial state where both cylinders are fully retracted and the hydraulic motor is
stopped.

Photoelectric switches

A photoelectric switch is a sensing element that uses a light beam to sense the
presence or motion of an object. Unlike a mechanical limit switch, it can perform
these functions without physical contact. Photoelectric switches have several useful
applications, including cylinder position sensing, level sensing, product detection and
counting, and speed monitoring.

The photoelectric switch consists of a light source, a receiver, and one or more
sets of N.O. and N.C. contacts. The light source and receiver can be in the same
casing or separate casings. The light source projects a light beam, which may be
visible or infrared. The receiver picks up the light from the source, but ignores
ambient light.

Figure 4-2 shows the Diffuse Reflective Photoelectric Switch supplied with your
Hydraulics Trainer. This switch is of the proximity type. It consists of a visible light
source and a receiver combined in the same casing. When powered by a 24-V DC

4-5
Drilling System

voltage, the light source projects a beam of red light. When no object is within the
detection zone of the switch, the receiver sees dark and keeps the switch contacts
deactivated. When a reflective object such as the rod of a hydraulic cylinder enters
the detection zone, light reflects off the object back to the receiver. This causes the
receiver to activate the switch contacts and to keep them activated until the object
is removed from the detection zone. A red LED at the rear of the switch indicates the
status of the contacts. When turned on, this LED indicates that the switch contacts
are activated.

Figure 4-2. Photoelectric proximity switch.

The Diffuse Reflective Photoelectric Switch of the trainer has a detection range of
10.2 cm (4 in), which means that it is able to detect objects located within 10.2 cm
(4 in) of it. This range will vary slightly depending upon the reflectance, or ability to
reflect light, of objects. The more reflective an object, the longer the detection range.
The reflectance of an object depends on its surface material, colour, and texture.

Procedure summary

In this exercise, you will assemble and test the industrial drilling system described
in the DISCUSSION section of the exercise. You will first set up the system by
mounting the photoelectric and magnetic proximity switches and connecting the
system. You will then make the adjustments necessary for the system to start
working. Finally, you will test system operation.

4-6
Drilling System

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

Setting up the drilling system

G 1. Get the Diffuse Reflective Photoelectric Switch from your storage location.
Clamp the switch to the Work Surface. Connect the + and ! terminals of the
switch to the corresponding terminals of the 24-V DC Power Supply. Turn
on the 24-V DC Power Supply, which will power the light source inside the
switch.

G 2. Pass your hand in front of the Diffuse Reflective Photoelectric Switch. Does
the red LED at the rear of the switch turn on, indicating the switch contacts
are activated?

G Yes G No

G 3. Slowly move your hand away from the Diffuse Reflective Photoelectric
Switch. Does the switch LED turn off, indicating the switch contacts are
deactivated?

G Yes G No

G 4. Turn off the DC Power Supply.

G 5. Get the 3.8-cm (1.5-in) bore cylinder from your storage location. Clamp this
cylinder to the Work Surface. Connect the two ports of this cylinder to the
Power Unit return line port through a manifold.

G 6. Mount the Diffuse Reflective Photoelectric Switch so that it is activated

when the rod of the 3.8-cm (1.5-in) bore cylinder is extended. To do so,
perform the following steps:

– Make sure that a cylinder tip (bullet) is installed onto the rod end of the
cylinder. Manually extend the cylinder rod completely.

– Position the Diffuse Reflective Photoelectric Switch so that it is

perpendicular to the end of the cylinder rod and at a distance of
10 cm/4 in (2 rows of perforations) from it, as Figure 4-3 shows. Clamp
the switch into place.

Note: The distance separating two adjacent rows of perforations

on the Work Surface is 5 cm (2 in).

4-7
Drilling System

– Make sure the + and ! terminals of the Diffuse Reflective Photoelectric

Switch are connected to the 24-V DC Power Supply. Turn on the DC
Power Supply.

– Adjust the positioning of the Diffuse Reflective Photoelectric Switch so

that it is activated when the cylinder rod is extended. To test this out,
manually retract and extend the cylinder rod. The red LED at the rear of
the switch should turn on whenever the cylinder rod becomes fully
extended and turn off when the cylinder rod retracts.

– When the switch is correctly positioned, turn off the 24-V DC Power
Supply. Disconnect the Diffuse Reflective Photoelectric Switch from the
24-V DC Power Supply.

Figure 4-3. Mounting the Diffuse Reflective Photoelectric Switch at the end of the cylinder
extension stroke.

G 7. Mount a Magnetic Proximity Switch so that it is activated when the 3.8-cm

(1.5-in) bore cylinder rod is fully retracted. Leave the cylinder rod in the fully
retracted position.

G 8. Get the 2.5-cm (1-in) bore cylinder from your storage location. Clamp the
cylinder to the Work Surface.

4-8
Drilling System

G 9. Mount a Magnetic Proximity Switch so that it is activated when the rod of the
2.5-cm (1-in) bore cylinder is fully retracted. Leave the cylinder rod in the
fully retracted position.

G 10. Remove and store all hoses and electrical leads.

G 11. Connect the system shown in Figure 4-4. While doing this, be careful not to
modify the mounting of the cylinders and limit switches.

Note: Make sure the flywheel has been removed from the motor
shaft.

Note: The Magnetic Proximity Switches and Diffuse Reflective

Photoelectric Switch require a 24-V DC voltage to operate.
Therefore, make sure to connect the + and ! terminals of these
switches to the 24-V DC Power Supply.

Preliminary adjustments

G 12. Close the Sequence Valve completely. To do so, first loosen the locking nut
on the adjustment screw by turning this nut fully counterclockwise. Then,
turn the valve adjustment knob fully clockwise.

G 13. Close the Pressure-Compensated Flow Control Valve completely by turning

its adjustment knob fully clockwise.

G 14. Set the actuation pressure of the Pressure Switch to the maximum value.
To do so, turn the actuation pressure adjustment knob fully
counterclockwise (when viewed from the hydraulic pressure port of the
switch).

Set the differential of the Pressure Switch to the maximum value. To do so,
turn the differential adjustment knob fully clockwise (when viewed from the
hydraulic pressure port of the switch).

G 15. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

4-9
Drilling System

Figure 4-4. Industrial drilling system to connect.

4-10
Drilling System

G 16. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 17. With the clamp cylinder (2.5-cm/1-in bore) fully retracted and the Sequence
Valve closed, all the pump oil is now being forced through the Relief Valve.
Turn the adjustment knob of the Relief Valve until the system pressure at
Pressure Gauge A is 2800 kPa (400 psi).

G 18. Set the operating pressure of the Sequence Valve to 2350 kPa (340 psi). To
do so, turn the valve adjustment knob counterclockwise until the reading of
Pressure Gauge A is 2350 kPa (340 psi).

G 19. Press the START pushbutton, PB1, to energize solenoid A of Directional

Valve 1 and extend the clamp cylinder (2.5-cm/1-in bore). When the cylinder
is fully extended, slowly turn the Pressure-Compensated Flow Control Valve
adjustment knob counterclockwise to start the hydraulic motor. Adjust the
Pressure-Compensated Flow Control Valve until the reading of Pressure
Gauge B is 2100 kPa (300 psi).

G 20. Slowly decrease the actuation pressure of the Pressure Switch by turning
its actuation pressure adjustment knob clockwise until the drill cylinder
(3.8-cm/1.5-in bore) starts to extend. The pressure setting of Pressure
Switch PS1 is now 2100 kPa (300 psi).

Note: If the drill cylinder extends too slowly, very slightly

decrease the pressure setting of the Sequence Valve (turn knob
counterclockwise), which will allow a little more oil to go to the drill
cylinder.

This completes the preliminary adjustments. Wait until the system has
returned to the initial state where both cylinders are retracted and the
hydraulic motor is stopped. Proceed to the next part of the exercise.

Testing the operation of the drilling system

G 21. Start the system by pressing START momentarily. The system should
operate as follows:

– The clamp cylinder (2.5-cm/1-in bore) starts to extend first;

– When the clamp cylinder becomes fully extended, the hydraulic motor
starts rotating and the drill cylinder (3.8-cm/1.5-in bore) extends;
– When the drill cylinder becomes fully extended, it automatically retracts.
During retraction of this cylinder, the hydraulic motor continues to rotate
and the clamp cylinder remains extended.
– When the drill cylinder becomes fully retracted, it stops. The hydraulic
motor also stops, while the clamp cylinder retracts.
– When the clamp cylinder becomes fully retracted, it stops. The system
is now ready for a new cycle.

4-11
Drilling System

This cycle simulates an industrial drilling system. Is this what you observe?

G Yes G No

G 22. Repeat step 21 several times to become familiar with the operation of the
drilling system.

What causes the clamp cylinder to extend when the START pushbutton is
pressed? Explain by referring to the ladder diagram in Figure 4-4.

G 23. What keeps the hydraulic motor from rotating during the extension of the
clamp cylinder? Explain.

G 24. What causes the drill cylinder to start extending when the clamp cylinder
becomes fully extended? Explain.

G 25. What causes the drill cylinder to automatically retract when it becomes fully
extended? Explain.

G 26. What causes the hydraulic motor to stop and the clamp cylinder to retract
when the drill cylinder becomes fully retracted? Explain.

4-12
Drilling System

G 27. Press the START pushbutton, then press the RESET pushbutton while the
clamp cylinder is extending. What happens?

G 28. Press the START pushbutton, then press the RESET pushbutton while the
drill cylinder is extending. What happens? Explain by referring to the ladder
diagram in Figure 4-4.

G 29. If the pressure setting of the Sequence Valve was set at 2800 kPa (400 psi),
would the drill cylinder start to extend upon activation of Pressure
Switch PS1? Explain.

G 30. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 31. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 32. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you assembled and tested a drilling system that simulated the
sequential operation of a clamp cylinder and a drill cylinder attached to a
hydraulically-driven drill unit. You learned that a pressure switch and a sequence
valve can be used to sequence the operation of two cylinders. You also learned that
a photoelectric switch, unlike a mechanical limit switch, can detect the presence of
a cylinder rod without physical contact. You saw that a reset function can be added
to a drilling system to permit the operator to stop the system at any sequential step
and reset it back to the initial state.

4-13
Drilling System

REVIEW QUESTIONS

1. Describe the operation of a photoelectric switch of the proximity type.

2. Name the characteristics of an object that determine its ability to reflect light.

3. What is the purpose of the reset pushbutton in the drilling system of Figure 4-4?

4. What will the drill cylinder do in the system of Figure 4-4 if the actuation pressure
of pressure switch PS1 is set to 2800 kPa (400 psi)? Explain.

5. In the system of Figure 4-4, what purpose is served by the sequence valve?
Explain.

4-14
 Exercise 4-2

Safety Circuits

EXERCISE OBJECTIVE

C To describe the purpose of a safety circuit;

C To assemble and operate a basic two-hand safety circuit;
C To assemble and operate a two-hand, non-tie-down safety circuit.

DISCUSSION

Safety circuits

Hydraulic cylinders and motors often operate mechanisms which may present a
safety hazard to personnel. For example, the hydraulic press shown in Figure 4-5
could easily crush the hands of an operator. On hydraulic applications where a safety
hazard exists, a safety circuit should be designed to prevent injury to personnel as
well as the equipment and the product being made. In designing a safety circuit, first
priority should go into protecting the personnel, second into the equipment itself and
third, the product being made.

Figure 4-5. Hydraulic press.

4-15
Safety Circuits

Two-hand safety circuits

Two-hand safety circuits is the type of safety circuit most often used for protecting
operators. In this circuit, the operator must press two pushbuttons at the same time
to operate the machine. The pushbuttons are placed far enough apart so that one
hand must be used for each pushbutton. This ensures that both hands are clear of
the machine before it operates.

Two-hand safety circuits are used, for example, on hydraulic presses. Since both
hands are required to operate the press, the operator cannot carelessly place his
hands beneath the ram during the pressing stage of the cycle.

Figure 4-6 shows a basic two-hand safety circuit. Two pushbuttons, one for each
hand, are connected in series, so the operator must use two hands to start the
cylinder. There is no holding relay contact across pushbutton contacts PB1 and PB2.
The reason for this is to have the valve solenoid de-energized immediately when
either or both pushbuttons are released. This allows the operator to instantly retract
the cylinder at any time during its extension if a hazardous situation should occur.

Figure 4-6. Hydraulic system controlled through the use of a basic two-hand safety circuit.

Two-hand safety circuits must be designed so that they cannot be overridden or

bypassed. The reason is that many operators are paid for each piece or part they
make. In an effort to speed up machine operation, operators sometimes attempt to
bypass the safety circuit by tying down one of the pushbuttons. In Figure 4-6, for
example, if either pushbutton were tied down, the operator would be able to operate
the equipment with the other pushbutton.

A solution to this problem is to use a two-hand, non-tie-down safety circuit, as

Figure 4-7 shows. This circuit uses a time-delay relay (TD1) set for a delay of
1 second. If both pushbuttons are not pressed within a 1-second interval, the supply

4-16
Safety Circuits

voltage is removed at the + input of timer TD1, causing relay contacts TD1-A and
TD1-B to open, which prevents valve solenoid SOL-A from being energized and
keeps the cylinder in the fully retracted position. If one of the pushbuttons should be
tied down, relay contacts TD1-A and TD1-B in the open condition would prevent
valve solenoid SOL-A from being energized until both pushbuttons are released.

Figure 4-7. Hydraulic system controlled through the use of a two-hand, non-tie-down circuit.

Procedure summary

In this exercise, you will connect a basic two-hand safety circuit and a two-hand,
non-tie-down safety circuit, and study their operation.

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

Basic two-hand safety circuit

G 1. Connect the system shown in Figure 4-6. Make sure pushbuttons PB1 and
PB2 are located far enough apart so that two hands are required for
operating them.

4-17
Safety Circuits

G 2. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hydraulic hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

G 3. Close the Pressure-Compensated Flow Control Valve completely (turn knob

fully clockwise), then open it 1 turn.

G 4. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 5. Turn the adjustment knob of the Relief Valve clockwise until the system
pressure at Pressure Gauge A is 1700 kPa (250 psi).

G 6. Press pushbutton PB1 and watch the motion of the cylinder rod. Does the
rod extend?

G Yes G No

G 7. Release pushbutton PB1 and then press pushbutton PB2. Does the cylinder
rod extend?

G Yes G No

G 8. Press both pushbuttons at the same time and hold them in. What happens?

G 9. Release one of the pushbuttons. Does the cylinder rod retract?

G Yes G No

G 10. Press both pushbuttons to extend the rod, then release one pushbutton
while the rod is extending and in mid-stroke. What happens?

4-18
Safety Circuits

G 11. If pushbutton PB1 was tied down, would you be able to operate the cylinder
circuit with one hand? Explain.

G 12. Turn off the Power Unit and the 24-V DC Power Supply. Do not modify the
setting of the Relief Valve and Flow Control Valve.

Two-hand non-tie-down safety circuit

G 13. Connect the system shown in Figure 4-7, using the Time-Delay Relay /
Counter as timer TD1. Use the same hydraulic circuit you used in the first
part of the exercise.

G 14. On the Time-Delay Relay / Counter, set the thumbwheel switches to

"A 0 0 1 S". This will program the Time-Delay Relay / Counter for on-
delay operation and set the preset time to 1 second.

G 15. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 16. Press pushbuttons PB1 and PB2 simultaneously and watch the motion of
the cylinder rod. Does the cylinder rod extend?

G Yes G No

G 17. Press and hold pushbutton PB1, then wait a few seconds and press PB2.
Does the cylinder rod extend? Why? Explain by referring to the ladder
diagram in Figure 4-7.

G 18. If pushbutton PB1 and then pushbutton PB2 is pressed, how much time can
elapse between the two events before the cylinder fails to operate? Explain.

4-19
Safety Circuits

G 19. If pushbutton PB2 was tied down, would you be able to operate the cylinder
circuit with one hand? Why? Explain by referring to the ladder diagram in
Figure 4-7.

G 20. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 21. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 22. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you assembled and tested a basic two-hand safety
circuit. You learned that the pushbuttons have to be located far enough apart so that
two hands are required for operating them. You also learned that this type of circuit
cannot assure that the operator is required to use two hands to start the circuit, as
he can likely find a method of wiring down one of the pushbuttons.

In the second part of the exercise, you assembled and tested a two-hand, non-tie-
down safety circuit. You saw that if the first pushbutton is pressed and then the other
pushbutton is pressed, the time which can elapse between the two events before the
circuit fails to respond is the time set on the time-delay relay. This circuit is safer than
the basic two-hand circuit, because if either pushbutton were tied down, the operator
would be unable to operate the circuit with the other pushbutton.

REVIEW QUESTIONS

1. In order for the two-hand safety circuit of Figure 4-6 to be effective, how do the
two pushbuttons, PB1 and PB2, have to be located?

4-20
Safety Circuits

2. Would the two-hand safety circuit of Figure 4-6 assure safe operation of the
circuit if a holding relay contact was connected in parallel with pushbuttons
contacts PB1 and PB2? Explain.

3. What is meant by a two-hand, non-tie-down safety circuit?

4. In the two-hand, non-tie-down safety circuit in Figure 4-7, what happens when
both pushbuttons are not pressed within the time delay set on the time-delay
relay?

5. Name one type of hydraulic machine that would need a two-hand, non-tie-down
safety circuit.

4-21
4-22
 Exercise 4-3

Counting of Actuator Cycles

EXERCISE OBJECTIVE

C To describe the operation of an electrical counter;

C To extend and retract a cylinder a definite number of times using an electrical
counter;
C To measure the rotation speed of a hydraulic motor using an electrical counter.

DISCUSSION

Electrical counters

Electrical counters are used in electrically controlled hydraulic systems when parts
of the system must be activated or de-activated after a definite number of events
have occurred. They are widely used in industry to count quantities produced during
process and control operation. They are also used for machine maintenance
scheduling by controlling the number of machine operations.

A typical application is an automated packaging system that stacks and counts

production items into groups. The usual method is for one cylinder to continuously
extend and retract, picking and stacking one item on each cycle, and for a counter
to count the number of cycles which have been made by the cylinder. When the
required count is reached, the counter generates a switching signal which causes
another cylinder to push the stack away.

Basic counter operation

An electrical counter basically consists of one or more N.O. and N.C. contacts, a
control terminal on which to receive input pulses to be counted, a reset terminal on
which a momentary pulse can be applied to reset the counter to zero, and some
means to set the counter preset value, usually thumbwheel switches.

The counter preset value specifies the value the counter must reach before
activating its output contacts. Each time a pulse is received at the control terminal,
the counter count is incremented by one count. When the preset count is reached,
the counter activates its output contacts. Additional inputs continue to increment the
count. Momentary activation of the reset input de-activates the counter contacts and
resets the count to zero.

4-23
Counting of Actuator Cycles

Hydraulics Trainer counter

As was said in Exercise 3-4, the Time-Delay Relay / Counter supplied with your
Hydraulics Trainer can be programmed for counting function by configuring the
thumbwheel switches on top of the unit accordingly. Three parameters are to be
configured, which are the counter mode, the preset count, and the counting interval,
as Figure 4-8 shows.

Figure 4-8. Programming the Time-Delay Relay / Counter for counting function.

Î Counter mode switch: programs the counter for either Operate at Preset Count
or Release at Preset Count operation:

Operate at Preset Count (switch set to CO): each time the CONTROL (C)
input is switched to common (!) and then disconnected from common, the
counter value is incremented by one count. When the preset count is
reached, both sets of relay contacts are shifted to their activated state.
Additional inputs continue to increment the displayed count. Momentarily
switching the RESET input to common de-activates the relay contacts and
resets the counter value to zero.

Release at Preset Count (switch set to CR): momentarily switching the

RESET input to common activates the relay contacts. Operation is similar
to CO mode except that the relay contacts are de-activated when the preset
count is reached.

4-24
Counting of Actuator Cycles

Ï Preset count switches: specify the value the counter must reach before the relay
contacts are activated (CO operation) or de-activated (CR operation). Can be set
between 001 and 999.

Ð Counting interval switch: selects the interval counted by the counter. Selectable
as Normal, Divide by 10, or Divide by 100:

Normal (switch set to A, or D to J) : the counter value is incremented each

time an input signal is received at the CONTROL input.

Divide by 10 (switch set to B): the counter value is incremented for every
10 input signals for a maximum count of 9990.

Divide by 100 (switch set to C): the counter value is incremented for every
100 input signals for a maximum count of 99 900.

Note: For detailed information on the Potter & Brumfield Time-Delay

Relay / Counter, refer to Appendix E of the manual.

Procedure summary

In the first part of the exercise, you will test the operation of an electrical counter.

In the second part of the exercise, you will connect and test a system that uses an
electrical counter to extend and retract a cylinder a definite number of times.

In the third part of the exercise, you will use an electrical counter to measure the
rotation speed of a hydraulic motor.

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

Operation of an electrical counter

G 1. Connect the circuit shown in Figure 4-9.

4-25
Counting of Actuator Cycles

Figure 4-9. Testing the operation of an electrical counter.

G 2. On the Time-Delay Relay / Counter set the thumbwheel switches to

“A 0 0 5 CO”, as Figure 4-8 shows. This will program the Time-Delay
Relay / Counter for CO (Operate at Preset Count) counting function, set the
preset value to 5, and select a normal counting interval.

G 3. Turn on the 24-V DC Power Supply.

G 4. What is the count value on the display of the Time-Delay Relay / Counter?

G 5. Momentarily press the COUNT pushbutton, PB1. What happens to the

displayed count? Why? Explain by referring to the ladder diagram in
Figure 4-9.

4-26
Counting of Actuator Cycles

G 6. While observing pilot lamp L1, press pushbutton PB1 several times until the
displayed count reaches the preset value of 5. What happens to lamp L1 as
the displayed count reaches 5? Why? Explain by referring to the ladder
diagram in Figure 4-9.

G 7. Again, press pushbutton PB1 several times while observing the displayed
count. Do additional inputs continue to increment the displayed count?

G Yes G No

G 8. Momentarily press the RESET pushbutton, PB2. What happens to the

displayed count? To pilot lamp L1? Why?

G 9. While observing the displayed count, press and hold pushbutton PB1 for a
few seconds, then release PB1. Is the displayed count incremented
immediately when PB1 is pressed or after PB1 is released?

G 10. Based on the observation you made in step 9, is the counter value
incremented each time the CONTROL (C) input is switched to common (!)
and then disconnected from common?

G Yes G No

G 11. Turn off the 24-V DC Power Supply. Disconnect and store all leads and
components.

Counting of cylinder cycles

G 12. Get the 2.5-cm (1-in) bore cylinder from your storage location. Clamp the
cylinder to the Work Surface.

G 13. Mount a Magnetic Proximity Switch so that it is activated when the rod of the
2.5-cm (1-in) bore cylinder is fully retracted.

4-27
Counting of Actuator Cycles

G 14. Mount a Magnetic Proximity Switch so that it is activated when the rod of the
2.5-cm (1-in) bore cylinder is fully extended. Leave the cylinder rod in the
fully retracted position.

G 15. Remove and store all hoses and electrical leads.

G 16. Connect the system shown in Figure 4-10. While doing this, be careful not
to modify the mounting of the cylinders and limit switches.

Note: The Magnetic Proximity Switches require a 24-V DC

voltage to operate. Therefore, make sure to connect the + and
! terminals of these switches to the 24-V DC Power Supply.

G 17. On the Time-Delay Relay / Counter, make sure the thumbwheel switches
are set to “A 0 0 5 CO”.

G 18. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hoses are firmly connected.

b. Check the level of the oil in the reservoir. Oil should cover, but not be
over, the black line above the temperature/oil level indicator on the
Power Unit.
c. Put on safety glasses.
d. Open the Relief Valve completely by turning its adjustment knob fully
counterclockwise.

G 19. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 20. With the 2.5-cm (1-in) bore cylinder in the fully retracted position, all the
pumped oil is blocked at the cylinder piston and is now being forced through
the Relief Valve. Turn the adjustment knob of the Relief Valve clockwise
until the system pressure at Pressure Gauge A is 1700 kPa (250 psi).

G 21. Start the system by pressing the START pushbutton momentarily. The
cylinder rod should automatically extend and retract 5 times, then it should
stop at home position. Does this happen?

G Yes G No

4-28
Counting of Actuator Cycles

Figure 4-10. Industrial drilling system to connect.

4-29
Counting of Actuator Cycles

G 22. Repeat step 21 several times to become familiar with the operation of the
system. What causes the cylinder rod to extend when the START
pushbutton is pressed? Explain by referring to the ladder diagram in
Figure 4-10.

G 23. What causes the cylinder rod to retract when it becomes fully extended?

G 24. Press the START pushbutton and observe the count value on the display
of the Time-Delay Relay / Counter. Is the displayed count incremented by
one count each time the cylinder rod becomes fully extended? Why?

G 25. Is the counter value automatically reset to zero at the moment when the
cylinder completes its fifth extension stroke? Why?

G 26. Why does the cylinder rod stop after it has completed 5 cycles?

G 27. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

Counting of motor revolutions

G 28. Get the hydraulic motor and lightweight flywheel from your storage location.
Install the flywheel onto the shaft of the motor by performing the following
steps:

– Slip the flywheel onto the motor shaft, taking care to align the set screw
in the flywheel hub with the notch in the motor shaft.

4-30
Counting of Actuator Cycles

– Fully tighten the set screw, using the Allen key supplied with your
hydraulic motor.

– Check that the set screw is completely screwed into its hole. The head
of the set screw should be flush with the flywheel hub. If not, it is likely
the flywheel that is not secured properly. In that case, loosen the set
screw and realign the flywheel properly. Retighten the set screw and
again check that the set screw is completely screwed into its hole.

CAUTION!

Make absolutely certain the flywheel is secured to the motor

shaft.

G 29. Clamp the Diffuse Reflective Photoelectric Switch to the Work Surface.
Referring to Figure 4-11, place the hydraulic motor in front of the Diffuse
Reflective Photoelectric Switch and at a distance of 10 cm/4 in (2 rows of
perforations) from it, aligning the motor axis with the beam of the switch.
Clamp the motor into place.

Figure 4-11. Positioning the Diffuse Reflective Photoelectric Switch.

4-31
Counting of Actuator Cycles

Figure 4-12. Counting of motor revolutions.

G 30. Connect the + and ! terminals of the Diffuse Reflective Photoelectric Switch
to the corresponding terminals of the 24-V DC Power Supply. Turn on the
DC Power Supply.

4-32
Counting of Actuator Cycles

G 31. Manually turn the motor flywheel to check that the Diffuse Reflective
Photoelectric Switch is activated when it sees the white area of the motor
flywheel and de-activated when it sees the black area of the flywheel.

G 32. Turn off the 24-V DC Power Supply. Connect the system shown in
Figure 4-12. While doing this, be careful not to modify the mounting of the
motor and Diffuse Reflective Photoelectric Switch.

Note: The Diffuse Reflective Photoelectric Switch requires a

24-V DC voltage to operate. Therefore, make sure to connect the
+ and ! terminals of this switch to the 24-V DC Power Supply.

G 33. On the Time-Delay Relay / Counter, set the thumbwheel switches to

“B 0 0 0 CO”. This will program the Time-Delay Relay / Counter for
CO counting function, set the preset value to 0, and select a divide-by-10
counting interval.

G 34. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 35. Turn the adjustment knob of the Relief Valve clockwise until the system
pressure at Pressure Gauge A is 2100 kPa (300 psi).

G 36. Press the START pushbutton, PB1, to energize valve solenoid A and start
the motor. Observe the count value on the display of the Time-Delay
Relay / Counter. Since a divide-by-10 counting interval has been selected,
the displayed count is incremented by one count for every 10 revolutions of
the motor.

G 37. Using a stopwatch, measure the rotation speed of the motor by performing
the following steps:

– Press the RESET pushbutton, PB3, and simultaneously start the

stopwatch.

– Let the motor turn for 60 seconds, then stop the motor by pressing the
STOP pushbutton, PB2.

– Multiply the displayed count by 10 to obtain the motor speed, in

revolutions per minute (r/min). Record this speed below.

Motor speed: r/min

4-33
Counting of Actuator Cycles

G 38. Again press pushbutton PB1 to start the motor. Place a tachometer on the
motor shaft and measure the motor speed. Does this speed approximately
correspond to the speed recorded in step 37?

G Yes G No

G 39. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 40. Remove the flywheel from the motor shaft.

G 41. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 42. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you tested the operation of an electrical counter
placed in CO (Operate at Preset Count) mode of operation. You saw that the
electrical counter does not shift its contacts to the activated state until a preset count
is reached. It returns them to the de-activated state when the accumulated count is
reset.

In the second part of the exercise, you learned that an electrical counter can cause
a cylinder to repeat a cycle a definite number of times. This function is often used
when parts of the system must be activated or de-activated after a definite number
of events have occurred.

In the third part of the exercise, you determine the speed of a hydraulic motor by
counting the number of revolutions performed in 1 minute.

REVIEW QUESTIONS

1. Name two ways an electrical counter is used in electrically controlled hydraulic

systems.

4-34
Counting of Actuator Cycles

2. Describe basic operation of an electrical counter.

3. What is meant by “preset value”?

4. Once the preset value is reached, do additional inputs continue to increment the
counter?

5. How can the counter value be returned to zero?

4-35
4-36
 Exercise 4-4

Multi-Pressure System

EXERCISE OBJECTIVE

C To use a solenoid-operated directional valve as a pressure selector valve to

select between two or more operating pressures;
C To design, assemble, and test a three-pressure level system simulating a spring
testing bench.

DISCUSSION

Multi-pressure systems

A multi-pressure system is a system that operates the same actuator at different

pressures during different stages of operation. Multi-pressure systems are commonly
used in industry to protect components and workpieces being worked on by
actuators, and to save energy. In certain testing situations, such as on a test bench
or in a laboratory, multi-pressure systems save the time needed to construct different
single-pressure test circuits.

As an example, Figure 4-13 shows a three-pressure level system using a 3-position

directional valve as a pressure selector valve. When solenoids A and B of the
directional valve are de-energized, the system pressure is allowed to rise to the
highest pressure level as set on the main relief valve 1. When solenoid A of the
directional valve is energized, the system pressure is allowed to rise to the lowest
pressure level as set on auxiliary relief valve 2. When solenoid B of the directional
valve is energized, the system pressure is allowed to rise to the intermediate
pressure level as set on auxiliary relief valve 3.

4-37
Multi-Pressure System

Figure 4-13. Choice of three pressure levels with a pressure selector valve.

Procedure summary

In this exercise, you will create, assemble, and test an electrically controlled spring
testing system. The designed system will use a solenoid-operated directional valve
to select between a low test pressure, a high test pressure, and a minimum pump-
unloading pressure. A sequence valve will provide the low test pressure, while a
relief valve will provide the high test pressure.

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

Designing a spring testing system

G 1. Design an electrically controlled spring testing system that will operate as

follows:

– The spring to be tested is manually screwed onto a 3.8-cm (1.5-in) bore

cylinder.

– Pressing a START pushbutton causes the system pressure to rise to

the low test pressure of 1700 kPa (250 psi). This pressure level remains
for 20 seconds, allowing the operator to measure and record the
compressed spring length.

– The system pressure then automatically rises to the high test pressure
of 3500 kPa (500 psi). This pressure level remains until the operator
presses a MINIMUM PRESSURE pushbutton. This causes the system
pressure to drop to the minimum level, unloading the pump and causing
the spring to decompress.

4-38
Multi-Pressure System

– The tested spring is then removed from the cylinder and a new spring
can be tested.

Draw the hydraulic and electrical sections of your system on paper. The
designed system must use a relief valve, a sequence valve, and a 4-way,
3-position, tandem-center, solenoid-operated directional valve. Once the
hydraulic and electrical sections of your system are drawn, have them
verified and approved by your instructor.

HINT: Connect the Relief Valve and Sequence Valve downstream of the
4-way, 3-position, tandem-center, solenoid operated Directional
Valve.

G 2. Get the 3.8-cm (1.5-in) bore cylinder from your storage location. Remove
the cylinder from its adapter by unscrewing its retaining ring. Remove the
cylinder tip (bullet) from the end of the cylinder rod.

G 3. Make sure the cylinder rod is fully retracted. Screw the 3.8-cm (1.5-in) bore
cylinder into the spring Loading Device.

G 4. Connect the system which you designed.

G 5. Open the Relief Valve and Sequence Valve completely (turn knobs fully
counterclockwise).

G 6. Before starting the system, use a ruler to measure the length of the spring
while it is uncompressed. Record this length below.

Uncompressed spring length: cm or in

G 7. Turn on the Power Unit and the 24-V DC Power Supply. Make the Relief
Valve and Sequence Valve adjustments necessary for the system to work
properly.

G 8. Test the system which you designed by completing the following verification
steps:

a. Press the START pushbutton momentarily. The 3.8-cm (1.5-in) bore

cylinder rod should extend to compress the spring, while the pressure
at the cap end of this cylinder should rise to 1700 kPa (250 psi).
Measure and record the new compressed spring length.

Spring length @ 1700 kPa (250 psi): cm or in

b. 20 seconds later, the 3.8-cm (1.5-in) bore cylinder should extend more
to compress the spring further, while the pressure at the cap end of this

4-39
Multi-Pressure System

cylinder should rise to 3500 kPa (500 psi). Measure and record the new
compressed spring length.

Spring length @ 3500 kPa (500 psi): cm or in

c. Press the MINIMUM PRESSURE pushbutton. The spring should

decompress and the cylinder rod should retract, while the pressure at
the cap end of this cylinder should drop to the minimum level (about
500 kPa/70 psi).

G 9. Have your instructor verify the operation of your system.

G 10. Turn off the Power Unit and the 24-V DC Power Supply. Disconnect and
store all hoses and electrical leads. Remove and store all electrical and
hydraulic components. Wipe off any hydraulic oil residue.

G 11. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you designed, assembled, and tested a three-pressure level system
simulating a spring testing bench. A solenoid-operated directional valve was used
as a pressure selector valve to select between the low test pressure, the high test
pressure, and the minimum unloading pressure. This allowed you to test the spring
at two different pressures and save the time needed to construct two different single-
pressure test circuits.

REVIEW QUESTIONS

1. In the system which you designed, what makes the 3.8-cm (1.5-in) bore cylinder
extend and compress the spring? Explain by referring to your ladder diagram.

2. Why does the system pressure rise to 1700 kPa (250 psi) first?

3. Why does the system pressure remain at 1700 kPa (250 psi) for 20 seconds and
then automatically rise to 3500 kPa (500 psi)?

4-40
Multi-Pressure System

4. What happens to the cylinder, spring, and system pressure when the MINIMUM
PRESSURE pushbutton is pressed? Why?

5. What would happen to the cylinder and spring if the Power Unit was turned off
before returning the system pressure to the minimum level? Explain.

4-41
4-42
 Exercise 4-5

Rapid Traverse-Slow Feed System

EXERCISE OBJECTIVE

C To design, assemble, and test a two-speed system simulating a rapid traverse-

slow feed system.

DISCUSSION

Deceleration of a hydraulic cylinder

Many hydraulic machine tools involve a cylinder that extends up to a workpiece at

a high speed before it performs a work on it. However, as the rod of a fast-moving
cylinder reaches a workpiece, it impacts against it with a great force. This impact can
cause serious damage to either the cylinder or the workpiece.

Impact damage can be minimized by decelerating the cylinder rod just before it
contacts the workpiece using the rapid traverse-slow feed method. With this
method, the cylinder is extended at full speed during the approach and decelerated
down to a slower speed before it contacts the workpiece. A limit switch is placed at
the point where deceleration must start. This point is sufficiently ahead of the
workpiece to allow the cylinder to slow down to a safe speed before impacting
against it.

During the approach, the oil forced out of the rod end of the cylinder is allowed to
return directly to the reservoir, causing the cylinder rod to extend at full speed. When
the cylinder rod reaches the point where deceleration must start, it hits the limit
switch. This causes the oil forced out of the rod end of the cylinder to be redirected
through a flow control valve which has been set for a slow speed. The cylinder rod,
therefore, finishes extending at a slow speed. Once fully extended, the rod retracts
at full speed through the bypass check valve of the flow control valve. As the rod is
retracting, it will reactivate the limit switch but this will not affect system operation so
the rod will continue to retract at full speed.

Procedure summary

In this exercise, you will design, assemble, and test an electrically controlled rapid
traverse-slow feed system.

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.

4-43
Rapid Traverse-Slow Feed System

PROCEDURE

Designing a rapid traverse-slow feed system

G 1. Design an electrically controlled rapid traverse-slow feed system that will

operate as follows:

– In the normal condition of the system, the cylinder rod is fully retracted.
Pressing a START pushbutton causes the rod to start extending at full
speed.

– When the rod has completed two thirds of its extension stroke, it
activates a limit switch. This causes the rod to decelerate down to a
slower speed.

– When the rod becomes fully extended, it automatically retracts at full

speed. As it is retracting, the rod reactivates the limit switch but this
does not change its speed.

– When the cylinder rod becomes fully retracted, it stops and waits for the
operator to start another cycle.

Draw the hydraulic and electrical sections of your system on paper, then
have them verified and approved by your instructor.

G 2. Connect the system which you designed.

G 3. Test the system which you designed.

G 4. Have your instructor verify the operation of your system.

G 5. Make sure the Power Unit and 24-V DC Power Supply are turned off.
Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 6. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you designed, assembled, and tested a rapid traverse-slow feed
system. This type of system extends the cylinder rod at two different speeds in
different parts of its stroke. It changes from a full flow system to a meter-out control
system as the cylinder rod activates a limit switch. It then retracts the cylinder rod at
full speed without being affected by reactivation of the limit switch.

4-44
Rapid Traverse-Slow Feed System

REVIEW QUESTIONS

1. In the system which you designed, what causes the cylinder rod to start
extending when the START pushbutton is pressed? Explain by referring to your
ladder diagram.

2. Why does the cylinder rod extend at full speed during the first portion of its
stroke?

3. What causes the cylinder rod to decelerate to a slower speed when it has
completed two thirds of its extension stroke?

4. Why does the cylinder rod retract at full speed?

5. Why does the cylinder rod continue to retract at full speed after reactivation of
the limit switch?

6. What modification must be done in your system to provide the capability to

adjust the speed of the rod during the first portion of its extension stroke?

4-45
4-46
 Unit Test

1. Which one of the following describes the operation of a photoelectric switch of

the proximity type?

a. It keeps its contacts deactivated when the receiver sees dark;

b. When a reflective object enters the detection zone and light reflects off the
object back to the receiver, it shifts its contacts to the activated state;
c. It keeps its contacts activated until the object is removed from the detection
zone;
d. All the above.

2. The reflectance of an object depends on its surface

a. material.
b. colour.
c. texture.
d. All the above.

3. Which one of the following is a machining function that involves drilling?

a. Boring a hole.
b. Tapping and threading a hole.
c. Countersinking the top edge of a hole.
d. All the above.

4. What is the main purpose of a safety circuit?

a. To protect the electrical equipment against overcurrent and overvoltage.

b. To prevent the hydraulic components from being over pressurized.
c. To reduce operating costs.
d. To protect the operator and equipment.

5. In designing a safety circuit, first priority should go into protecting the

a. personnel;
b. electrical equipment;
c. hydraulic equipment;
d. product being made.

6. The disadvantage to a basic two-hand safety circuit is that

a. it takes two hands to operate the machine.

b. the pushbuttons must be placed close enough to each other so that only one
hand is required to start the machine.
c. the circuit can easily be overriden by tying down one of the pushbuttons.
d. it takes two hands to operate two machines.

4-47
 Unit Test (cont'd)

7. In a two-hand, non-tie-down safety circuit, what happens when both pushbuttons

are not pressed within the time delay set on the time-delay relay?

a. The machine starts to operate after the time delay has elapsed.
b. The machine continues to operate until both pushbuttons are released.
c. The machine continues to operate after the time delay has passed.
d. Nothing happens; the machine remains stopped.

8. Multi-pressure systems are primarily used to

a. unload the pump at less than system pressure.

b. provide different pressures during different stages of operation.
c. synchronize two actuators.
d. continuously reciprocate a cylinder.

9. Which one of the following can be used as a pressure selector valve:

a. Sequence valve;
b. Relief valve;
c. Check valve;
d. Directional control valve.

10. What is the function of a rapid traverse-slow feed system?

a. To extend the cylinder at a slow speed during the approach and speed it up
just before it contacts the workpiece.
b. To extend the cylinder at a fast speed during the approach and decelerate
it to a slower speed just before it contacts the workpiece.
c. To extend the cylinder at a fast speed and retract it at a slower speed.
d. To retract the cylinder at a fast speed and decelerate it to a slower speed
just before it reaches the home position.

4-48
 Unit 5

Troubleshooting

UNIT OBJECTIVE

When you have completed this unit, you will know a method to troubleshoot and
repair electrically controlled hydraulic systems. You will make the necessary
corrections and test the corrected systems for proper operation.

DISCUSSION OF FUNDAMENTALS

Troubleshooting electrically controlled hydraulic systems is basically the same as

troubleshooting any electronic, mechanical, or pneumatic system. Individual initiative
and imagination, coupled with efficient and effective techniques are important
elements in successful troubleshooting. Good troubleshooting techniques depend
on a sound understanding of the equipment and the way it normally operates, as well
as a procedure that limits the number of verification steps.

Troubleshooting can be structured according to four levels of activity designed to

identify, locate, and correct a problem. Each level brings us closer to the source of
the problem. The levels of activity, listed in order, are:

1. Observation of the operation of the system;

2. Location of the defective component;

3. Component checking;

4. Substitution or replacement.

In this unit, you will concentrate on the first two levels of activity, with special
emphasis being placed on locating the defective part of circuitry.

To successfully troubleshoot an electrically controlled hydraulic system, it is

necessary to understand the equipment and its operation. The best way to start the
troubleshooting job is to read through the instruction manual, which will tell you how
the equipment should operate. Often, the manual will have lists of typical faults and
probable causes.

5-1
5-2
 Exercise 5-1

Troubleshooting Electrical Control Circuits

EXERCISE OBJECTIVE

C To locate instructor-inserted faults in the electrical control section of an

electrically controlled drilling system;
C To apply the voltmeter and ohmmeter methods of troubleshooting.

DISCUSSION

Troubleshooting the electrical control section of an electrically controlled hydraulic

system requires a sound knowledge of the system and the way it normally operates,
as well as a systematic troubleshooting procedure that limits the number of signals
to be tested.

Before troubleshooting any system, the best way to start is to observe the symptoms
in order to relate the problem to some specific rung(s) of the ladder. The choice of
which signal to analyze should never be done on a random basis, as industrial
control circuits may be composed of a large number of rungs.

Once enough information concerning the problem has been gathered,

troubleshooting is carried out within the ladder rung(s) suspected to be defective.
The two most often used methods of troubleshooting electrical control circuits are the
voltmeter method and the ohmmeter method.

Voltmeter method of troubleshooting

The voltmeter method consists in tracing the voltage through the ladder rungs
suspected to be defective using a voltmeter or multimeter placed in voltmeter mode.
Basically, this method requires that the voltage supplied to each component on the
rung be checked to detect an abnormal or zero voltage level. Figure 5-1 illustrates
this method for a problem located at component C. The dotted lines show where
voltages are checked and the circled numbers indicate the steps in sequential order.

5-3
Troubleshooting Electrical Control Circuits

Figure 5-1. The voltmeter method of troubleshooting a ladder rung.

The supply voltage is checked first. With the power supply turned on, the
+ (red) probe of the voltmeter is connected to the + side of the first input device
(component A in Figure 5-1), while the ! (black) probe is connected to the ! side of
the output device (component E in Figure 5-1). The voltmeter should indicate the
supply voltage. If not, the leads connecting the + and ! terminals of the power supply
to components A and E may be damaged or open.

If the supply voltage is correct, the + probe of the voltmeter is moved to the + side
of component B, while the ! probe is left connected to the ! side of component E.
The voltmeter should indicate the supply voltage. If not, component A or the lead
connecting components A and B may be damaged or open.

If the voltage at the + side of component B is correct, the + probe of the voltmeter is
moved to the + side of component C, and the voltage is again checked. This
approach is repeated until the defective component or lead is located.

It is important to understand that voltage tracing through a rung requires that all input
devices on the rung be in the closed condition so as to allow the current to flow
through the rung. Industrial circuits are often equipped with jog pushbuttons that
allow the operator to manually move the cylinders and place specific limit switches
in the closed condition during troubleshooting.

Ohmmeter method of troubleshooting

The ohmmeter method, also called continuity test method, consists in testing the
completeness of the path on a ladder rung for the purpose of detecting damaged or
open components. It requires that the resistance of each component and lead on the
rung be measured with an ohmmeter or multimeter placed in ohmmeter mode to
detect an open, or infinite-resistance condition.

5-4
Troubleshooting Electrical Control Circuits

Figure 5-2 illustrates ohmmeter testing of the first input device on a rung
(component A). With the power supply turned off, the ohmmeter + and – probes are
respectively connected to the input and output terminals of the component to test.
If the component is in good condition, the ohmmeter will read low value or zero
resistance (0 Ω). On the other hand, if the component is damaged or open, the
ohmmeter will read very high or infinite resistance. An infinite resistance is indicated
by a “1” or a “4” sign on the ohmmeter display.

Figure 5-2. The ohmmeter method of troubleshooting a ladder rung.

This method is successively applied to test each ladder component and lead on the
rung until the defective (open) component or lead is located.

When the ladder rung to test has two or more branches in parallel, the ohmmeter
method requires that each branch be tested separately by disconnecting the
branches from each other. This is because if one of the parallel branches is open
due to a damaged component or lead, the other branch will still allow the ohmmeter
current to flow, resulting in a zero resistance reading on the ohmmeter.

As an example, Figure 5-3 illustrates ohmmeter testing of a ladder rung that consists
of a main branch and two secondary branches in parallel with the main branch. The
first step is to test continuity of the main branch by disconnecting the secondary
branches at the + side of components E and G, as Figure 5-3(a) shows. The second
step is to test continuity of the secondary branches by disconnecting the main branch
at the + side of components A and D, as Figure 5-3(b) shows.

5-5
Troubleshooting Electrical Control Circuits

Figure 5-3. Ohmmeter testing a ladder rung with parallel branches.

5-6
Troubleshooting Electrical Control Circuits

The ohmmeter method is a valuable diagnostic tool when it is dangerous or

impossible to energize the malfunctioning circuit to test. This method is probably less
easy to use than the voltmeter method because it requires that the power supply be
turned off and parallel branches be disconnected. On the other hand, the ohmmeter
is often required to verify the continuity of components that make part of a defective
section of circuitry located with the voltmeter method.

Procedure summary

In the first part of the exercise, you will set up the electrically controlled drilling
system you used in Exercise 4-1 of the manual.

In the second part of the exercise, you will be guided through the voltmeter method
of troubleshooting to locate a fault in the electrical control circuit.

In the third part of the exercise, you will locate another fault in the electrical control
circuit by yourself.

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

Setting up the drilling system

G 1. Set up an electrically controlled drilling system using the diagram shown in

Figure 4-4 of Exercise 4-1. Make sure to mount switches PX1, PX2, and
PE1 as illustrated in Figure 4-4.

Note: Make sure the flywheel has been removed from the motor
shaft.

G 2. Close the Sequence Valve completely. To do so, first loosen the locking nut
on the adjustment screw by turning this nut fully counterclockwise. Then,
turn the valve adjustment knob fully clockwise.

G 3. Close the Pressure-Compensated Flow Control Valve completely by turning

its adjustment knob fully clockwise.

G 4. Set the pressure-switch actuation pressure to the maximum value. To do so,

turn the actuation pressure adjustment knob fully counterclockwise (when
viewed from the hydraulic pressure port of the switch).

5-7
Troubleshooting Electrical Control Circuits

Set the differential of the Pressure Switch to the maximum value. To do so,
turn the differential adjustment knob fully clockwise (when viewed from the
hydraulic pressure port of the switch).

G 5. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 6. Turn the adjustment knob of the Relief Valve until the system pressure at
Pressure Gauge A is 2800 kPa (400 psi).

G 7. Turn the adjustment knob of the Sequence Valve counterclockwise until the
reading of Pressure Gauge A is 2350 kPa (340 psi).

G 8. Momentarily press the START pushbutton, PB1, to extend the clamp

cylinder (2.5-cm/1-in bore). When the cylinder is fully extended, slowly turn
adjustment knob of the Pressure-Compensated Flow Control Valve
counterclockwise to start the hydraulic motor. Adjust the Pressure-
Compensated Flow Control Valve until the reading of Pressure Gauge B is
2100 kPa (300 psi).

G 9. Slowly decrease the actuation pressure of the Pressure Switch by turning

its actuation pressure adjustment knob counterclockwise until the drill
cylinder (3.8-cm/1.5-in bore) starts to extend. The pressure setting of
Pressure Switch PS1 is now 2100 kPa (300 psi). This completes the system
set up.

Note: If the drill cylinder extends too slowly, very slightly

decrease the pressure setting (turn knob counterclockwise) of the
Sequence Valve, which will allow a little more oil to go to the drill
cylinder.

G 10. Start the system by pressing pushbutton PB1 momentarily. The system
should operate as follows:

– The clamp cylinder (2.5-cm/1-in bore) starts to extend first;

– When the clamp cylinder becomes fully extended, the hydraulic motor
starts rotating and the drill cylinder (3.8-cm/1.5-in bore) extends;
– When the drill cylinder becomes fully extended, it automatically retracts.
During retraction of this cylinder, the hydraulic motor continues to rotate
and the clamp cylinder remains extended.
– When the drill cylinder becomes fully retracted, it stops. The hydraulic
motor also stops, while the clamp cylinder retracts.
– When the clamp cylinder becomes fully retracted, it stops. The system
is now ready for a new cycle.

5-8
Troubleshooting Electrical Control Circuits

Guided troubleshooting of a fault in the electrical section of the drilling system

G 11. Turn off the 24-V DC Power Supply and Power Unit. Ask your instructor to
insert the fault intended for the guided troubleshooting of Exercise 5-1 as
indicated in the Lab-Volt Instructor’s Guide for Hydraulics - Electrical Control
of Hydraulic Systems.

G 12. Turn on the 24-V DC Power Supply and Power Unit. Press pushbutton PB1
and observe the effect of the fault that has been inserted on your system.
Record your observations below.

G 13. Trace the voltage through ladder rung 1. Get a multimeter and set it to
measure DC volts. Connect the + probe of the multimeter to the + side of
N.O. contact PX1 and the ! probe to the ! side of relay coil CR1. Does the
multimeter indicate the supply voltage (24 V)?

G Yes G No

G 14. What can you conclude about the condition of the leads connecting the +
and ! terminals of the DC Power Supply to N.O. contact PX1 and relay
coil CR1?

G 15. Move the + probe of the multimeter to the + side of N.O. contact PB1. Leave
the ! probe connected to relay coil CR1. Since the clamp cylinder is fully
retracted, N.O. contact PX1 should be closed and the multimeter should
indicate the supply voltage. Do you observe this?

G Yes G No

G 16. What can you conclude about the condition of N.O. contact PX1 and the
lead connecting this contact to N.O. contact PB1?

G 17. Move the + probe of the multimeter to the + side of N.C. contact PB2. Press
the START pushbutton and keep it pressed to allow the current to flow to
N.C. contact PB2. Does the multimeter indicate the supply voltage?

G Yes G No

5-9
Troubleshooting Electrical Control Circuits

G 18. What can you conclude about the condition of N.O. contact PB1 and the
lead connecting this contact to N.C. contact PB2?

G 19. Move the + probe of the multimeter to the + side of the relay coil CR1. Press
the START pushbutton and keep it pressed. Does the multimeter indicate
the supply voltage?

G Yes G No

G 20. From your observation, which component(s) do you suspect of being

defective?

G 21. Turn off the 24-V DC Power Supply and Power Unit. Test the continuity of
N.C. contact PB2 to see if it is open. To do so, set the multimeter to read
ohms and connect the multimeter probes across N.C. contact PB2. Record
below whether the multimeter indicates zero resistance or infinite resistance.

G 22. What can you conclude about the condition of N.C. contact PB2?

G 23. Test the continuity between the ! side of N.C. contact PB2 and the + side
of relay coil CR1. To do so, connect a multimeter probe to the ! side of
N.C. contact PB2. Connect the other probe to the + side of relay coil CR1.
Is there a continuity between these two points? Explain.

G 24. Does this problem plausibly explain the problem observed in step 12?
Explain.

G 25. Perform the appropriate modification to correct the problem. Then, turn on
the 24-V DC Power Supply and hydraulic power system and verify that the
system operates as it did previously.

5-10
Troubleshooting Electrical Control Circuits

Troubleshooting an unknown fault in the electrical section of the drilling

system

G 26. Ask you instructor to insert another fault in the electrical section of your
drilling system, as indicated in the Lab-Volt Instructor's Guide.

G 27. Troubleshoot your system in order to locate and correct the problem, using
either the voltmeter or ohmmeter method.

G 28. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 29. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 30. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you applied the voltmeter method to locate a fault
inserted in the electrical control section of a drilling system. In the second part of the
exercise, you gained further experience with troubleshooting by locating an unknown
fault in the electrical control system.

This exercise has allowed you to verify that, when possible, observing the problem
and its symptoms may often help relate the problem to some specific rung(s) of the
ladder. Familiarity with the system operation, therefore, is essential when
troubleshooting the electrical control circuit of an electrically controlled hydraulic
system.

REVIEW QUESTIONS

1. What is the best way to start troubleshooting any electrical control circuit?

2. What are the two most often used methods of troubleshooting electrical control
circuits?

5-11
Troubleshooting Electrical Control Circuits

3. True or false: The ohmmeter method requires that the power supply be turned
off and parallel branches be disconnected.

4. How can a rung component be tested to see that power is supplied at its + side?

5. How can a rung component be tested for continuity?

5-12
 Exercise 5-2

Troubleshooting Electrically Controlled

Hydraulic Systems

EXERCISE OBJECTIVE

C To locate instructor-inserted faults in an electrically controlled hydraulic system.

DISCUSSION

Troubleshooting an electrically controlled hydraulic system can be fairly complex

because a great deal of circuitry is usually involved in such a system. When possible,
the periodic maintenance procedure of the electrically controlled hydraulic system
should be carried out as frequently as recommended by the manufacturer of the
equipment. If a malfunction is revealed when carrying out this procedure, it can
usually be located quite readily. Often, the equipment manual will have lists of typical
faults and probable causes. This kind of information, along with electrical and
hydraulic schematics, can be useful and time saving.

However, a malfunction may appear during normal utilization of the electrically

controlled hydraulic system. In this situation, a logical approach based on a sound
understanding of the system operating principles, as well as the use of good
troubleshooting procedures will minimize the time and effort required to locate the
defective part of circuitry.

The best way to start troubleshooting an electrically controlled hydraulic system is

to observe the problem and its symptoms, in order to determine whether the problem
is located in the hydraulic or electrical section of the system. The observed
symptoms may often point to a single component or specific part of circuitry, and no
further search is necessary. For example, if the full system pressure cannot be
reached and the flow rate decreases as the relief valve pressure setting is increased,
the pump is probably malfunctioning. If, on the other hand, the full system pressure
cannot be reached, but the flow rate and system pressure remain constant as the
relief valve pressure setting is increased, the relief valve is probably malfunctioning.

Once the problem has been related to one branch or to a specific section of the
system, each component in that area can be checked out one at a time. Once a
defective component has been located, you must be cautious before drawing any
conclusions. In certain unusual cases, the problem may be caused by more than one
defective component. Therefore, you must make sure that the malfunction
discovered plausibly explains the problem observed. If not, there is more likely
another defective component which would complete the explanation of the problem.

5-13
Troubleshooting Electrically Controlled
Hydraulic Systems
Procedure summary

In the first part of the exercise, you will set up an electrically controlled hydraulic
system that simulates the operation of a clamp and grind system.

In the second part of the exercise, you will be guided through a systematic
troubleshooting procedure to locate a fault in the clamp and grind system.

In the third part of the exercise, you will locate another fault in the clamp and grind
system by yourself.

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

Setting up a clamp and grind system

G 1. Connect the system shown in Figure 5-4. Mount Magnetic Proximity

Switches PX1 and PX2 so that they are activated when the cylinder rod is
fully extended and fully retracted, as Figure 5-4(a) shows.

Note: Make sure the flywheel has been removed from the motor
shaft.

G 2. Open the Sequence Valve completely. To do so, first loosen the locking nut
on the adjustment screw by turning this nut fully counterclockwise. Then,
turn the valve adjustment knob fully counterclockwise.

G 3. Close the Pressure-Compensated Flow Control Valve completely by turning

its adjustment knob fully clockwise.

G 4. On the Time-Delay Relay / Counter (TD1), set the thumbwheel switches to

"A 0 6 0 S" to program the Time-Delay Relay / Counter for on-delay
operation and set the preset time to 60 seconds. This will allow you to
perform the preliminary circuit adjustments.

G 5. Turn on the Power Unit. Then, turn on the 24-V DC Power Supply.

G 6. Turn the adjustment knob of the Relief Valve clockwise until the system
pressure at Pressure Gauge A is 2800 kPa (400 psi).

5-14
Troubleshooting Electrically Controlled
Hydraulic Systems

Figure 5-4. Clamp and grind system.

G 7. Open the Pressure-Compensated Flow Control Valve completely by turning

its knob fully counterclockwise.

5-15
Troubleshooting Electrically Controlled
Hydraulic Systems

G 8. Press the START pushbutton, PB1, which will cause the clamp cylinder to
extend and the hydraulic motor to rotate. When the cylinder is fully
extended, adjust the adjustment knob of the Sequence Valve until the
reading of Pressure Gauge B is 2100 kPa (300 psi).

Note: If the cylinder retracts before you have been able to adjust
the valve to 2100 kPa (300 psi), press START again to extend the
clamp cylinder.

G 9. Wait until the system has returned to the initial state where the clamp
cylinder is retracted and the hydraulic motor is stopped. Then, perform the
following adjustments:

– On the Time-Delay Relay / Counter (TD1), set the thumbwheel switches

to "A 0 1 0 S". This will program the Time-Delay Relay / Counter for
on-delay operation and set the preset time to 10 seconds.

– Adjust the knob of the Pressure-Compensated Flow Control Valve until

the Flowmeter reads 2.5 l/min [0.7 gal(US)/min]. This completes the
system set up.

G 10. Start the system by pressing pushbutton PB1 (START) momentarily. The
system should operate as follows:

– The clamp cylinder (2.5-cm/1-in bore) extends full stroke;

– When the clamp cylinder becomes extended, it dwells, while the
hydraulic motor starts rotating;
– 10 seconds later, the hydraulic motor stops and the clamp cylinder
retracts;
– When the clamp cylinder becomes fully retracted, it stops. The system
is now ready for a new cycle.

G 11. Repeat step 10 several times to become very familiar with the operation of
the system. As you do this, note and record the Pressure Gauge and
Flowmeter readings in Table 5-1.

GAUGE A GAUGE B FLOWMETER

CIRCUIT CONDITION
PRESSURE PRESSURE READING

Cylinder retracted, motor stopped

Cylinder extending

Cylinder extended, motor rotating

Cylinder retracting, motor stopped

Table 5-1. System pressures and flow rates.

5-16
Troubleshooting Electrically Controlled
Hydraulic Systems
Guided troubleshooting of a fault in the clamp and grind system

G 12. Turn off the 24-V DC Power Supply and Power Unit. Ask your instructor to
insert the fault intended for the guided troubleshooting of Exercise 5-2 as
indicated in the Lab-Volt Instructor’s Guide for Hydraulics - Electrical Control
of Hydraulic Systems.

G 13. Turn on the 24-V DC Power Supply and Power Unit. Press pushbutton PB1
and observe the effect of the fault that has been inserted on the operation
of the system. Record your observations below.

G 14. Start the system again and note the Pressure Gauge and Flowmeter
readings during each step of the cycling sequence. Compare these with the
values recorded in Table 5-1 to determine whether or not they are normal.
Record your observations below.

G 15. From your observations, determine whether the problem is located in the
hydraulic or electrical section of the system. Explain why.

G 16. Is it necessary to verify the operation of the Power Unit, Relief Valve,
supply manifold, Directional Valve, Flow Control Valve, and hoses
connected between the supply manifold and Pressure Gauge B? Explain.

G 17. Perform the following steps to determine the condition of the Sequence
Valve and hoses connecting the Sequence Valve to Pressure Gauge B and
the grinder motor:

– Turn off the Power Unit.

– Disconnect the hose coming from port S of the Sequence Valve at the
inlet of the grinder motor and connect it directly to the return manifold.
– Turn on the Power Unit.

5-17
Troubleshooting Electrically Controlled
Hydraulic Systems
– Start the system and observe what happens to the reading of Pressure
Gauge B when the clamp cylinder becomes fully extended. If the valve
and hoses are in good condition, the valve will open so the pressure at
Pressure Gauge B will not rise beyond the valve 2100-kPa (300-psi)
pressure setting. Do the valve and hoses seem to be in good condition?

G Yes G No

G 18. Turn off the Power Unit. Reconnect port S of the Sequence Valve to the
motor inlet.

G 19. Perform the following steps to determine the condition of the motor and the
hose connecting the motor outlet to the 4-port manifold on the Directional
Valve:

– Disconnect the hose coming from the motor outlet at the Check Valve
and connect it directly to the return manifold.
– Turn on the Power Unit.
– Start the system. If the motor and hose are in good condition, the motor
will rotate when the cylinder is fully extended. Does the motor and hose
seem to be in good condition?

G Yes G No

G 20. Perform the following steps to determine the condition of the Check Valve
and the hose connecting the Check Valve to the 4-port manifold on the
Directional Valve:

– Disconnect the hose coming from the Check Valve at the 4-port
manifold and connect it directly to the return manifold.
– Turn on the Power Unit.
– Start the system. If the Check Valve and hose are in good condition, the
motor will rotate when the cylinder is fully extended.

Does the Check Valve and hose seem to be in good condition?

G Yes G No

G 21. Turn off the Power Unit. Verify the connections of the Check Valve to see
if it is correctly connected to the circuit. Record your observations below.

G 22. Does your observation plausibly explain the problem observed in step 13?

5-18
Troubleshooting Electrically Controlled
Hydraulic Systems

G 23. Perform the appropriate modification to correct the problem. Then, turn on
the Power Unit and verify that the system operates as it did previously.

Troubleshooting an unknown fault in the clamp and grind system

G 24. Turn off the 24-V DC Power Supply and Power Unit. Ask your instructor to
insert another fault in your system, as indicated in the Lab-Volt Instructor's
Guide. Turn on the 24-V DC Power Supply and Power Unit.

G 25. Troubleshoot your system in order to locate and correct the problem.

G 26. Turn off the Power Unit. Open the Relief Valve completely by turning its
adjustment knob fully counterclockwise. Turn off the 24-V DC Power Supply.

G 27. Disconnect and store all hoses and electrical leads. Remove and store all
electrical and hydraulic components. Wipe off any hydraulic oil residue.

G 28. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In the first part of the exercise, you followed a guided method of troubleshooting to
locate a fault in a clamp and grind system. This allowed you to verify that observing
the problem and its symptoms may sometimes minimize the time and effort required
to locate the defective component or part of circuitry.

You also gained further experience with troubleshooting by locating an unknown fault
in the clamp and grind system. You have been able to verify that a sound approach
leads to quicker identification of the problem source. While you should not neglect
any personal talents for troubleshooting that you have discovered, it is important to
combine these talents with the fundamental principles given in the exercise. This will
reduce the chances of making errors when troubleshooting.

REVIEW QUESTIONS

1. What is the best way to start troubleshooting an electrically controlled hydraulic

system?

5-19
Troubleshooting Electrically Controlled
Hydraulic Systems
2. Which component of the hydraulic system should you suspect of being defective
when the full system pressure cannot be reached and the flow rate decreases
as the pressure setting of the Relief Valve is increased?

3. Which component of the hydraulic system should you suspect of being defective
when the full system pressure cannot be reached, but the flow rate and system
pressure remain constant as the pressure setting of the Relief Valve is
increased?

4. Once the problem has been related to one branch or to a specific section of the
system, what is the next step to perform?

5. Why should you be cautious before drawing any conclusions, once a defective
component has been located? Explain.

5-20
 Unit Test

1. A good troubleshooting procedure

a. depends on a sound understanding of the equipment and the way it

normally operates.
b. limits the number of verification steps.
c. should always begin by observing the symptoms in order to relate the
problem to some specific part of circuitry.
d. All the above.

2. Troubleshooting can be structured according to four levels of activity which,

listed in order, are

a. component checking, location of the defective component, substitution or

replacement, and observation of the operation of the system.
b. observation of the operation of the system, substitution or replacement,
location of the defective component, and component checking.
c. observation of the operation of the system, location of the defective
component, component checking, substitution or replacement.
d. location of the defective component, component checking, substitution or
replacement, observation of the operation of the system.

3. The two most often used methods of troubleshooting electrical control circuits
are

a. the ammeter method and the voltmeter method.

b. the power meter method and the ohmmeter method.
c. the voltmeter method and the ammeter method.
d. the voltmeter method and the ohmmeter method.

4. The voltmeter method consists in

a. testing the completeness of the path on a ladder rung using a voltmeter or

multimeter placed in voltmeter mode.
b. tracing the voltage through a ladder rung using a voltmeter or multimeter
placed in voltmeter mode.
c. tracing the voltage through a ladder rung using an ammeter or multimeter
placed in ammeter mode.
d. testing the completeness of the path on a ladder rung using an ohmmeter
or multimeter placed in ohmmeter mode.

5. Voltage tracing through a rung requires that all input devices on the rung be

a. activated.
b. deactivated.
c. in the closed condition.
d. In the open condition.

5-21
 Unit Test (cont'd)

6. The ohmmeter method consists in

a. testing the completeness of the path on a ladder rung using an ohmmeter

or multimeter placed in ohmmeter mode.
b. tracing the voltage through a ladder rung using an ohmmeter or multimeter
placed in ohmmeter mode.
c. tracing the current through a ladder rung using an ohmmeter or multimeter
placed in ohmmeter mode.
d. testing the completeness of the path on a ladder rung using an ammeter or
multimeter placed in ammeter mode.

7. The ohmmeter method is less easy to use than the voltmeter method because
it requires that

a. the power supply be turned on and parallel branches be disconnected.

b. the ohmmeter be turned off and parallel branches be disconnected.
c. the power supply be turned on and the ohmmeter be disconnected.
d. the power supply be turned off and parallel branches be disconnected.

8. When testing a rung component with the ohmmeter method, a low value or zero
resistance indicates

a. a damaged component.
b. an open component.
c. continuity of the component.
d. a damaged ohmmeter.

9. The best way to start troubleshooting an electrically controlled hydraulic system

is to

a. increase the relief valve pressure setting to determine if the hydraulic pump
is in good condition.
b. increase the relief valve pressure setting to determine if the relief valve is in
good condition.
c. check the condition of the hydraulic pump and electric power supply.
d. observe the problem and its symptoms in order to determine whether the
problem is located in the hydraulic or electrical section of the system.

10. When the problem has been related to the hydraulic section of the electrically
controlled hydraulic system, the next step to perform is to

a. check out each component in that area one at a time.

b. replace each component in that area with a similar component known to be
good.
c. replace the hydraulic pump.
d. talk to the equipment manufacturer.

5-22
 Appendix A
Equipment Utilization Chart
The following Lab-Volt equipment is required to perform the exercises in this manual.

EQUIPMENT EXERCISE
MODEL DESCRIPTION 1-1 2-1 2-2 2-3 3-1 3-2 3-3
6310 Power Unit, Lifting Frame 1 1 1 1 1

6320 Directional Valve, Lever-Operated 1

6321 Flow Control Valve 1 1

6322 Relief Valve 1 1 1 1 1

6323 Pressure Reducing Valve

6324 Directional Valve, Double-Solenoid Operated 1 1 1 1

6325 Directional Valve, Single-Solenoid Operated 1 1 1 1

6326 Sequence Valve 1 1

6327 Flow Control Valve, Pressure Compensated 1

6328 Check Valve 1 1

6340 Double-Acting Cylinder, 2.5-cm Bore 1 1

6341 Double-Acting Cylinder, 3.8-cm Bore 1 1 1 1

6342 Bidirectional Motor and Flywheel 1

6350 Pressure Gauge 1 1 2 2 2

6351 Flowmeter 1 1

6360 DC Power Supply 1 1 1 1 1 1 1

6361 Pushbutton Station 2 1 2 1 1 1 2

6362 Limit-Switch Assembly 1 1 1 1

6363 Relay 2 1 1 1 1 1

6364 Time-Delay Relay / Counter 1

6365 Pilot-Lamp Station 1 1 1 1 1 1

6370 Pressure Switch 1 1

6371 Magnetic Proximity Switch 2 1 2

6372 Diffuse Reflective Photoelectric Switch 1

6380 Loading Device

6390 Manifold, 5 Ports, Fixed 2 2 2 2 2

6391 Manifold, 4 Ports, Mobile 2

6392 Hose Set 1 1 1 1 1

6393 Electrical Leads and Additional Hoses 1 1 1 1 1 1 1

(continued on next page)

A-1
 Equipment Utilization Chart

EQUIPMENT EXERCISE
MODEL DESCRIPTION 3-4 4-1 4-2 4-3 4-4 4-5 5-1 5-2
6310 Power Unit, Lifting Frame 1 1 1 1 1 1 1 1

6320 Directional Valve, Lever-Operated

6321 Flow Control Valve

6322 Relief Valve 1 1 1 1 1 1 1 1

6323 Pressure Reducing Valve

6324 Directional Valve, Double-Solenoid Operated 1 1 1 1 1

6325 Directional Valve, Single-Solenoid Operated 1 1 1 1 1 1

6326 Sequence Valve 1 1 1 1

6327 Flow Control Valve, Pressure Compensated 1 1 1 1 1

6328 Check Valve 1 1

6340 Double-Acting Cylinder, 2.5-cm Bore 1 1 1 1 1

6341 Double-Acting Cylinder, 3.8-cm Bore 1 1 1 1 1

6342 Bidirectional Motor and Flywheel 1 1 1 1

6350 Pressure Gauge 1 2 1 1 1 2 2 2

6351 Flowmeter 1

6360 DC Power Supply 1 1 1 1 1 1 1 1

6361 Pushbutton Station 2 1 1 2 1 1 1 1

6362 Limit-Switch Assembly 1 1

6363 Relay 2 1 2 2 1 2 1 1

6364 Time-Delay Relay / Counter 1 1 1 1 1

6365 Pilot-Lamp Station 1 1 1 1 1 1 1 1

6370 Pressure Switch 1 1

6371 Magnetic Proximity Switch 2 2 1 2 2

6372 Diffuse Reflective Photoelectric Switch 1 1 1

6380 Loading Device 1

6390 Manifold, 5 Ports, Fixed 2 2 2 2 2 2 2 2

6391 Manifold, 4 Ports, Mobile 2 1 1 2 1

6392 Hose Set 1 1 1 1 1 1 1 1

6393 Electrical Leads and Additional Hoses 1 1 1 1 1 1 1 1

ADDITIONAL COMPONENTS

Multimeter, Tachometer 0-2000 r/min, stopwatch

A-2
 Appendix B
Care of the Hydraulics Trainer
General rules of good maintenance

a. Keep all components and work area in a clean, dirt-free condition.

b. Spilled or drained hydraulic oil should NOT be re-used. If re-use is imperative,

the oil must be stored in a clean container. It should be carefully strained of
filtered as it is returned to the Power Unit reservoir.

c. Use only a clean, lint-free cloth to wipe or dry component parts or to clean dust
and dirt from the outside of the system.

d. Clean quick disconnects carefully before each re-assembly.

e. Flush out old oil and replace with clean oil at least once per year.

Oil and filter change

Regular oil changes are the most important preventive maintenance procedures that
can be done. As hydraulic oil ages, it becomes diluted and contaminated, which
leads to premature pump wear. A new filter should also be installed every time the
oil is changed.

Oil change

To change oil, perform the following steps:

1. If the Power Unit is running, turn it off. Allow the system oil to drain back into the
reservoir for 5 minutes.

2. A drain pan large enough (about 18.9 liters/5 US gallons) to hold all of the oil in
the Power Unit reservoir is required to drain the Power Unit. Place such a pan
under the reservoir drain, as shown in Figure B-1. Remove the drain cap with a
wrench and allow the reservoir to drain completely.

B-1
 Care of the Hydraulics Trainer

Figure B-1. Changing the Power Unit oil.

3. Replace the drain cap and remove the drain pan after the reservoir is completely
emptied. Use Teflon tape or pipe joint compound to seal the drain cap threads.

4. Open the reservoir breather/filler cap, as shown in Figure B-1. Fill the reservoir
up to the black line on the thermometer/oil level indicator. Use one of the fluids
listed on the Power Unit information decal on the front of the reservoir.

5. Replace the reservoir breather/filler cap.

6. Empty the drained oil into a container (capped plastic jugs, topped bottles, milk
cartons, etc.) for transport to a disposal site. Oil reclamation centers will normally
accept the oil, which can be refined and used again.

Filter change

To change the filter, perform the following steps:

1. Turn off the Power Unit if it is running. Allow oil to drain out of the filter and into
the reservoir for 5 minutes.

2. When the filter has drained or if the power unit is cold, completely unscrew the
filter, as Figure B-2 shows. Be careful; it is full of oil. Empty the oil inside the
filter into the drain pan.

B-2
 Care of the Hydraulics Trainer

Figure B-2. Changing the oil filter.

3. Compare the old filter with the new one to make sure they are the same type
and micron rating (10-microns or less). Lubricate the gasket of the new filter with
a few drops of oil and screw the new filter onto the Power Unit assembly. The
filter should be hand-tightened only.

4. Empty the drained oil into a container (capped plastic jugs, topped bottles, milk
cartons, etc.) for transport to a disposal site. Oil reclamation centers will normally
accept the oil, which can be refined and used again.

B-3
B-4
 Appendix C
Conversion Factors
Use the following conversion factors to convert S.I. measurements to English
measurements and vice versa.

Length (distance)

Centimeters (cm) x 0.394 = Inches (in) x 2.54 = Centimeters (cm)

Meters (m) x 3.281 = Feet (ft) x 0.305 = Meters (m)

Volume (capacity)

Cubic centimeters (cc; cm3) x 0.061 = Cubic inches (in3) x 16.387 = Cubic centimeters (cc; cm3)

Liters (l) x 0.264 = US gallons (US gal) x 3.785 = Liters (l)

Mass (weight)

Kilograms (kg) x 2.205 = Pounds (lb) x 0.454 = Kilograms (kg)

Force

Newtons (N) x 0.225 = Pounds-force (lb; lbf) x 4.448 = Newtons (N)

Pressure

Bars (bar) x 14.5 = Pounds-force per squarex 0.069 = Bars (bar)

inch (psi; lb/in2)

Kilopascals (kPa) x 0.145 = Pounds-force per squarex 6.895 = Kilopascals (kPa)

inch (psi; lb/in2)

Area

Square centimeters (cm2) x 0.155 = Square inches (in2) x 6.45 = Square centimeters (cm2)

Flow rate

Liters per minute (l/min) x 0.264 = Gallons (US) per minute x 3.79 = Liters per minute (l/min)
[gal(US)/min]

C-1
 Conversion Factors

Velocity

Centimeters per minute x 0.394 = Inches per minute x 2.54 = Centimeters per minute
(cm/min) (in/min) (cm/min)

Work

Joules (J) x 0.738 = Foot-pounds (ft@lb) x 1.355 = Joules (J)

Power

Watts (W) x 0.0013 = Horsepowers (hp) x 745.7 = Watts (W)

C-2
 Appendix D
Hydraulics and Pneumatics Graphic Symbols

Figure D-1. Hydraulics and pneumatics graphic symbols.

D-1
 Hydraulics and Pneumatics Graphic Symbols

Figure D-2. Hydraulics and pneumatics graphic symbols (cont’d).

D-2
 Appendix E
Time-Delay Relay / Counter Specifications
SERIES INSTRUCTION SHEET

CNT PROGRAMMABLE, MULTIFUNCTION

DIGITAL TIME DELAY RELAY/COUNTER
FOR PLUG-IN OR PANEL MOUNTING

ORDERING INFORMATION Recycle Time: 45 ms, typ.;

60 ms, max.
Part Number Input Voltage Stock Item Available Timing Functions: Delay on operate; delay on release;
CNT-35-26 12 V dc Yes interval on (input and switch controlled by closure); interval on
CNT-35-76 120 V ac Yes (switch controlled on opening); recycle (equal on and off times start
CNT-35-96 Universal (24-240 V ac/V dc) Yes with off time upon momentary switch closure); single cycle (equal on
and off time); interval on (switch controlled on closure and opening);
FEATURES delay on operate and release (switch controlled on opening and
C 10 programmable timing functions plus 2 counting functions closure); output pulsing (0.5 second on time, thumbwheel set off
C 0.1 second to 9990 hour programmable timing range time) and cumulative delay on operate.
C 1 to 99 900 counting range
C Universal input (24-240 V ± 15%, 50/60 Hz, ac or dc) COUNTING SPECIFICATIONS
C Fixed input types (12 V dc ± 15%; 120 V ac ± 15%, 50/60 Hz) Maximum Count: 1 to 999;
C 10 A, 240 V ac or 30 V dc, DPDT electromechanical relay output 10 to 9990 (divide by 10);
C LCD digital display 100 to 99 900 (divide by 100).
C 1/16 DIN style enclosure (48 mm x 48 mm) with 11-pin plug-in Maximum Count Rate: 100 counts per second.
base Minimum Pulse Width: Count (Control): 50 ms.
C Thumbwheel switches for programming Reset: 50 ms.
Available Counting Functions: Operate at preset count and
GENERAL DATA release at preset count.
Duty: Continuous.
Output Contact Arrangement: 2 form C (DPDT). OUTLINE DIMENSIONS
Contact Rating: 10 A @ 30 V dc or 277 V ac, resistive; 1/2 HP
@ 250 V ac; 1/3 HP @ 120 V ac.
Contact Material: Sllver-cadmium oxide.
Expected Electrical Life at Rated Load: 100 000 operations.
Expected Mechanical Life: 10 million operations.
Isolation (input to output): 1500 V RMS, 60 Hz, between all
elements.
Temperature Range: Storage: !20EC to +70EC.
Operating: !10EC to +55EC.
Humidity: 85% relative humidity, non-condensing.
Input Transient Protection: Yes.
Input Polarity Protection: Yes.
Case Color: Beige.
Weight: 4.3 oz (122 g).
External Control: CONTROL, RESET: Active on contact closure
or solid state switch closure to RETURN,
0-1.0 V dc maximum voltage level (see wiring OPERATING DIAGRAM
diagrams for interface circuits).
Input Power Consumption (Max.):
Universal Input Model: 10 VA @ 240 V ac; 5 VA @
120 V ac; 3 VA @ 24 V ac.
10 W @ 240 V dc; 5 W @ 110 V dc;
1 W @ 24 V dc.
Fixed Input Models: 3 W @ 12 V dc; 3 VA @ 120 V ac.

TIMING SPECIFICATIONS
Timing Ranges: 0.1 to 99.9/ 1 to 999 seconds;
0.1 to 99.9 /1 to 999 minutes;
0.1 to 99.9/ 1 to 999 / l0 to 9990 hours.
Tolerance: ± 0.1% ± 0.05 seconds.
Repeatability (including first cycle of operation): ± 0.1% ± 0.05
seconds.
Delta Time: ± 0.1% ± 0.05 seconds.
Reset Time (power interruption): 45 ms, typ.; 60 ms, max.
Minimum Pulse Width, Control/Reset: 50 ms.

E-1
 Time-Delay Relay / Counter Specifications

SOCKET HOOK-UP AND TERMINAL LOCATION

Terminal No. Hook Up Terminal No. Hook Up

1 Movable #1 7 External Sw. (Reset)
2 Input (+) 8 Normally Closed #2
3 Normally Open #1 9 Normally Open #2
4 Normally Closed #1 10 Input (!) & Ext. Sw. Common
5 External Sw. (Common) 11 Movable #2
6 External Sw. (Control)

WIRING DIAGRAMS PROGRAMMING SWITCH DIAGRAM

Bottom Views — Pins
numbered clockwise from keyway

COUNTER FUNCTION DESCRIPTION

Presettable Counter:

E-2
 Time-Delay Relay / Counter Specifications

CO - Operate at Preset Count (normal mode): CO, CR - Divide-by-10 Mode:

After initializing by momentary activation of RESET input, each Operation is as described above except count is incremented for
on/off signal at COUNT (CONTROL) input increments displayed every 10 on/off input signals for a maximum presettable count of
count in up-counting manner from initial 000 value until preset count, 9990.
set by thumbwheel switches, is reached and output relay is turned
on. Additional inputs continue to increment displayed count. CO, CR - Divide-by-100 Mode:
Continued counting past maximum count (999) results in a Operation as described above except count is incremented for every
"wrap-around" effect to 000, followed by continued up-counting. 100 on/off input signals for a maximum presettable count of 99 900.
Activation of RESET input turns relay off and resets count to zero.
Notes:
CR - Release at Preset Count (normal mode): Note Î Timing initiated upon first transition of CONTROL input;
Initializing by momentary activation of RESET input turns relay on. timing restarted on subsequent transitions as notcd.
Operation is similar to CO mode except relay is turned off at preset Note Ï Timing initiated upon first transition of CONTROL input;
count. subsequent transitions ignored until cycle completed.
General Note: High level of "Control" and "Reset" denote external
contact or solid state switch closure between
respective input and "Return" terminal.

TIMER FUNCTION DESCRIPTIONS

Output relay turned on at end of

programmed timed interval which Output relay turned on at end of
is started by CONTROL input or programmed time interval which is
power-on with CONTROL on. started by momentary CONTROL
Relay turned off by RESET input input or power-on with CONTROL
until next cycle is started. With on. Relay stays on for equal time
CONTROL on, turning RESET off interval, then turns off and cycle is
restarts timing. repeated on a free-running basis
until terminated by momentary
RESET, turning relay off. With
CONTROL on, turning RESET off
Output relay turned on with restarts cycle.
CONTROL input and remains on
for programmed time interval
following removal of CONTROL.
During time interval after release Output relay turned on at end of
of CONTROL, RESET turns relay programmed time interval which is
off until cycle restarted with started by momentary CONTROL
reapplication of CONTROL. With input or power-on with CONTROL
CONTROL on, relay is held off on. Relay stays on for equal time
while RESET is activated. interval, then turns off. RESET
terminates timing and turns relay
off. Turning RESET off does not
restart timing.
Output relay turned on for pro-
grammed time interval by
CONTROL or power-on with
CONTROL on. RESET turns relay Output relay turned on and
off until next cycle is started, and programmed time interval started
does not restart timing when or restarted by changeof
RESET is removed. CONTROL input. RESET turns
relay off and stops timing. Turning
RESET off does not restart timing.

Output relay turned on for pro-

grammed time interval by turn-off
of CONTROL. RESET turns relay Output relay turned on at end of
off until next cycle is started, and programmed timing interval which
does not restart timing when is started or restarted by change
RESET is removed. of CONTROL input. If relay is on,
turn-off of relay occurs at end of
programmed time interval which is
started or restarted by change of
CONTROL input. RESET turns
relay off and stops timing. Turning
RESET off does not restart timing.

Output relay turned on at end of

programmed time interval, which
is started by CONTROL input, for
0.5 second duration, and
continues in pulsed mode at
programmed time interval with
fixed 0.5 second on-time. Turning

E-3
 Time-Delay Relay / Counter Specifications

CONTROL off turns relay off and stops timing. RESET turns relay off
and inhibits operation. With CONTROL on, removal of RESET restarts Output relay turned on at
timing. completion of total accumulate
CONTROL input duration equal to
programmed time. Turning
CONTROL off before
accumulation of programmed time
results in measured time total
being held until CONTROL is
again turned on and total
programmed time value is
reached. RESET input resets time
value to zero and turns relay off if
energized. Turning RESET off
restarts timing if CONTROL is on.

Siemens Electromechanical Components, Inc.

Potter & Brumfield Products Division
200 S. Richland Creek Drive
Princeton, IN 47671-0001

Specifications and availability subject to change without notice

12C058 (REV. 5/90) Printed in U.S.A.

E-4
 Bibliography

Hedges, Charles S., Electrical Control of Fluid Power, Third Edition, Dallas, Texas:
Womack Educational Publications, Department of Womack Machine Supply
Company, 1987
ISBN 0-9605644-9-7

Hedges, Charles S., Industrial Fluid Power, Volume 2, Fourth Edition, Dallas, Texas:
Womack Educational Publications, Department of Womack Machine Supply
Company, 1988
ISBN 0-943719-01-1
 We Value Your Opinion!

Your comments will allow us to produce better manuals and develop new systems
in order to better meet the needs of our users. Please contact us by Email at:

services@labvolt.com

For further information, visit our Web site at www.labvolt.com