CHAPTER 7

BASIC ELECTRICAL
CONTROLS FOR
FLUID POWER

1
 Contents
7.1 Introduction
7.2 Electrical components
7.3 Applications
7.3.1 Control of a cylinder using a single limit switch
7.3.2 Reciprocation of a cylinder using pressure or
limit switches
7.3.3 Dual-cylinder sequence circuits
7.3.4 Electrical control of regenerative circuit
7.3.5 Counting, timing, and reciprocation of
hydraulic cylinder 2
Learning objectives
Upon completing this chapter, you should be able to:

1. Understand the operation of the various electrical

components used in electromechanical relay
control system.
2. Read and understand the operation of electrical
ladder diagrams

3. Interrelate the operation of electrical ladder logic

diagrams with the corresponding fluid power
circuit
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7.1 Introduction
Electrical devices have proven to be an important
means of improving the overall control flexibility of
fluid power systems. In recent years, the trend has
been toward electrical control of fluid power
systems..
7.1.1 Basic electrical devices
Seven basic electrical devices commonly used in
control of fluid power:
Manually actuated push-button switches, limit
switches, pressure switches, solenoids, relays,
timers, and temperature switches. Can be wired
either normally open (NO) or normally closed (NC). 4
1. Push-button switch. Mainly used for starting and
stopping operation of machinery. By the use of
simple push-button switches, an operator can cause
sophisticated equipment to begin performing
complex operation.
2. Limit switches. These open and close circuits
when they are actuated at the end of the retraction
or extension strokes of hydraulic or pneumatic
cylinders. fig-chp7\fig7.1.pptx incorporates its
own limit switches at the end of each stroke. Each
switch can be wired normally open or closed.
Symbols are also shown in the same figure.
5
3. Pressure switches. Pressure switches open or close
their contacts based on system pressure. For high
and low pressure setting, say, for a pump, it will
start the pump when pressure is low and stop the
pump when the pressure is high.
fig-chp7\fig7.2.pptx an actual pressure switch
(adjustable) and the symbol used in hydraulic
circuits. It can be wired NO or NC. It has three
terminals C (common), NC and NO.
4. Solenoids. These are electromagnets that provide
a push or pull force to operate fluid power valves
remotely.
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5. Relays. Relays are switches whose contacts open
or close when their corresponding coils are
energized. Normally used for energizing and de-
energizing solenoids (high current low voltages).
6. Timers. These are time delay devices to control
the time duration of a working cycle.
7. Temperature switches. It senses a change in
temperature and opens or closes an electrical
switch. fig-chp7\fig7.3.pptx shows a temperature
screw (adjustable) with the symbol. Also shown is
a long capillary tube that enables remote sensing.

7
7.1.2 Circuit diagrams
For electrohydraulic or electropneumatic circuits,
separate circuits are drawn for the fluid and electrical
system. Electrical circuits use ladder diagrams with
the power connected to the left leg.
7.2 Electrical Components
Five basic types of electrical switches used, namely
push-button, limit, pressure, temperature, and relay
switches.
1. Push-button switches. fig-chp7\fig7.4.pptx shows
different types of switches: (a) and (b) single pole
and single-throw type; (c) double-pole, single throw
type; (d) double-pole, double throw type. 8
2. Limit switches (LS). fig-chp7\fig7.5.pptx shows
the various types of limit switches. The difference
with push-buttons is that they are mechanically
actuated. Among these are cams, levers, rollers,
and plungers.
3. Pressure switches (PS). fig-chp7\fig7.6.pptx
shows the symbols for pressure switches.
4. Temperature switches. Shown in
fig-chp7\fig7.7.pptx
5. Electrical relays. This is an electrically actuated
switch. In fig-chp7\fig7.8a.pptx, when switch 1-
SW is closed the electromagnet is energized and
pulls 9
 the spring loaded relay arm to open the upper one and close
the lower one. The symbols are also shown in the same
figure. fig-chp7\fig7.8b.pptx
When time delay for a certain operation is required timers
are used. fig-chp7\fig7.9a,b.pptx & fig-chp7\fig7.9c,d.pptx
show different types of timer arrangements.
(a) Normally open but when energized closes after a
predetermined time
(b) Normally closed but when energized opens after a
predetermined time
(c) Normally open but when de-energized opens after a
predetermined time
(d)Normally closed but when de-energized closes after a
predetermined time
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 The symbol for solenoid is shown in
fig-chp7\fig7.10.pptx including that of an indicator
lamp.
Indicator lamps show the active switch in a circuit
while in operation or which solenoid operator of a
DCV is energized.
7.3 Applications
7.3.1 Control of a cylinder using a single limit
switch
fig-chp7\fig7.11.pptx uses a single solenoid valve
and a single limit switch to control the double-acting
cylinder. In (a) is shown the fluid circuit while (b)
shows the electrical circuit. 11
 Fig. 7-11(a) gives the hydraulic circuit in which the
limit switch is labeled 1-LS and the solenoid is labeled
SOL A. Fig. 7-11(b) shows the use of one relay with a
coil designated as 1-CR, two separate normally open sets
of contacts, the limit switch 1-LS (NC), normally closed
(STOP) and normally open (START) push-button
switches
A momentary press on the START button energizes the
relay to close contact of the two CR’s. This will energize
solenoid A which will make the left envelope of the DCV
to be in operation. This will then extend the cylinder.
At the end of extension the piston rod cam will open the
NC limit switch 1-LS and this will de-energize coil 1-CR.
This reopens the contacts of 1-CR to 12
de-energize solenoid A. Thus, the DCV will then be
in its spring-off-set mode which will make the right
envelope to be in action and the cylinder retracts. The
cylinder stops at the end of the end of the retraction
stroke, but the cycle is repeated each time the START
button is momentarily pressed.
The STOP button can be a sort of emergency
button. A momentary press opens the whole circuit,
immediately stops the extension and retracts the
cylinder.

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7.3.2 Reciprocation of a cylinder using pressure or
limit switch
fig-chp7\fig7.12.pptx shows the arrangement how
pressure switches can replace limit switches to control
the operation of double-acting hydraulic cylinder.
Operation starts as the switch 1 SW is closed. Then,
the cylinder reciprocates continuously until 1-SW is
opened.
When rod is in motion both switches are open.
Assuming SOL A was last energized (left envelope
was in operation) pressure builds up when the
cylinder has fully extended. This is transmitted to 1-
PS which energizes SOL B and makes the right 14
 envelope in operation resulting in retraction. At the end
of pressure builds up again to switch on 2-PS and
energize SOL A to repeat the cycle.
fig-chp7\fig7.13.pptx gives the exact operation
except LS replaces PS. Note that switches are shown in
their unactuated mode in the electrical circuit.
7.3.3 Dual-cylinder sequence circuits
fig-chp7\fig7.14.pptx shows the arrangement. These
are two double acting pneumatic cylinders using 3
solenoids and 2 limit switches for simultaneous
retraction.
When start button is momentarily pressed SOL A will
get energized. Left envelope of valve V1 will be in
operation –cylinder 1 extends-closes 1LS at the 15
 end of extension which energizes SOL C. Left
envelope of valve V2 will be in operation-cylinder 2
extends –closes 2LS-energizes SOL B. This will retract
cylinder1 which motion opens switch 1 LS. This
action de-energizes SOL C and sets V2 in spring offset
mode. This sets the cylinders to retract simultaneously.
To summarize, the complete cycle sequence
established by the momentary pressing of the START
button is as follows:
1.Cylinder 1 extends
2.Cylinder 2 extends
3.Both cylinders retract
4.Cycle is ended. 16
 A second dual-cylinder circuit with a slight change
of sequence is shown in fig-chp7\fig7.15.pptx.
Pressing the START button momentarily closes
switch 1-CR which energizes SOL A and cylinder 1
will extend. At the end of extension the rod acts on
the NO -1LS (energizes SOL B) and the other NC-
1LS which de-energizes SOL A (V1 will be spring
offset mode). These two operations will extend
cylinder2 and retract cylinder1 simultaneously. At the
end of extension of cylinder 2 the NC 2-LS will be
opened and relay 2CR is de-energized. This will de-
energize SOL B and V2 will be in spring offset mode
and cylinder 2 will retract-end of the cycle.
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7.3.4 Electrical Control of Regenerative Circuit
fig-chp7\fig7.16.pptx shows the arrangement.
Switch 1-SW can be positioned in three locations:
extend, retract and unload. In the extend mode SOL
A is energized , cylinder extends, oil from the rod
end flows back to the piston end to increase the
velocity of extension.
When the cylinder starts to pick load higher
pressure will be generated which will actuate 1-PS
resulting coil relay 1 CR and SOL C energized.
Valve V2 will drain the oil thus reducing the speed of
the extension.
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 When 1-SW is placed in to the retract position,
SOL B becomes energized while the relay coil and
SOL C becomes de-energized. Therefore, the
cylinder retracts in a normal fashion to its fully
retracted position.
In unload position all contact will be open and
the valve will be in spring centered mode. The pump
will be relieved.

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7.3.5 Counting, Timing, and Reciprocation of Hydraulic
Cylinder
This arrangement is shown in fig-chp7\fig7.17.pptx
A momentary push on the START button will, start the
timer, energize relay 1-CR, and close the NO switch 1-CR.
This will, energize SOL A, light lamp L1 and the cylinder
extends (1-LS closes). At the end of extension the NO 2-LS
is closed. This switches on the counter, energizes relay 2-
CR, the two NO contacts 2-CR close, and opening the NC
contact 2-CR , resulting in SOL A de-energized, SOL B
energized and lamp L2 lit. This retracts the cylinder at the
end of which the NC 1-LS is opened which opens all the NO
2-CR switches (de-energizes SOL B) except the one NC 2-
CR ,on rung 2. This energizes SOL A and the cycle
continues in automatic reciprocation mode. 20
 A momentary pressing of the STOP button puts the
DCV in spring centered mode and the cylinder is
immediately stopped and locked. The pump is also
unloaded.
The COUNTER registers an integer increase in value
each time an electrical pulse is received and removed.
Since the TIMER line is always live, it registers how
long the system has been operating since the START
button was depressed.
Two lamps (L1 and L2) show when the cylinder is
extending or retracting. L1 ON-extension, L2 ON-
retraction. The cylinder speed is controlled by the
pressure and temperature compensated flow control
valve. 21