Electroneumatics Manual

PNEUMATICS
The science of the motions and properties of air. It has been adopted by
engineers to as the branch of physics that deals with the pressure, elasticity, weight,
and other mechanical properties of air and other gases. The English word pneumatic
and its associate noun pneumatics are derived from the Greek root pneuma meaning
“breath “.
Compressed air is one of the oldest forms of energy known to man. However it
is not until the last century that the fundamentals of pneumatics were researched
systematically. While this energy can be used in many facets of industry, the true and
worldwide introduction of pneumatics in industry, commenced only when the need for
automation and rationalization of operational sequences continued to increase
Properties of compressed air:
Repeated releases of new developments in equipment and announcement of

newer fields of application demonstrate that pneumatics is in a continuous process of
growth. This is because in some problems of automation, no other medium can be used
more readily and economically than air.
Some of the important reasons for the wide use of compressed air in industry
are as follows:
Availability
Air is available practically everywhere for compression, in unlimited quantities.
Storage
It is easily stored in large volumes if required.
Environmentally clean
It is clean and with proper exhaust air treatment, can be installed to clean room
standards.
Resistance to Environment
It is largely unaffected in the high temperature, dusty and corrosive atmospheres in
which other system may fail.
Overload Safe
Pneumatic tools and operating components can be overloaded to the point of stopping
and they are therefore overloading safe.
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PNEUMATICS SYSTEM
6
6
4
3
2
The component parts and their main functions are:
Air Production System
1. Compressor
Air taken in at atmospheric pressure is compressed and delivered at a higher
pressure to the pneumatic system. It thus transforms mechanical energy into
pneumatic energy.
2. Electric Motor
Supplies the mechanical power to the compressor. It transforms electrical energy
into mechanical energy.
3. Pressure Switch
Controls the electric motor by sensing the pressure in the tank. It is set to a
maximum pressure at which it stops the motor, and a minimum pressure at
which it restarts it.
4. Check Valve
Lets the compressed air from the compressor into the tank and prevents it
leaking back when the compressor is stopped.
5. Tank
Stores the compressed air. Its size is defined by the capacity of the compressor.
The larger the volume, the longer the intervals between compressor runs.
6. Pressure Gauge
Indicates the Tank Pressure.
7. Auto Drain
Drains all the water condensing in the tank without supervision.
8. Safety Valve
Blows compressed air off if the pressure in the tank should rise above the
allowed pressure.
9. Refrigerated Air Dryer

Cools the compressed air to a few degrees above freezing point and condenses
most of the air humidity. This avoids having water in the downstream system.
10. Line Filter

Being in the main pipe, this filter must have a minimal pressure drop and the
capability of oil mist removal. It helps to keep the line free from dust, water and
oil.
Air Consuming System
1. Air Take-off
For consumers air is taken off from the top of the main pipe to allow occasional
condensate to stay in the main pipe, when it reaches a low point a water take off
from beneath the pipe will flow into an Automatic Drain and the condensate will
be removed.
2. Auto Drain
Every descending tube should have a drain at its low end. The most efficient
method is an Auto Drain which prevents water remaining in the tube should
manual be neglected.
3. Air Service Unit

Conditions the compressed air to provide clean air at optimal pressure, and
occasionally adds lubricant to extend the life of those pneumatic system
components which need lubrication.
4. Directional Valve
Alternately pressurizes and exhausts the two cylinder connection to control the
direction of movement
5. Actuator
Transforms the potential energy of the compressed air into mechanical work.
Shown is a linear cylinder, it can also be a rotary actuator or an air tool etc.
6. Speed Controllers
Allow an easy and step less speed adjustment of the actuator movement.

Types of Compressor
The selection of a compressor depends upon the working pressure and the required air
quantity.
Reciprocating piston The piston draws air in through the suction valve during
the downward stroke; compressor compresses it during
the upward stroke and pushes it out through the
pressure valve.
Pressure: Single-stage up to approx. 600 kPa (6 bar)

Two-stage up to approx. 1500 kPa (15 bar)
Screw compressor The air drawn in through the suction nozzle is moved
axially through two impellers at high speed to the
pressure side.
Pressure: Up to approx. 1000 kPa (10 bars)
Radial flow compressor Through rapidly rotating blades, the air is accelerated
radially. The kinetic energy of the air is converted into
pressure energy.
Pressure: With multistage design up to approx. 1000

kPa (10 bars)
Sliding vane compressor Sliding vanes in an eccentrically located rotor divide

the compressor (Rotary compressor) chamber into
closed cells. By reducing the size of the cells during
the revolution, the air is compressed.
Pressure: Single-stage up to approx. 400kPa (4bars)

two-stage up to approx. 800 kPa (8 bars)
Axial compressor
Through rapidly rotating blades, the air is accelerated
radially. The kinetic energy of the air is converted into
pressure energy.
Pressure: Up to approx. 600 kPa (6 bars

Symbols for the Principal Working Elements
The symbol is represented with the advance motion to the right in the system circuit
diagram
Single-acting: Performs work in one direction

Double-acting: Performs work in both directions
(Sloping arrow over piston: denotes adjustable end position cushioning )
Linear Actuators
Single-acting cylinder
Double-acting cylinder
Double-acting cylinder with through piston rod
Double-acting cylinder with single, non-adjustable cushioning
Double-acting cylinder with single, adjustable cushioning
Double-acting cylinder with adjustable cushioning at both ends
Rod less cylinder with magnetic coupling
Rotary Drives
Air motor, constant displacement, rotation in one direction
Air motor, variable displacement, rotation in one direction
Air motor, variable displacement, rotation in both directions
Pneumatic rotary motor

Types of Mounting
The type of mounting is determined by the attachment of the cylinder to a fixture or

machine. Through additional parts (modular principle), the cylinder can be converted
for another type of attachment
Advantages: • Reusability
• Simplification of inventory keeping
• Cost savings
Center swivel flange Rear swivel flange Foot mounting
Front flange Rear mounting Swivel flange
Front swivel flange Rear flange

Single Acting Cylinder
The piston rod of a single acting cylinder is operated by the input of compressed air
at the back end position. When the compressed air is shut off, the piston returns to
its starting position via a return spring.
Actual device Symbol
Operation:
No compressed air is applied. Compressed air is applied. The cylinder

This is the initial position of extends. Upon released of air, the
the cylinder. (Retracted) cylinder will retract.
Double Acting Cylinder
The piston rod of a double acting cylinder is operated by the reciprocal input of
compressed air at the front and back of the cylinder. The end position damping is
adjustable via two regular screws.
operation:
Compressed air When air is Compressed air When air is

applied at the removed. applied at the removed
back input front input
(The cylinder retains its last position after the compressed air is removed.)

One-way flow control valve
The one-way flow control valve is made up of a throttle valve and a check valve. The
check valve stops the flow from passing in a certain direction. The flow then passes
through the throttle valve. The cross-section of the throttle is adjustable via a regular
screw. In the opposite direction the flow can pass through the check valve
Operation:
The check valve is closed. The air The check valve is open. The air
passes through the throttle. The passes through the check valve. The
flow can be regulated. flow cannot be regulated.
Quick exhaust valve
The compressed air passes from connection 1 to connection 2. If the pressure should
decrease at connection 1, then the compressed air from connection 1 will escape to
the outside via the installed silencer.
Operation:
When pressure is applied in 1, the steel ball When back pressure is applied in connection
will move to the right and closes the 2, the steel ball will move to the left and
exhaust port 3. The compressed air then closes input 1. The compressed air passes
passes thru connection 2. thru the exhaust port 3.

Directional Control Valves Symbol Development
Valve switching positions are represented by

squares
The number of switching positions of the

valve is shown by the number of squares
Lines indicate flow paths, arrows show the

direction of flow
Shut off positions are identified in the boxes

by lines drawn at right angle
The connections (inlet and outlet ports) are

shown by lines on the outside of the box and
are drawn in the initial position

Directional Control Valves Ports and Positions
Written title: 2/2-Way valve

Spoken tittles: Two-two way valve
(Note: The box on the left is the initial position for n/2 way valve)
Number of ports
Number of switching positions
2
2/2-way valve, (normally open position)

1
3/2-way valve, (normally closed position)
1 3
3/2-way valve, (normally open position)

1 3
4 2
4/2-way valve, (flow from 1 to 2 and from 4 to 3)

1 3
4 2
5/2-way valve, (flow from 1 to 2 and from 4 to 5)

5 1 3
4 2
5/3-way valve, (mid-position closed)
5 1 3
One way flow control valve (throttle)

Port designations
(by numbers) (by letters)

Supply port: 1 (P)
Working ports: 2, 4 (A, B)
Pilot ports: 10 Signal applied blocks flow from 1 to 2 (X)
12 Signal applied opens flow from 1 to 2 (Y)
14 Signal applied opens flow from 1 to 4 (Z)
Exhaust ports: 3, 5 (R, S)
Types of Actuation
The symbols for the types of actuation are drawn directly on the valve symbols.
Selection: (Depending upon system requirements)
Manually actuated
Electrically actuated
Mechanically actuated
Pneumatically actuated
Combined types of actuation
Purpose: Actuate, Reset, Center
MANUAL ACTUATION
General
Push button operated
Lever operated
Via lever with detent
Fool pedal operated

MECHANICAL ACTUATION

Roller actuated
in both direction
Roller actuated
only in one direction
Spring actuated
Spring centered
PNEUMATIC ACTUATION
Direct pneumatic actuation
Indirect pneumatic actuation,

piloted
ELECTRICAL ACTUATION
Solenoid with one winding
Double solenoid actuation

(valve remembers its last position)
Solenoid or manual actuation
Solenoid and pilot actuation with

Manual override
Solenoid with spring return

(Spring returns the valve to
initial position when solenoid
is de-energized)
1
PNEUMATIC-ELECTRIC (PE) P
CONVERTER
4 2
Electro-pneumatic

Is the integration of pneumatic and electrical technologies in industrial
automation solutions. Electricity is used for control energy and pneumatics for the
work energy.
An Electro-pneumatic control offers a number of advantages to the developer

of control systems. Where signals are transmitted over great distances in a control
system, the time between signal transmission and signal reception is minimized using
electricity as the transmission medium.
Switches and relay contacts
Normally open contacts Normally close contacts
Changeover contacts Two way, normally open

switch with three positions
Switch with normally open contacts Switch with Normally close contacts
(non automatically reset/latching) (non automatically reset/latching)
Mechanically linked contacts Normally open contacts, actuated
Pushbutton switch manually actuated

by pressing by pulling by rotating
Roller actuated Pneumatics actuated

(Normally open but initially actuated)
ELECTRICAL RELAY
An electrical relay is a switch which is under the control of another circuit.

Historically, electrical relays were often made with electromagnets, which continue to be
used today, although for some applications solid state relays are preferred. The key
difference between electromagnetic and solid state options is that electromagnetic relays
have moving parts, and solid-state relays do not. Electromagnets also conserve more
energy than their solid-state counterparts do. One of the reasons an electrical relay is such
a popular tool for electricians and engineers is that it can control electrical output, which is
higher than the electrical input it receives, and it can control several electrical outputs
simultaneously with just one input.
Switches connected for an equivalent AND logic function:

+24V
●
Switches S1, S2, S3 are connected in series and
must be close together to operate the lamp. The
S1 Boolean expression of the lamp is S1 and S2 and S3.
Lamp = S1•S2•S3
S2
Digital Symbolic representation:

S3
S1
S2 Lamp
S3
Lamp
For several inputs logic AND function, switches are
connected in series.
+0V
●
Switches connected for an equivalent OR logic function:
+24V
● Switches S1 & S2 are connected in parallel and any
of the switches or both must be close to operate the
lamp. The Boolean expression of the lamp is S1 or
S1 S2
S2.
• Lamp = S1 + S2
Digital Symbolic representation:
S1 Lamp
S2
Lamp
For several inputs logic OR function, switches are
+0V connected in parallel.
●
Switch connected for an equivalent NOT logic function:

+24V
●
S1 is a normally close switch and when actuated the
lamp turns off. The Boolean expression of the lamp
S1 is not S1
Lamp = S1
Lamp
S1 Lamp
+0V
●
Memory function: Latching circuit
+24V 1 2
● ● Relays and switch contacts can be use to hold
solenoid valves, relay and lamps active for extended
S1 K periods without the need to apply additional signals.
This is called the memory function.
• A parallel path (2), which latches the output
permanently, forms a simple memory circuit.
K Switch S1 operates relay K. Once relay K is

active, it changes the initial states of its sets of
+0V contacts. A contact of relay K that is parallel to S1
●
hold the relay active even switch S1 is not active.
1 2
+24V
● ● The relay remains active until its power cut
from the line. In actual application, additional switch
is use to cut the power supply of relay K1.
S1 K
+0V
●

Control and operation of a single solenoid with spring return 5/2 way valve.
4 2 4 2
Y14 12 Y14 12
5 1 3 5 1 3
Pb1 Pb1
24V ● 24V ●
● ●
0V 0V
A single solenoid 5/2 way valve is When Pb1 is pressed, electrical
also known as mono stable valve. It supply lines (24V) energized the
always has initial position. solenoid Y14. The solenoid then
pushes the second position of the
valve in line with supply port and
compressing the spring.
4 2
Y14 12
5 1 3
Pb1
24V ●
●
0V
When Pb1 is open, the solenoid Y14

will be de-energized. The position of
the valve returns to its initial position
because of the expansion of the
spring (12).
Control and operation of a double solenoid 5/2 way valve.

Y12 - Retract solenoid of the valve.
Y14 - Extend solenoid of the valve.
4 2 4 2
14 12 14 12
5 1 3 5 1 3
Pb1 Pb2 Pb1 Pb2
24V ● ● 24V ● ●
● ● ● ●
0V 0V
A double solenoid 5/2 way valve is When Pb1 is pressed, electrical

also known as memory valve. It supply lines (24V) energized the
remembers the position of its last solenoid Y14. The solenoid then
operation. Considering that, the pushes the second position of the
figure above is the position of its last valve in line with supply port.
operation.
4 2 4 2
14 12 14 12
5 1 3 5 1 3
Pb1 Pb2 Pb1 Pb2
24V ● ● 24V ● ●
● ● ● ●
0V 0V
If Pb1 is open, the solenoid Y14 is When Pb2 is pressed, electrical

de-energized. The position of the supply lines (24V) energized the
valve remains the same. solenoid Y12. The solenoid then
pushes the first position of the valve
in line with supply port.
Direct control of a lamp by a push button switch.

The current in the switch is the same as that of the lamp.
24V 24V
Pb Pb
Lamp A Lamp A
0 0
Fig. 1 Fig. 2
Initially the switch is open. There is no current in the circuit (Fig. 1). When push button
Pb is pressed, the current from the 24V source will pass through the Pb switch, the lamp
A then to the 0V line. The current in the switch is the same as the current that energized
the lamp. This is a direct control of the lamp (Fig. 2).
24V 24V
K K
Pb Pb
Ik IL
K K
Lamp A Lamp A
0 0
When push button Pb is pressed, the relay K coil will be energized through the Pb switch,
then the contact K of the relay will close the second circuit. The lamp will be energized
through the relay contact K. The current in the control switch Pb is not the same as the
current that energized the lamp. This is indirect control of the lamp using relay.

Dominant set
+24V
● ●
S2 a normally close contact connected in
series with the latching contact (K).
S1 K
Pressing S2 alone breaks the current path to
relay K coil and the circuit is unlatched. If S1 held
S2 actuated whilst pressing S2, relay K is active.
Therefore, the setting current path is dominant.
•
+0V
●
Dominant set
+24V
● ●
S2 a normally close contact connected in
S1 K series with S1.
• Pressing S2 alone breaks the current path to

relay K coil and the circuit is unlatched. If S1 held
S2 actuated whilst pressing S2, relay K is inactive.
Therefore, the resetting current path is dominant.
+0V
●
Latching circuit is a current path that shorted the momentary input signal (NO pushbutton)
to keep the supply current to the coil/solenoid continues. It is very useful when controlling
a single solenoid valve with set and reset switches.
Exercise 1
DIRECT AND INDIRECT CONTROL OF DOUBLE ACTING CYLINDER

Objectives:
1. To design a direct and indirect control circuit of a double acting cylinder.
2. To connect the control circuit diagram on the trainer board.
3. To describe the operation of the one way flow control valve.
The problem:
A double acting cylinder is to extend when a pushbutton is operated. Upon release of the
pushbutton the cylinder is to retract. The cylinder is of small bore (25 mm diameter)
requiring a small flow rate to operate at the correct speed
1.0
Set-up diagram
Draw the circuit diagram for the problem. Designate the pneumatic and electrical
components and indicate the numbering system for the valve ports and electrical
connections.
Questions
1. Adjust the flow control valve nearly close. What happen to the cylinder if the switch is
press for a very short period, and then release?
__________________________________________________________________________
______________________________________________________________________
2. Adjust the flow control valve to almost open. What happen to the cylinder if the switch
is press for a very short period and then release?
__________________________________________________________________________
______________________________________________________________________
3. Why is the current handling capacity of the switch is important?

__________________________________________________________________________
______________________________________________________________________
PNEUMATICS CIRCUIT DIAGRAM: 1.0

4 2
Y14 12
5 1 3
Switch Module Relay Module Relay Module
24V 24V 24V
A1 A1
Pb
A2 A2
ELECTRICAL CONTROL CIRCUIT DIAGRAM: (direct control)

A1 A1
24V 1
A2 A2
A1 A1
Pb
A2 A2
0V 0V 0V
Control Valve
Manifold
Y14
12 0 14
0V
SETUP CONNECTION DIAGRAM:
Cylinder
1
4 2
24V
1.0
1.0
ELECTRICAL CONTROL CIRCUIT DIAGRAM: (indirect control)
0V
ELECTRICAL CONTROL CIRCUIT DIAGRAM: (time delay control)
24V
0V

24V 24V 24V
A1 A1
A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
12 0 14
Cylinder
Exercise 2
THE SERIES AND CIRCUIT

Objectives:
1. To use the AND configuration of switches in the circuit to control a double acting
cylinder.
2. To connect the control circuit diagram in the trainer board.
The Problem
The ram of a press is only to extend if the protective guard is closed which actuates switch
S1 and the start button switch S2 is operated. If either of these conditions is not met the
ram is to retract immediately. The cylinder piston rod is operated by a single solenoid valve
with spring return.
S2
S1
Set-up diagram
Complete the circuit diagram for the problem. Designate the electric and pneumatic
components and indicate the numbering system for the connections.
Questions
1. Describe the method of connection of switches to achieve the AND function. Draw the
connection of 3 switches to achieve a 3 input logic AND function.
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. Draw the digital symbol of a 3 input AND gate?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
PNEUMATICS CIRCUIT DIAGRAM:

24V 24V 24V
A1 A1
ELECTRICAL CONTROL CIRCUIT DIAGRAM:

A2 A2
24V A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
12 0 14
0V
Cylinder
Exercise 3
THE LOGIC OR FUNCTION
Objectives:

1. To use the OR configuration of switches in the circuit to control a double acting
cylinder.
The Problem
Two switches can control a carton ejector from either side of a conveyor track. If switch S1
or S2 is pressed, the double acting cylinder ejects the rejected carton ton from the
conveyor. The ejector piston rod must retract when both switches are released. The
cylinder is to be controlled by a 5/2 way solenoid valve.
Set-up diagram
components and indicate the numbering system for the connections
Questions
1. Describe the method of connection of switches to achieve the OR function. Draw the
connection of 3 switches to achieve a 3 input logic OR function.
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. Draw the digital symbol of a 3 input OR gate?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________

24V 24V 24V
A1 A1
A2 A2
24V
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
0V 12 0 14
Cylinder
Exercise 4
THE LOGIC NOT FUNCTION: SIGNAL INVERSION
Objectives:

1. To use the NOT configuration of switches in the circuit to control a double acting
cylinder.
The Problem
When a pushbutton is pressed the piston rod of a double acting cylinder is to extend. A
roller limit switch is located at the retracted position of the rod. A lamp (L1) is to indicate
that the piston rod is carrying out work and is not home.
L1 S2 1.0
Set-up diagram
Note: Referring to the circuit diagram, S2 is located at the retracted position of cylinder
1.0 and is indicated by a marker and switch designation. This is the physical location of the
switch. The electrical circuit must also show the correct circuit position of S2 switch.
Question:
Describe the purpose of the NOT function.
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
1.0 S2

24V
0V

Switch Module Relay Module Lamp Module
24V
24V 24V
A1
A2
A1
A2
A1
A2 0V
0V 0V
Control Valve
Manifold
12 0 14
22 21 24
Cylinder
Exercise 5
DOMINANT SET MEMORY CIRCUIT
Objectives:
1. To use the dominant set circuit to control a double acting cylinder.

The Problem
A stop valve is to be opened and closed by a double acting cylinder. When the switch
marked ‘open’ is pressed the piston rod is to extend and remain extended until the ‘close’
switch is pressed. The switch that opens the valve must override the ‘close’ switch.
Set-up diagram
Questions:
1. What is meant by the term ‘latching path’?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. Which switch is dominant? Why is this switch dominant?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________

24V 24V 24V

A1 A1
24V A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
0V
12 0 14
Cylinder
Exercise 6
DOMINANT RESET MEMORY CIRCUIT
Objectives:
1. To use the dominant reset circuit to control a double acting cylinder.
The Problem

A roller lever limit switch is actuated by a tank float supply valve to open and increases the
level of the tank. The operator must override this signal with a pushbutton even when the
limit switch is actuated by the float arm.
1.0
Set-up diagram
Complete the circuit. Designate the electric and pneumatic components and indicate the
numbering system for the connections.
Questions:
1. Describe the operation of the circuit.
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. If a single acting cylinder replaced the double acting cylinder shown here, what type of
solenoid operated control valve would be required?
__________________________________________________________________________
_______________________________________________________________
3. In this circuit, which switches are connected in series?
__________________________________________________________________________
______________________________________________________________________

24V
24V 24V 24V
A1 A1
A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
0V
Control Valve
Manifold

12 0 14
Cylinder
Exercise 7
BISTABLE VALVE MEMORY CIRCUIT
Objectives:
1. To use a bistable valve to control a double acting cylinder.
The Problem

Boxes are lifted to conveyor height by a double acting cylinder. The piston rod is to extend
fully when a switch is operated. The piston rod must reach the fully extended position
before the operator can initiate rod retraction by a second switch. A roller limit switch
confirms full extension. The rod is to continue forward even if the extension switch is
released before full extension is reached. Rod extension and retraction speed is to be
adjustable. The control panel is remotely located; therefore the solenoid valve should be
indirectly controlled.
Set-up diagram
Questions:
1. What is the switching status of the bistable memory valve when first fitted to the system
and therefore what position will the cylinder be in?
__________________________________________________________________________
______________________________________________________________________
2. When the memory valve is initialized air is available at port 2, therefore what position
will the piston rod be in?
__________________________________________________________________________
______________________________________________________________________
3. Describe the operation of the circuit.
__________________________________________________________________________
______________________________________________________________________
4. If the switch that initiates extension is held operated what effect will this have on the
piston rod retraction?
__________________________________________________________________________
______________________________________________________________________
1.0

24V 24V 24V
24V A1 A1
A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
0V Manifold
12 0 14
Cylinder
22 21 24
Exercise 8
CONFIRMATION OF EXTENSION AND RETRACTION
Objectives:
1. To use sensors for confirmation of extension and retraction of a double acting
cylinder.

The Problem
At a transfer station, boxes are transferred from one conveyor to another. An operator
presses a button to shift the transfer station to conveyor(1). The transfer station is to
remain in this position until a second button is pressed to retract the transfer station to
conveyor(2). The extend and retract buttons must not be able to effect cylinder actuation
unless the respective reed switches mounted on the cylinder body provide a confirmation of
piston rod position.
Set-up diagram
Questions:
1. How would you indicate on the circuit diagram, that the reed switch of the retracted
position at the cylinder is actuated initially?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. What are the advantages of using the reed switches?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
1.0

ELECTRICAL
24V CONTROL CIRCUIT DIAGRAM:
24V 24V
A1 A1
24V
A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
0V
12 0 14
Cylinder
22 21 2
Exercise 9
PRESSURE DEPENDENT CONTROL
Objectives:
1. To use the pressure to electrical (PE) converter to control the operation a double
acting cylinder.

The Problem
A form tool is to press a metal plate. Extension of the piston rod must be disabled until the
supply pressure to the control valve reaches a preset pressure as measured by a PE
converter. Provided the preset pressure is reached, the operation of two pushbutton
switches advances the form tool. The advance and return speeds are to be adjustable. The
piston rod must return when either pushbutton is released.
1.0
Set-up diagram
Questions:
1. The two pushbuttons that initiate movement of the form tool are connected in series.
What logic function does this represent?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. How would you incorporate a limit switch to ensure that the piston rod fully extends
before retraction can occur?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________

1.0
1.01

PE converter
B1
1
4 2
24V 24V 24V

A1 A1
24V A2 A2
A1 A1
A2 A2
A1 A1
A2 A2
0V 0V 0V
Control Valve
Manifold
0V
12 0 14
Cylinder
PE converter
R Bk Bl
2.97
The counter circuit diagram:
24V
Counter
Output C
0
S1 S3
Cycle Sensor Counter Reset
switch switch
Lamp A Lamp B
C RC
C Counter C
RC Reset coil
S1 (Cycle Sensor Switch) serves as the signal input for increment counting.
S3 (Counter Reset Switch) will reset the number of counts made by S1 to zero.
C (Counter output) this will change its state when the setting of the counter is reach. The
close contact will open and the open contact will close.
In this case, each time the S1 switch closes, the counter adds 1. When the count
reaches the preset number, the contact output of the counter change state. Lamp A will
turn off and lamp B will turn on. When S3 is pressed, the counter resets it count back to
zero and the system is ready for the next operation.
Exercise 10
AUTOMATIC WASHING SYSTEM
Objectives:
1. To use the electro-mechanical counter to control a double acting cylinder.

The Problem
An acid bath is to clean metal components. The components are place in a basket, which
hung on a hook on a double-acting cylinder. A single actuation of a push button causes the
basket to be continuously lowered into and pulled out of the acid bath. The sequence stops
automatically after five cycles. Sensors s10 and s11 check the fully retracted and extended
positions, respectively, of the cylinder.
1.0
Set-up diagram
Questions:
1. Which of the sensors is use to determine the number of cycles the sequence had made?
Why?
__________________________________________________________________________
______________________________________________________________________
______________________________________________________________________

24V
0V
24V
SETUP CONNECTION DIAGRAM: A1
Switch Module A2 Relay Module Counter
24V A1 24V
A1 R1
A2
R2
A1

A2
0V
0 0 3
1 1 0
0 0 3
1
1 1 1
0V 0V
Control Valve
Manifold
12 0 14
22 21 24
Cylinder
Displacement-Step Diagram
This is the graph of the cylinder displacement and the steps of the operation. This is
represents the cylinder sequences and their displacements, steps of the operation and the
placement of the sensors in one complete cycle.
Steps Cylinder Displacement Graph Comments

0 1
1
Displacement

Initial position
Retract position
0
1 2 3 4 5 Steps
0 1 1
2 Cylinder extends
Extend position 0
1 2 3 4 5
0 1 1
3
No displacement
0
1 2 3 4 5
0 1 1
4 Cylinder retracts
0
1 2 3 4 5
1
0 1
5 Cylinder extends
0
1 2 3 4 5
Exercise 11
MULTIPLE CYLINDER CIRCUIT
Objectives:
1. To use the displacement-step diagram in making control circuits of multiple
cylinders in sequential operational.
The Problem
Two cylinders are use to transfer parts from a magazine onto a chute. When a pushbutton
is pressed, cylinder 1.0 extends, pushing the part from the magazine and positions it in

preparation for a transfer by cylinder 2.0 onto the out feed chute. Once the part is
transferred, the first cylinder retracts, followed by the second. The speed of both cylinders
is to be adjustable. Confirmation of all extended and retracted positions is required.
1.0
0
1
2.0
0
1 2 3 4 5=1
Displacement step diagram
Solution
Control of the sequence of actions for this task depends on sensors of the cylinder
displacements. The start conditions for the control are that the last action in the operation
sequence has occurred, that is cylinder 2.0 is retracted and the start button is pressed,
steps in the operating sequence are shown on the displacement step diagram.
Symbols notation:
Y112 S10
Control port Cylinder position

Solenoid number of the system Cylinder number
Solenoid Sensor
(Y114, Y212, Y214) (S11, S20, S21)
DISPLACEMENT STEP DIAGRAM
1.0
0
1

2.0
1 2 3 4 5=1
I. CYLINDER SEQUENCE:
_______________________________
II. OPERATION SEQUENCE:
__________________________________________________________________________
__________________________________________________________________________
III. BOOLEAN EXPRESSION OF CYLINDERS:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

1.0 S10 S11 2.0 S20 S21
4 2 4 2
Y114 Y112 Y214 Y212

14 12 14 12
5 1 3 5 1 3

24V
0V
24V
0V
EXAMPLE 12

DISPLACEMENT STEP DIAGRAM
1.0
0
1
2.0
1 2 3 4=1
I. CYLINDER SEQUENCE:
_______________________________
II. OPERATION SEQUENCE:
__________________________________________________________________________
__________________________________________________________________________
III. BOOLEAN EXPRESSION OF CYLINDERS:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

1.0 S10 S11 2.0 S20 S21
4 2 4 2
Y114 Y112 Y214 Y212

14 12 14 12
5 1 3 5 1 3

24V
0V
24V
0V

PROGRAMMABLE LOGIC CONTROLLER (PLC)
The first Programmable Logic Controller (PLC) was developed by a group of engineers
at General Motors in 1968, when the company was looking for an alternative to replace
complex relay control systems.
The new control system had to meet the following requirements:
• Simple programming
• Program changes without system intervention (no internal rewiring)
• Smaller cheaper and more reliable than corresponding relay control systems
• Simple, low cost maintenance
Subsequent development resulted in a system, which enabled the simple connection of

binary signals. The requirements as to how these signals were to be connected were
specified in the control program. With the new systems, it became possible for the first time
to plot signals on a screen and to file these in electronic memories.
The Ladder diagram:
The ladder diagram language represents a graphic programming language. The

elements available in a ladder diagram are contacts and coils in different forms. These are
laid out in rungs within the confines of power rails on the left and on the right.
Rung
+24V F1.5 Q3.5 0V

( )
Power rails
Fig. 1
Fig. 1 illustrates the basic structure of a current rung. In this example, the status of
the flag F1.5 is directly assigned to Q3.5. Listed below are the most common important
elements of a ladder diagram.

Table 1
Normally open contact ( S) Setting coil
`
Normally closed contact (R) Resetting coil
() Coil
- A normally open contact supplies the value 1 when the corresponding push button switch
is closed.
- A normally closed contact reacts with the value 1, when the corresponding switch or push
button is opened.
- A normal coil, the result (resulting logic operation of the contacts) is copied to the
specified variable.
- The setting coil assumes the value 1, if the result is 1 and remains unchanged even if the
result is 0 in between.
- The resetting coil only assumes the value 0, if the result is 1.
The logic AND & OR configuration of contacts:
The basic functions AND and OR may be realized by means of a corresponding

configuration of contacts in the current rung. The AND function is represented by means of
the serial connection of the two contacts (fig.1a). Output Q0.1 is set only if both input
I1.3 and F0.2 are set. In all other cases, output Q0.1 is reset. The OR function is
obtained via parallel switching of contacts (fig.1b). Output Q0.1 assumes the value 1, if
either input I1.3 or F0.2 assumes the value 1, or if both conditions are met
simultaneously.
AND function
I1.3 F0.2 Q0.1

( )
Fig 1 (a)
OR function
I1.3 Q0.1
( )

F0.2
fig 2 (b)
The Allocation list:
The operating resources for the controller (timer, counter, index, inputs, outputs etc.) are
addressed via operands (operating resources of the controller). For each program, the
operating resources can be accessed via:
- Symbolic operands (e.g. label used in the control circuit diagram S10; Pb; K1; Y112 etc.)
- Absolute operands (e.g. I0.1; Q0.1; F0.2; etc.).
Symbolic operands:
You can specify any symbolic name for the operand. If, for instance, output Q0.1
switches a motor on and off, you can define this output in your programs as
"MotorOn".
Absolute operands: An absolute operand consists of:
- A character denoting the operand type (O for output, I for input etc.)
- Where applicable the character W to denote word (for multi-bit operands)
- The address of the operating resources. (0.1, 1.2, etc)
Opening the Allocation List Editor:
To open the Allocation List, select [View] [Allocation List] in the project window or double-
click on the Allocation List item. The absolute operand, symbolic operand, and a comment
are displayed in columns. The symbols at the start of the line help to differentiate between
the inputs and outputs of internal operands. Table below is an example of Allocation List.

PLC Module:
The PLC module has input ports where the shorting devices such as switches,
sensors are connected. The signal flow is from the positive (+) supply of the PLC, shorting
devices then to the input ports of the PLC. The driven devices such are solenoid,
contactors, and high rating relays are connected to the output ports of the PLC. The signal
flow is from the output ports, driven devices then to the ground/0V supply. Fig B8.3 shows
the signal flow connections.
24 V
Pb S1
Input ports
i0.0 i0.1 i0.2 i0.3 i0.4 i0.5 i0.6 i0.7 i1.0 i1.1 i1.2 i1.3
i1.3
PLC MODULE
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7
Output ports
L1 Y114

LADDER DIAGRAM (EXERCISE ) ABSOLUTE SYMBOLIC
COMMENTS
OPERAND OPERAND

+ 24 V
i0.0 i0.1 i0.2 i0.3 i0.4 i0.5 i0.6 i0.7 i1.0 i1.1 i1.2 i1.3
i1.3
PLC MODULE
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7
0V
There is no need to change the Input / Output connections. Use the address of the ports
where the needed input signals are connected. Modify the operand in the allocation list if
necessary.

COMMENTS
OPERAND OPERAND

+ 24 V
i0.0 i0.1 i0.2 i0.3 i0.4 i0.5 i0.6 i0.7 i1.0 i1.1 i1.2 i1.3
i1.3
PLC MODULE
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7
0V
necessary.

COMMENTS
OPERAND OPERAND

+ 24 V
i0.0 i0.1 i0.2 i0.3 i0.4 i0.5 i0.6 i0.7 i1.0 i1.1 i1.2 i1.3
i1.3
PLC MODULE
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7
0V
necessary.

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PNEUMATICS

Properties of compressed air:

Repeated releases of new developments in equipment and announcement of

wtandingan 2sem2014 page 1

The component parts and their main functions are:

Air Production System

9. Refrigerated Air Dryer

10. Line Filter

Air Consuming System

3. Air Service Unit

wtandingan 2sem2014 page 3

Pressure: Single-stage up to approx. 600 kPa (6 bar)

Pressure: Up to approx. 1000 kPa (10 bars)

Pressure: With multistage design up to approx. 1000

Sliding vane compressor Sliding vanes in an eccentrically located rotor divide

Pressure: Single-stage up to approx. 400kPa (4bars)

Pressure: Up to approx. 600 kPa (6 bars

wtandingan 2sem2014 page 4

Single-acting: Performs work in one direction

(Sloping arrow over piston: denotes adjustable end position cushioning )

Double-acting cylinder with through piston rod

Double-acting cylinder with single, non-adjustable cushioning

Double-acting cylinder with single, adjustable cushioning

Double-acting cylinder with adjustable cushioning at both ends

Rod less cylinder with magnetic coupling

Air motor, constant displacement, rotation in one direction

Air motor, variable displacement, rotation in one direction

Air motor, variable displacement, rotation in both directions

Pneumatic rotary motor

wtandingan 2sem2014 page 5

The type of mounting is determined by the attachment of the cylinder to a fixture or

Center swivel flange Rear swivel flange Foot mounting

Front flange Rear mounting Swivel flange

Front swivel flange Rear flange

wtandingan 2sem2014 page 6

Actual device Symbol

No compressed air is applied. Compressed air is applied. The cylinder

Double Acting Cylinder

Actual device Symbol

Compressed air When air is Compressed air When air is

wtandingan 2sem2014 page 7

Actual device Symbol

Quick exhaust valve

Actual device Symbol

wtandingan 2sem2014 page 8

Valve switching positions are represented by

The number of switching positions of the

Lines indicate flow paths, arrows show the

Shut off positions are identified in the boxes

The connections (inlet and outlet ports) are

wtandingan 2sem2014 page 9

Written title: 2/2-Way valve

2/2-way valve, (normally open position)

3/2-way valve, (normally closed position)

3/2-way valve, (normally open position)

4/2-way valve, (flow from 1 to 2 and from 4 to 3)

5/2-way valve, (flow from 1 to 2 and from 4 to 5)

One way flow control valve (throttle)

wtandingan 2sem2014 page 10

(by numbers) (by letters)

Purpose: Actuate, Reset, Center

Push button operated

Via lever with detent

Fool pedal operated