Laboratory EPN

Electro-Pneumatics Laboratory 203
ELECTRO-PNEUMATICS
ELECTRO-PNEUMATICS

LABORATORY EXPERIMENTS
LABORATORY EXPERIMENTS
GENERAL INSTRUCTIONS
AND SAFETY PRECAUTIONS
The arrangement of the equipment on
the workstation should be as shown in
the evaluated electro-pneumatic circuit
diagram sketch.
The working pressure of pe=5 bar shall
be at the pressure regulator of the air
service unit.
The pneumatic components are to be
firmly connected with plastic tubes and
accessories according to the circuit
diagram.
Also observe the proper removal of the
connections of the hoses and other
accessories from the components.
The working voltage for the electrical
wiring diagrams shall be provided 2!
"# power supply unit and an electric
manifold unit.
The electrical components are to be
firmly connected with $umper wires and
accessories according to the circuit
diagram
%andle the components with care and
caution.
Arrange the components and other
equipment after use.
&e guided accordingly with your sub$ect
instructor.
DRIVE
ELEMENT
ACTUATI
NG
ELEMENT
#ylinder
"irectional
#ontrol !alve
Air
#ompressor
'lectr
ic (otor
Y1
SIGNALI
NG
ELEMENT
)ush-
button
*elay
#ontact
*elay #oil
+olenoid
CONTR
OL
ELEMENT
24V
0V
L1
N
S1
K1
Y1 K1
ELECTRO-PNEUMATIC
CONTROL CHAIN
ENERGY GROUP
)neumatic and electrical energies are
required in electro-pneumatic controls.
+ignal elements, control elements and
actuating elements are supplied with
electrical energy.
Actuating elements and drive elements are
supplied with pneumatic energy.
SIGNAL ELEMENTS
The signaling elements convert manual
commands and mechanical motions into
electrical signals.
CONTROL ELEMENTS
The control elements connect the
approaching signals and direct these to the
components of the actuating element group.
ACTUATING ELEMENTS
The actuating elements take over the
function of connecting or converting
electrical energy and pneumatic energy
DRIVE ELEMENTS
The drive elements convert the pneumatic
energy into mechanical energy and motions.
REPRESENTATION OF
PNEUMATIC CIRCUIT
DIAGRAMS
Pneumatic Diagram
Electrical Wiring Diagram
EXPERIMENT 1
COMMAND-VARIABLE CONTROL OF
CYLINDERS WITH SINGLE -SOLENOID
VALVES
Objective
This e-periment provides basic know-how
and skills on the proper design, set-up and
operation of electro-pneumatic controls using
the direct and indirect control of a single-acting
cylinder as an e-ample.
List of Components and Equipment
Qty. Des!"#t"$%
. )neumatic power supply
. Air service unit /filter with water
separator, pressure regulator and
pressure gauge0 with 122 directional
control ball valve
. )neumatic "istributor, 3-fold
. 2!"# power supply unit
. 'lectric (anifold unit
. #ontrol switch-2 pushbutton unit
. +ingle-acting cylinder
. "ouble-acting cylinder
. 122 directional control valve, electrically
operated, spring return, closed neutral
position
operated, spring return, closed neutral
position
. *elay units, changeover contacts
)neumatic and 'lectrical Accessories

Problem Definition 1
.. 4pon pressing a normally-open key-
operated pushbutton switch, the solenoid
coil of a directional valve shall be
directly energi5ed by this electrical
switch causing the cylinder rod of a
single-acting cylinder to move outward
to its ma-imum e-tended position.
2. The piston rod of the single-acting
cylinder should remain e-tended as long
as the button is pressed.
1. 4pon releasing the said electrical switch,
solenoid coil of that directional valve
will cause the piston rod of the single-
acting cylinder to retract and return to its
rear-end position.
. 4pon pressing a normally-open key-
operated pushbutton switch, the coil of
an electro-mechanical relay shall be
energi5ed by this electrical switch
causing the electrical contact of this
relay to indirectly energi5e the solenoid
coil of a directional valve which then
causes the cylinder rod of a double-
acting cylinder to move outward to its
ma-imum e-tended position.
5. The piston rod of the double -acting
cylinder should remain e-tended as long
as the button is pressed.
3. 4pon releasing the said electrical switch,
the coil of the electro-mechanical relay
shall relieved of its electrical signal,
which then causes the electrically-
controlled directional valve to be
relieved of its pilot energy which then
acting cylinder to retract and return to its
rear-end position
Procedure
.. +ketch the pneumatic circuit diagram
based on the stated problem definition.
2. +ketch the electrical circuit diagram
1. %ave your instructor check your circuit
diagram for proper evaluation.
. 6ather the required components and
arranged them properly on the
workstation and in accordance with the
verified electro-pneumatic circuit
diagram.
5. #onnect the pneumatic components with
plastic tubes and accessories according
to the circuit diagram.
3. #onnect the electrical components with
$umper wires and accessories according
7. (ake sure that the air service unit switch
is in the off position and double check
the connections of the hoses and other
accessories if they are firmly coupled to
the components for safe operation.
8. Turn on the pneumatic power supply
/compressor0 compressed-air distributor.
9. Turn on the switch the air service unit
and set the working pressure of pe=5 bar
at the pressure regulator.
.:. Turn on the 2"#! power supply
distributor.
... The e-periment is started and the proper
function is verified.
.2. *eturn and arrange the components and
other equipment properly upon
completion of the e-periment.
.1. "raw the pneumatic circuit diagram on
the data sheet. +tate your observations
and conclusion.
EXPERIMENT 1
DATA SHEET
COMMAND-VARIABLE CONTROL OF
CYLINDERS WITH SINGLE -SOLENOID
VALVES
Pneumatic Circuit Diagram
Observation and Conclusion
EXPERIMENT &
HOLDING-ELEMENT CONTROL OF A
DOUBLE-ACTING CYLINDER WITH AN
IMPULSE VALVE' DIRECTLY
CONTROLLED
Objective
This e-periment demonstrates the control of
a double-acting cylinder with an electrically
controlled 522 directional control impulse valve
without the use of a relay.
Qty. Des!"#t"$%
control ball valve
operated both ways

Problem Definition
.. 4pon momentarily pressing a normally-
open key-operated pushbutton switch,
the solenoid coil of a directional valve
shall be directly energi5ed by this
electrical switch causing the cylinder rod
of a double-acting cylinder to move
outward to its ma-imum e-tended
position.
cylinder should remain e-tended even
after the pushbutton is released.
1. 4pon momentarily pressing another
normally-open key-operated pushbutton
switch, the opposite solenoid coil of the
directional valve shall be directly
energi5ed by this second electrical
switch causing the cylinder rod of a
double-acting cylinder to retract and
return to its rear-end position.
. The piston rod of the double -acting
cylinder should remain retracted even
after the latter pushbutton is released.
5. %ence, each pushbutton switch has its
own unique function of either e-tending
or retracting the cylinder only.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT &
DATA SHEET
HOLDING-ELEMENT CONTROL OF A
DOUBLE-ACTING CYLINDER WITH AN
IMPULSE VALVE' DIRECTLY
CONTROLLED
EXPERIMENT (
STOPPING CONTROL OF A DOUBLE-
ACTING CYLINDER WITH A )*(
DIRECTIONAL CONTROL VALVE WITH
A CLOSED MID-POSITION'
INDIRECTLY CONTROLLED
Objective
The aim of this e-periment is to demonstrate
the most often applied solution for stop control
in electro-pneumatics. A 521 directional control
valve with a closed mid-position is used as an
actuator.
Qty. Des!"#t"$%
control ball valve
2 ;ne-way <low #ontrol !alve
operated, closed mid position, spring
centered
2 *elay units
changeover contacts

Problem Definition
.. 4pon pressing a normally-open key-
an electro-mechanical relay shall be
coil of a directional valve which then
acting cylinder to slowly move outward
to its ma-imum e-tended position such
that the length of its forward stroke is
dependent upon the duration of the
pressing of the pushbutton.
2. 4pon pressing another normally-open
key-operated pushbutton switch, the coil
of another electro-mechanical relay shall
be energi5ed by this second electrical
switch causing the electrical contact of
this relay to indirectly energi5e the
opposite control-solenoid coil of the
same directional valve which then
causes the cylinder rod to slowly move
inward to its ma-imum retracted
position such that the length of its
backward stroke is also dependent upon
the duration of the pressing of that
pushbutton.
cylinder should remain in whatever
position it has reached when either of the
two pushbuttons is released or not being
pressed.
. %ence, each pushbutton switch has its
own unique function of either e-tending
or retracting the cylinder to a certain
length of stroke only.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT (
DATA SHEET
STOPPING CONTROL OF A DOUBLE-
ACTING CYLINDER WITH A )*(
DIRECTIONAL CONTROL VALVE WITH
A CLOSED MID-POSITION'
INDIRECTLY CONTROLLED
EXPERIMENT +
LOGICAL CONTROL OF A DOUBLE-
ACTING CYLINDER WITH A SINGLE--
SOLENOID VALVE AND A DOUBLE-
SOLENOID VALVES'
Objective
The aim of this e-periment is to convey the
understanding for the logical =A>"? and =;*?
functions in relay technology.
Qty. Des!"#t"$%
control ball valve
2 "ouble-acting cylinder
operated, spring return,
operated both ways
2 *elay units, changeover contacts

.. 4pon pressing neither of two key-
operated pushbutton switches, the spring
of a single-solenoid spring return valve
shall cause the cylinder rod of a double-
acting cylinder to assume a retracted
position.
2. 4pon pressing either of the two
switches alone, the coil of its
corresponding electro-mechanical relay
shall be energi5ed by the actuated
electrical switch causing the electrical
contact of that relay to indirectly
energi5e the solenoid coil of a single-
solenoid valve which then causes the
cylinder rod of the double-acting
cylinder to move outward to its
ma-imum e-tended position. 4pon
releasing the chosen pushbutton, the
cylinder rod will retract and return to its
rear-end position.
1. 4pon pressing both pushbutton switches
/not necessarily being at the same time0,
the cylinder rod shall also assume a
retracted position.
. 4pon pressing neither of two key-
operated pushbutton switches, the
double-solenoid valve shall cause the
cylinder rod of a double-acting cylinder
to assume a retracted position. %ence,
the opposite solenoid should be initially
energi5ed by the proper relay contact
arrangement.
5. 4pon pressing either of the two
switches alone, the coil of its
corresponding electro-mechanical relay
shall be energi5ed by the actuated
electrical switch causing the electrical
contact of that relay to indirectly
energi5e the solenoid coil of a double-
solenoid valve which then causes the
cylinder rod of the double-acting
ma-imum e-tended position. >ote that
when the solenoid is energi5ed, the
initially energi5ed opposite solenoid
should be de-energi5ed at the same time.
4pon releasing the chosen pushbutton,
the cylinder rod will retract and return to
its rear-end position.
3. 4pon pressing both pushbutton switches
/not necessarily being at the same time0,
the cylinder rod shall also assume a
retracted position.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT +
DATA SHEET
LOGICAL CONTROL OF A DOUBLE-
SOLENOID VALVE AND A DOUBLE-
SOLENOID VALVES'
EXPERIMENT )
PRIORITY CONTROL OF A DOUBLE-
SOLENOID VALVE' SPRING RETURN'
Objective
@n this e-periment, the most common priority
control methods for actuating circuit systems are
demonstrated as well as the various possible
circuits with latching /storage circuits0 using
relay.
Qty. Des!"#t"$%
control ball valve
2 #ontrol switch-2 pushbutton unit
2 522 directional control valve, electrically
operated, spring return,
1 *elay units, changeover contacts

Problem Definition
.. @nitially, upon momentarily pressing a
key-operated pushbutton switch, the coil
of an electro-mechanical relay shall be
coil of a directional valve causing the
cylinder rod of a double-acting cylinder
to move outward to its ma-imum
e-tended position and stay e-tended.
2. 4pon momentarily pressing another key-
another electro-mechanical relay shall be
coil of another directional valve causing
the cylinder rod of another double-acting
ma-imum e-tended position and stay
e-tended. >ote that the first cylinder will
now move to its ma-imum retracted
position and stay retracted the same time
the second cylinder will e-tend.
1. 4pon momentarily pressing the first
pushbutton switch again, the coil of the
first electro-mechanical relay shall be
energi5ed again by this electrical switch
coil of the first directional valve causing
the cylinder rod of the first double-acting
ma-imum e-tended position and stay
e-tended. >ote that the second cylinder
will now move to its ma-imum retracted
position and stay retracted the same time
the first cylinder will e-tend.
. %ence, whichever pushbutton switch is
actuated at any time shall cause its own
controlled cylinder to e-tend and stay
e-tended the same time making the other
cylinder to retract and stay retracted.
5. %owever, upon momentarily pressing a
third key-operated pushbutton switch,
the cylinder rod of any of the two
cylinders that is e-tended at any time
shall be retracted and stay retracted.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT )
DATA SHEET
PRIORITY CONTROL OF A DOUBLE-
SOLENOID VALVE' SPRING RETURN'
EXPERIMENT ,
TIMER CONTROL OF A DOUBLE-
ACTING CYLINDER WITH A DOUBLE--
SOLENOID VALVE
Objective
This e-periment shows the use of an electric,
switch-on timer relay element in a hold element
control.
Qty. Des!"#t"$%
control ball valve
operated both ways
2 *elay unit, changeover contacts
2 Timer *elay units

Problem Definition
.. 4pon momentarily pressing a key-
operated pushbutton switch, a pre-
determined time shall elapse after which
will energi5e a double-solenoid valve
shall cause an initially retracted cylinder
rod of a double-acting cylinder to move
outward to its ma-imum e-tended
position and stay e-tended. />ote that
being a double-solenoid valve, the
opposite solenoid should be initially
energi5ed to ensure that the cylinder rod
is also initially retracted0.
2. &y the same time that the cylinder had
e-tended, another pre-determined time
should elapsed after which will cause the
cylinder rod to automatically retract and
return to its rear-end position and stay
retracted.
1. >ote that only electro-mechanical relays
and their corresponding contacts are to
be used for the circuit and that roller
limit switches and cylinder switches are
not allowed for this problem.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT ,
DATA SHEET
TIMER CONTROL OF A DOUBLE-
ACTING CYLINDER WITH A DOUBLE--
SOLENOID VALVE
EXPERIMENT -
POSITION -DEPENDENT
SEQUENTIAL CONTROL OF A DOUBLE-
ACTING CYLINDER USING A DOUBLE--
SOLENOID VALVE
Objective
This e-periment intends to facilitate the
understanding of reciprocation controls of a lone
cylinder and provides practical knowledge of
setting up a simple reciprocating control system.
Qty. Des!"#t"$%
control ball valve
operated both ways
*elay unit, changeover contacts
2 *oller limit switch or cylinder switch

Problem Definition
operated pushbutton switch, a double-
solenoid valve shall cause the cylinder
rod of a double-acting cylinder to
immediately to move outward to its
ma-imum e-tended position. />ote that
being a double-solenoid valve, the
opposite solenoid should be initially
energi5ed to ensure that the cylinder rod
is also initially retracted0. 4pon reaching
its ma-imum outward stroke, the
cylinder rod will automatically retract
and return to its rear-end position.
2. 4pon reaching its initial position, the
cylinder rod will again automatically
e-tend and retract repeatedly until
another key-operated pushbutton switch
is momentarily pressed at any time to
bring it to a complete stop but finishing
the last sequence and returning the
cylinder rod in its initial position.
1. %ence, .$se/-.$$# se01e%e $2 A3 A-
using roller limit switches or cylinder
switches.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT -
DATA SHEET
POSITION-DEPENDENT SEQUENTIAL
CONTROL OF A DOUBLE-ACTING
CYLINDER USING A DOUBLE--
SOLENOID VALVE
EXPERIMENT 4
CONTROL OF TWO DOUBLE-ACTING
CYLINDER USING DOUBLE--SOLENOID
VALVES
Objective
understanding of sequential controls of two
cylinders and provides practical knowledge of
setting up a control system with two pneumatic
drives. The actual design and practice in
developing sequential diagram and pneumatic
and electrical circuit diagram shall also be
e-ercised.
Qty. Des!"#t"$%
control ball valve
operated both ways
*oller limit switch or cylinder switch
. 'lectronic sensor unit

Problem Definition
.. 4pon detecting an ob$ect, an electronic
sensor shall energi5e a double-solenoid
valve which will cause the cylinder rod
of a double-acting cylinder /cylinder A0
to immediately move outward to its
being double-solenoid valves, the
opposite solenoids should be initially
energi5ed to ensure that the two
cylinders rods are also initially
retracted0. 4pon reaching its ma-imum
outward stroke, another double-solenoid
valve shall cause the cylinder rod of
another double-acting cylinder /cylinder
&0 to automatically move outward to its
2. 4pon reaching cylinder &As ma-imum
outward stroke, cylinder A will
automatically retract and return to its
rear-end position. >ote that during the
retraction of cylinder A, cylinder &
remains e-tended. 4pon reaching
cylinder AAs initial position, cylinder &
will automatically retract and return to
1. 4pon reaching cylinder &As initial
position, the sequence of cylinder
actions will then repeat continuously if
the electronic sensors continuously
detects the ob$ect, otherwise the
sequence will automatically stop at &-
finishing the last sequence and returning
the cylinder rods in their initial
positions.
. /;)T@;>AB0 The initiation of the
sequence can also optionally triggered
by a key-operated switch and stopped by
another key-operated switch.
5. %ence, $#e%-.$$# * .$se/-.$$#
se01e%e $2 A3 B3 A- B- using roller
limit switches cylinder switches.
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT 4
DATA SHEET
CONTROL OF TWO DOUBLE-ACTING
CYLINDER USING DOUBLE--SOLENOID
VALVES
EXPERIMENT 5
TIME-BASED PROCESS CONTROL
FOR POSITION-DEPENDENT
SEQUENTIAL CONTROL OF TWO
DOUBLE-ACTING CYLINDER USING
DOUBLE--SOLENOID VALVES
Objective
understanding of incorporating a timer control
circuit on sequential controls based process of
two cylinders and provides practical knowledge
of setting up a control system with two
pneumatic drives.
Qty. Des!"#t"$%
control ball valve
operated both ways
. Timer *elay 4nit

Problem Definition
solenoid valve shall be energi5ed which
will cause the cylinder rod of a double-
acting cylinder /cylinder A0 to
immediately move outward to its
actions will then repeat continuously
until a predetermined time has elapsed
which will then automatically stop the
sequential movements of the cylinders at
&- finishing the last sequence and
returning the cylinder rods in their initial
positions.
. >ote that the sequence of cylinder
movements can also be manually
stopped at any instant without regards to
the timer-based process control element
when another key-operated pushbutton
switch is momentarily pressed.
5. %ence, t"6e-78se/ .$se/-.$$#
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT 5
DATA SHEET
TIME-BASED PROCESS CONTROL
FOR POSITION-DEPENDENT
EXPERIMENT 19
COUNTER-BASED PROCESS
CONTROL FOR POSITION-DEPENDENT
Objective
understanding of incorporating a counter control
circuit on sequential controls based process of
two cylinders and provides practical knowledge
of setting up a control system with two
pneumatic drives.
Qty. Des!"#t"$%
control ball valve
operated both ways
. #ounter 4nit

Problem Definition
solenoid valve shall be energi5ed which
will cause the cylinder rod of a double-
acting cylinder /cylinder A0 to
immediately move outward to its
actions will then repeat continuously
until a number of sequential movements
has been completed based on a
predetermined number of desired counts
which will then automatically stop the
sequential movements of the cylinders at
&- finishing the last sequence and
returning the cylinder rods in their initial
positions.
. >ote that the sequence of cylinder
movements can also be manually
stopped at any instant without regards to
the counter-based process control
element when another key-operated
pushbutton switch is momentarily
pressed.
5. %ence, $1%te!-78se/ .$se/-.$$#
Procedure
diagram.
distributor.
and conclusion.
EXPERIMENT 19
DATA SHEET
COUNTER-BASED PROCESS
CONTROL FOR POSITION-DEPENDENT

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Electro-Pneumatics Laboratory 203

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