EE060 Electro Hydraulic Controls TP Inst

SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL EDUCATION
ELECTRICAL and ELECTRONIC

ENGINEERING
Instructor Manual
Training Unit
Electro-Hydraulic Controls
Theory & Practice
No: EE 060
Training Unit
Electro-Hydraulic Controls
Theoretical & Practical Part
No.: EE 060
Edition:
2009
All Rights Reserved
Editor:
MCE Industrietechnik Linz GmbH & Co

Education and Training Systems, DM-1
Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austria
Tel. (+ 43 / 732) 6987 3475
Fax (+ 43 / 732) 6980 4271
Website: www.mcelinz.com
1
ELECTRO-HYDRAULIC CONTROLS
LIST OF CONTENT
CONTENTS
1
Safety regulation ............................................................................................................5

1.1
Safety regulations Electrics ...................................................................................5
1.2
Safety regulations Hydraulics................................................................................7
Foreword to the trainer's manual ...................................................................................8

2.1
Page
Didactic notes........................................................................................................8
Basic principles of electro-hydraulics...........................................................................10

3.1
General................................................................................................................10
3.2
Basics..................................................................................................................10
3.2.1
Electric current ................................................................................................10
3.2.2
Electric voltage ................................................................................................12
3.2.3
Electric resistance ...........................................................................................12
3.2.4
Electric power ..................................................................................................13
3.3
Basic circuits .......................................................................................................13
3.3.1
Series connection ............................................................................................13
3.3.2
Parallel connection ..........................................................................................14
3.4
Measuring of current I and voltage U ..................................................................16
3.4.1
Current measurement .....................................................................................16
3.4.2
Voltage measurement .....................................................................................16
3.5
Electro-hydraulic equipment................................................................................17
3.5.1
Power density..................................................................................................17
3.5.2
Electro-hydraulic valves ..................................................................................18
3.5.3
Direct operated directional valves ...................................................................21
3.5.4
Pilot operated directional valves......................................................................23
3.6
Extending a cylinder by pressing a push-button..................................................24
3.6.1
Time and current characteristics .....................................................................26
3.6.2
Making procedure............................................................................................27
3.6.3
Breaking procedure .........................................................................................27
3.6.4
Schematic diagram..........................................................................................29
3.6.5
Main circuit and control circuit .........................................................................29
3.6.6
Symbols of the most important switching elements.........................................31
3.6.7
Designation of contacts at contactor/relay.......................................................31
3.7
Electrical self-locking Suppression by means of a momentary-contact switch ...33
3.7.1
Signal storage .................................................................................................34
3.7.2
Function chart..................................................................................................36
3.8
Momentary-contact limit switches .......................................................................39
3.8.1
Magnetic momentary-contact limit switches with reed contacts ......................40
3.8.2
Optical momentary-contact limit switches .......................................................40
3.8.3
Capacitive proximity switches .........................................................................41
3.8.4
Inductive proximity switches ............................................................................41
3.8.5
Example of connection of an inductive proximity switch..................................42
3.8.6
Momentary-contact/proximity limit switches ....................................................42
3.8.7
Parallel and series connection of proximity switches ......................................44
3.9
Pressure switches ...............................................................................................45
3.10
Mechanical locking by means of momentary contacts ........................................48
3.11
Electrical locking by means of contactor/relay contacts ......................................49
3.12
Time relay............................................................................................................49
3.12.1
ON-delay .....................................................................................................50
3.12.2
OFF-delay....................................................................................................50
3.12.3
ON- and OFF-delay .....................................................................................51
Experiment cross-reference.........................................................................................53
Required electrical components ..................................................................................54
Required hydraulic components ..................................................................................55

6.1
Component plates ...............................................................................................56
Symbols .......................................................................................................................59
Experiment 1:
Extension of a cylinder upon the Operation of a push-button..................79
Experiment 2:
Signal storage by electrical self-locking...................................................86
Experiment 3:
Mechanical locking by means of momentary-contact switch contacts ...91
Experiment 4:
Electrical locking by means of contactor contacts ...................................97
Experiment 5:
Signal storage by means of electrical self-locking Resetting by means of
a proximity switch..............................................................................................................102
Experiment 6:
Rapid advance circuit ...........................................................................107
Experiment 7:
Pressure-dependent movement reversal ..............................................113
Experiment 8:
Pressure switches and proximity switches ............................................119
Experiment 9:
Pressure-dependent sequence control.................................................126
Experiment 10:
Feed control with time-dependent intermediate stop.........................133
1
1.1
Safety regulation
Safety regulations Electrics
For working with electrical systems and equipment, the regulations for the prevention of
accidents "Elektrische Anlagen und Betriebsmittel" (electrical systems and equipment)
(VBG4) issued by the industrial trade associations as well as the VDE regulations VDE
0105 part 1 and part 12 have to be observed. Electrical equipment means any apparatus
which is used for applying electric power or for the transfer and processing of information.
Electrical systems are formed by connecting electrical equipment.
The VBG 4 regulations are quite short and supplemented by procedure instructions of the
regulations for the prevention of accidents. These are interesting since they explain the
limiting conditions for working on live parts. An excerpt of this table is given in this manual.
Three categories of qualifications have to be differentiated:
The electrics specialist, the instructed person and the layman. It must be noted that
trainees are laymen. Even after the instruction according to this series of exercises, the
trainees are laymen from an electro-technical point of view. They may only carry out work
on systems and equipment with a nominal operating voltage of up to max. 25 V AC or 60 V
DC.
The trainees must expressly be informed that they, even as skilled workers, must not
connect equipment operating at voltages higher than the values given above, unless they
become instructed personnel who may service certain systems as a result of having
passed in company training seminars.
Working on electrical controls is only permitted if the source of danger of the system to be
controlled has been secured beforehand. When working on an electrical control, one must
be aware that this may trigger off machine movements which may represent a risk for man
and machine.
The VDE regulations are very detailed and comprehensive and are not given here for
copyright reasons. According to VDE 0105, part 12 these regulations must be procured,
made available at a suitable location and handed over to all instructors and teachers.
VDE 0105 part 1 describes:

"Betrieb von Starkstromanlagen - Allgemeine Bedingungen" (operation of high voltage
systems - general conditions)
VDE 0105 part 12 describes:

"Besondere
Festlegungen
fr
das
Experimentieren
mit
elektrischer
Energie
in
Unterrichtsrumen" (special regulations for experimenting with electrical energy in

classrooms).
THE FOLLOWING IS ALSO VALID FOR ELECTRICS:
SAFETY IS
PARAMOUNT!
1.2
Safety regulations Hydraulics
General guidelines for working with hydraulic systems
Make sure that the training stand is easily accessible! (Minimum distance to walls and
equipment at least 1 m)
"Where" and "How" can the training stand be shut down in an emergency other than
by actuating the "OFF" button ? (Disconnect electrical supply via connecting plug or
mains switch).
The electrics may only be serviced by a specialist !
Protect adjacent equipment from oil contamination ! (Oil spills must not damage
valuable equipment).
Observe cleanliness, wash your hands frequently, wipe off oil drips! Some oils can be
harmful, e.g. when they come in contact with the eye or the mouth! Apart from this,
there is the risk of injury from slipping on oil spills.
Working with the training stand
Set the master switch to "0" before and alter the experiment.
Protect yourself by ensuring that nobody can switch on the pump during the
experiment set-up and that the oil flow to the component carrier is interrupted.
Check all quick-release couplings for proper fit by pulling.
Hoses must not be excessively bent or curved (risk of bursting).
Check the condition of fittings and hoses from time for perfect condition.
THE FOLLOWING IS VALID FOR HYDRAULICS
SAFETY IS PARAMOUNT!
Foreword to the trainer's manual
The present trainer's manual is intended for trainers and instructors in the field of
hydraulics as complementary manual for the Fluidprax hydraulic test stand.
The manual describes experiments that were developed in line with practical applications
and are connected to hydraulics exercises prepared by the "Bundesinstitut fr Berufliche
Bildung" in Berlin (BIBB) (federal institute of vocational training in Berlin).
The experiments were carried out on the hydraulic training stand "Fluidprax".
Generally, it must be noted that the test results documented in this manual are intended to
provide a guideline for the trainer and instructor and reflect the tendency of the individual
experiment.
For explanations regarding the hydraulic training stand

"Fluidprax"
please refer to the system manual "Fluidprax".
The short codes (such as DW3E, ZY1, DF14 etc.) refer to the complete training component
with connecting plate, coupling connector or sleeve and fixing elements.
Descriptions and calculation principles for the individual components can be found in the
092-Hydraulic Controls.
Flow measurements can be taken with high precision using the DZ30 flow meter. However,
it is also possible to use the measuring reservoir on the Fluidprax. For procedures on how
to take the measurements with this device, please refer to the general notes.
2.1
Didactic notes
The Fluidprax is a perfect tool for carrying out hydraulics exercises in the laboratory as
required in training schedules.
At the same time, this system allows both teamwork and individual training.
These new training methods were taken into account when this manual was developed.
Thanks to suitable operating symbols on directional valves, independent and individual

working can be supported.
To promote cooperation, the method of questions and answers should also be applied.
Although these training methods were taken into account in the present manual, the
concept is also suitable for autodidacts, as the general structure was developed "from easy
to difficult tasks".
Basic principles of electro-hydraulics
3.1
General
The exercises for the Electroprax are a continuation of the hydraulic exercises, which you
have carried out with the Hydroprax HP3, HP4 or HP6. With these exercises you have
deepened your knowledge of "mechanical" hydraulics and put it into practice. This electrohydraulic series of experiments deals, of course, also with "mechanical" hydraulics. Since
you, alter having carried out exercises with the Hydroprax, are almost an expert, these
exercises with the Electroprax do not go into details of hydraulics but focus on the electrical
part (e.g. control etc.). Naturally, questions with regard to hydraulics have also to be
clarified in connection with the Electroprax, e.g. the drawing up of hydraulic circuit
diagrams. In any case, it is therefore recommended to clarify any arising questions or
misunderstandings with the help of the 092-Hydraulic Controls or to make oneself again
and again aware of the functional diagrams of hydraulic equipment. In this way you can
deepen your knowledge further, forth Electroprax does not deal in detail with components
which you have become familiar with in the course of exercises with the Hydroprax. As
already mentioned, with the Electroprax, emphasis is put on the electro-technical part of
hydraulics. Since you have "only" dealt with hydraulics so far, we want to repeat the most
important electro-technical basic terms and principles before starting the series of
experiments. Thus, the introduction into electro-hydraulics is to be simplified.
3.2
3.2.1
Basics
Electric current
Electric current can only flow in a closed electric current circuit. The simplest current circuit
consists of a current source (e.g. battery), a consumer (e.g. bulb) and the line between the
current source and the consumer. The current circuit can be opened and closed by means
of a switch.
10
Fig. 1: Electric circuit
Electrical current has different effects:

1) Induction (solenoids)
2) Capacitive effect (capacitors)
3) Resistance heating (resistance wire)
4) Electrolytic effect (electroplating)
In view of electro-hydraulics, the magnetic effect of the current is to be mentioned

specifically. The electric current I is measured using an ampere meter (see 3.4.1 current
measurement). The unit of electric current is ampere (A).
In connection with electrical current, the following current types have to be differentiated:
Fig. 2: Type of current
Direct current is an electric current which flows in one direction only of an unchanged rate,
whereas alternating current permanently changes the direction and intensity.
11
Comparison with hydraulics:

With certain restrictions, electric current (electrons) can be understood as flow (oil). In the
first case, electrons flow through a conductor, in the other case oil through a pipe.
3.2.2
Electric voltage
Electric voltage is the actual reason for current. In line with the types of current, direct
voltage and alternating voltage must be distinguished.
Electric voltage U is measured using a voltmeter (see 3.4.2 voltage measurement). The
unit of electric voltage is volt (V).
3.2.3
Electric resistance
In an electric curcuit, the consumers as well as the lines create a resistance vis--vis the
electric current. The unit of resistance R is ohm (S2). The correlation of current I, voltage U
and resistance R is described by Ohm's Iaw. Either in electrics and hydraulics, it is valid
that a resistance affects current (flow) and voltage (pressure).
Ohm's law is as follows:

Resistance = Voltage
Current
R () =
(V)
(A)
Ohm's law can be used to calculate currents from a known voltage and a known
resistance.
Power mains have a constant voltage, e.g.

220/380 V in the supply network, 12 V in the on-board network of a car, the supply network
for hydraulics often has 24 V.
12
3.2.4
Electric power
Power is indicated in the unit watt (W) or kilowatt (kW). With electrical equipment, the
power is the product from current and voltage. Thus, the equation for electric power P is as
follows:
Power = Current Voltage
P (W) = I U
Here, we would like to refer to the comparison with hydraulic power. In principle, the
following can be applied:
Power = Flow Pressure
P (W) = Q p
3.3
Basic circuits
According to the arrangement of the consumers in an electrical circuit, we speak of series

connection or parallel connection.
3.3.1
Series connection
With a series connection, the individual consumers (resistances) are connected in series
one alter the other.
Fig. 3: Series connection

13
With this type of circuit, the same current flows through the consumers (resistances).
However, the voltage is subdivided into partial voltages according to Ohm's law. The
individual consumers (resistances) can be added to one total resistance.
We already compared electrical engineering with fluid mechanics from time to time. The
series connection of consumers also allows such a comparison.
In a line, in which two throttles (resistances) are connected in series, each throttle causes a
pressure drop (voltage drop). The flow (current) through both throttles (resistances)
remains unchanged. In a series connection, the current flowing through the circuit is
always identical.
The sum of partial voltages equals the total

Ug = U1+ U2 + ...Un
The sum of the individual resistances equals the total resistance:
Rg = R1+R2 + ---Rn
Partial voltages behave like the related resistances:
U1
R1
=
U2
R2
3.3.2
Parallel connection
In a parallel circuit, the individual consumers (resistances) are connected in parallel.
Fig. 4: Parallel circuit
14
In contrast to the series connection, with a parallel connection the same voltage is applied
to the consumers (resistances). The current divides into partial current according to the
resistances.
Also here, the individual resistances can be voltage applied: added up to one total
resistance.
1
1
1
1
=
+
+
Rg
R1
R2
Rn
Comparison with hydraulics:
If two throttles are connected in parallel in a line, the same pressure (voltage) is applied to
Partial voltages behave like the related each of them. However, the flow (current)
resistances: subdivides depending and the resistances.
In a parallel circuit, the same voltage is applied to all resistances.
The sum of the partial currents corresponds to the total current:

Ig = I1 + I2 + In
The partial currents operate in reverse to the related resistances.
I1
R
= 2
R1
I2
15
3.4
3.4.1
Measuring of current I and voltage U

Current measurement
Current is measured using an ampere meter. For this, the ampere meter must be
connected to the electric circuit in series.
Fig. 5: Current measurement
When taking current measurements take care that you connect the ampere meter in series.
Otherwise, the measuring instrument can be destroyed.
3.4.2
Voltage measurement
The voltage is measured using a voltmeter. For this, the voltmeter must be connected in
parallel to the consumer.
Fig. 6: Voltage measurement
When taking voltage measurements take care that the voltmeter is connected in parallel.
16
When taking measurements using voltage or current measuring instruments always take
care that the largest possible measuring range is selected in order to avoid damage to the
measuring instrument.
3.5
Electro-hydraulic equipment
On the last few pages we repeated the general basic principles of electrical engineering in
order to polish up your knowledge of this topic. Now let us focus an the tasks and basic
principles of electrical engineering in electro-hydraulics:
In electro hydraulics the electrics assume mainly signalling and control tasks whereas the
hydraulics, due to their high power density, assumes the power functions.
3.5.1
Power density
The power density is one of the essential features of hydraulics. By this, we understand for
example the ratio of a power output by a motor (hydraulic motor) in relation to its weight or
its size. Electric motors have, for example, a considerably lower power density. An electric
motor, which provides the same output power as a hydraulic motor is by far heavier and
larger. However, it must be mentioned here that the power density of electric motors has
increased in the last few years and is expected to be further improved in the future.
17
3.5.2
Electro-hydraulic valves
The interface between electrics and hydraulics is the solenoid operated valve.
Fig. 7: Electro-hydraulic circuit
The solenoid valve

The heart of a solenoid valve is the solenoid.
The operating principle of the solenoid is founded on the fact that a magnetic field is
generated by a coil through which a current flows.
Due to this, a force acts on an iron rod (armature) immerged in this magnetic field.
Depending on the design features implemented, the armature can be attracted or repulsed.
With this movement, control processes can be realized. it can for example used to switch a
directional valve. The greater the current passed through the coil is the more the solenoid
attracts the armature.
18
Fig. 8: Solenoid which performs a stroke movement when the coil is energized
Fig. 9: Classification of solendoids
Wet pin solenoids are immersed in the oil of the individual hydraulic system. These
solenoids have the following features;
less corrosion
less wear
softer switching
better dissipation of heat
no special sealing required
between armature and valve plunger.
19
Type of solenoid:
Depending on the type of excitation voltage, two types of solenoids are available:
Direct current and alternating current solenoids.
Some differences between the two types of solenoids are listed below:
DC solenoid
-
No burning through
High switching frequency
Softer switching
Insensitive to overloading
Slower
Higher price
Higher control expenditure
AC solenoid
Advantages
- Shorter switching times
- Less expensive
Disadvantages
- Burning through
- Lower switching frequency
Solenoids in directional valves

The solenoid is fitted to the directional valve by means of screws in order to facilitate
maintenance and interchange ability in the case of faults. Three connector pins protrude
from the solenoids: 2 connector pins for the solenoid coils (opposite pins) and a ground
pin. The latter can also connect the entire valve body to the ground potential, but is not
connected in the case of a 24 V voltage.
Example of a nameplate for solenoid valves

Voltage/
220 V, 50 Hz or
type of current:
24 V DC
Voltage tolerance:
10%
Power consumption: 16 VA
with alternating current, 26 W
with direct current
Duty cycle:
100 %
Temperature range: In general:

- 30 C to +70 C
Type of protection:
IP 65
(IP 65: Shock-hazard protection, full protection against dust,
protection against jet water)
Switching times:
Between approx. 30 to 120 ms, depending on

a) size of the solenoid and
b) direct or alternating current
20
3.5.3
Direct operated directional valves
Air-gap solenoids
In order to provide a better comparison, fig. 10 shows an air-gap alternating current

solenoid (1) on the left and an air-gap direct current solenoid (2) on the right-hand side of.
In this example, the valve has 2 spool positions, with the spool being not pushed into a
certain Position by means of a spring. Here, we have a so called impulse or detented
spool.
When the solenoid coil is energized, the armature moves the control spool via a plunger.
Here, the AC solenoid (1) is energized and has pushed the spool into the right position.
With air-gap solenoids, the armature chamber is sealed towards the tank channel by
means of the seal in the bushings (3).
Here, the springs hold the bushings (3) in position.
Fig. 10: Air-gap solenoids
In this sectional drawing, the solenoids are fitted with a manual override (4). Thus, the
control spool can be operated manually and externally. Thus, the solenoid's switching
function can easily be verified.
21
Wet-pin solenoids
Figure 11 shows a wet-pin direct current solenoid (1) on the left, and a wet-pin alternating
current solenoid (2) on the right. Both armature chambers are connected to the tank. Here,
we have a valve with 3 spool positions.
Fig. 11: Wet-pin solenoids
In this sectional drawing, the solenoids are fitted with a manual override (4). This can be
used to operate the control spool manually and externally. Thus, the switching functions of
the solenoid can easily be verified.
Each of the channels P, A and B is separated by means of segments in the housing. The
Channel is not provided with this separation but is connected to the atmosphere and is only
sealed by fitting the control element or a cover.
The springs (3) are supported on the solenoid housings and hold the piston via bushing
and plate in the centred position.
When compared to the version with air-gap solenoid, the control spool is even and is
moved via the plunger at the solenoid armature.
Fig. 11 Wet-pin solenoids
22
3.5.4
Pilot operated directional valves
Directional valves of larger nominal sizes, i.e. for larger hydraulic powers, are pilot
operated. The reason for this is the operating forces required for moving the control spool
and the related solenoid sizes (power density).
For an exact functional description, see 092-Hydraulic Controls.
Fig. 12: Symbol (simplified)
Fig. 13: Pilot operated directional valve
23
3.6
Extending a cylinder by pressing a push-button
Relays or contactors are electro-magnetic switches with spring return. The switches are
electro-magnetically actuated or held in the switched position.
A relay or contactor consists of a coil, which attracts an armature when energized. Thus,
one or several contact decks are opened and/ or closed. When the coil is de-energized, the
armature and the contacts are returned to their initial position by means of the spring force
(see figure 14).
Contactor coils can be energized using either alternating current or direct current, and,
depending on the rating of the coils, different control voltages can be connected. We have
to differentiate between primary contactors and auxiliary contactors.
Primary contactors are used for switching primary circuits for DC and AC actuators.
Auxiliary contactors are used for switching secondary power circuits. Since the switching
ability of auxiliary contactors is limited, they are not suitable for primary power circuits with
higher loads. Relays assume similar functions as auxiliary contactors. Basically they are
suitable for lower excitation voltages and used almost exclusively for DX excitation. The
permissible current loads range from the smallest current value up to approx 1.5 A.
Relays assume similar functions as auxiliary contactors. Basically they are suitable for
lower excitation voltages and used almost exclusively for DC excitation. The permissible
current loads range from the smallest current value up to approx. 1.5 A.
When selecting contactors, the switching conditions have to be taken into account since
these have a major influence on the service life.
24
Fig. 14: Relay function
25
3.6.1
Time and current characteristics
Fig. 15: Characteristics of a DC-energized relay or contactor
26
3.6.2
Making procedure
When the coil is energized by the operating voltage, the armature starts to move against
the return spring after the rise time tag and when the pickup current is achieved (fig. 15).
The contacts usually start to move after the stroke time th which is determined by the
mechanics. However, the response of the individual contacts can be delayed or priority can
be assigned to them by mechanical means, e.g. spreading S (comparison tf). Although the
contacts are closed with the stopping of the armature, the switching process is not yet
terminated. The contacts vibrate at a natural frequency determined by their spring rate and
mass but this vibration will decay according to a damping rate which is determined by
friction. Thus the current is cut in and out several times.
This time is called chatter time tp .
Only after this time will the making process reach a stable condition.
3.6.3
Breaking procedure
With the breaking procedure, first the operating voltage is switched off, which results in a
drop of the operating current. After the rise time tal has elapsed, the falling current is
reached. This is far lower than the pickup current. Only then the larger force of the return
spring starts to move the armature into its initial position. During the armature stroke, the
contacts are switched earlier or later depending on their spread and arrangement. The
breaking procedure is only terminated after the chatter time tp.
A more detailed description of these expressions is included in the standard DIN 41215.
Operating voltage, operating current and/or coil resistance and load ability of the contacts
are indicated on the nameplate of the relay.
Notes on the electrical connection of contactors and relays:

In practice, the supply voltage is often grounded to its 0 V potential. For safety reasons,
contactors and relays should therefore always be connected with the electrical negative
line before being connected to the plus line via a momentary-contact switch, proximity
switch or relay contacts.
27
Theoretically it would, of course, also be possible to connect the relay to the plus pole (fig.
16).
Fig. 16: Electrical connection of contactor or relay to the plus wire
However, there is a risk that due to insulation defects or other reasons the minus terminal
can be connected to the ground thus creating an electrical conductive connection which is
not desirable (circuit fault).
Contactors are most often used to switch higher powers, whereas relays are used to
interlink electrical signals in a control circuit.
Letter symbols
The letter symbols are standardized to DIN 40719, part 2.
Fig. 17: Schematic diagram
28
3.6.4
Schematic diagram
Instead of a manual Operation of the valve, the solenoid fitted to the valve is energized and
operates it.
The control function is illustrated in the schematic diagram. However, this does not provide
any information and the wiring of the individual elements but only represent the principle
procedure. In fact, the contacts of contactor K1 are for example not separated from the
contactor but are integrated into its housing.
The schematic diagram is drawn up using standardized symbols. All the elements are
arranged in parallel, vertical lines which are numbered. These lines are called circuit sections and correspond to the current paths.
When drawing up a circuit diagram, the following rules must be observed:
a) Switches and relays are clearly arranged without taking into account the mechanical
interrelation of the individual components.
b) The circuit is represented in the de-energized status.
c) The equipment is drawn in the non-operated condition.
d) The theoretical direction of movement of the symbols must be in the plane of projection
and as a standard always be illustrated from left to right.
3.6.5
Main circuit and control circuit
In practice, we have to differentiate between main and control circuit.

"Control circuit" means that it assumes only control tasks and therefore requires less
power.
29
The consumers in the main circuit most often require higher powers which are cut in and
out via contactors. The power supply to the main and the control circuit can be a separate
or a common supply.
a) Control directly at the main circuit b) Separation of main and control circuit
b) Separation of main and control circuit
Fig. 18: Types of controls
30
3.6.6
Symbols of the most important switching elements
Fig. 19: Representation of contacts
The contact designation refers to the condition after Operation (figure 19).
3.6.7
Designation of contacts at contactor/relay
Fig. 20: Table of switching elements re fig. 21
The relation of contactor, coil and associated switches is made clear by proper
identification (fig. 21). Thus, lines representing the effects between coil and contacts can
be omitted.
The number of contacts of the individual contactor can be represented in a switching element table (fig. 20). The switching element table is drawn below the exciter coil of the
contactor.
31
Fig. 21: Contact designation
32
3.7
Electrical self-locking Suppression by means of a momentary-contact switch
In circuit engineering, signal storage via electrical self-locking is indispensable. By the use
and the proper arrangement of switches and relays circuits can be realized which are
capable of storing switching impulses. The principle behind signal storage can be made
clearer using the following example.
You are riding on a bus and want to get out at the next Station. In order to Signal this to the
driver you press one of the push-buttons "next stop", which are fitted in several locations
on the bus. After pressing this push-button, a display lights up at the driver console even
when you no longer press the "next stop" pushbutton. Your Signal is and continues to be
applied until it is suppressed by another signal ("open doors").
a) Break contact Priority
Fig. 22: Break contact priority
33
3.7.1
Signal storage
Signal storage or a self-locking circuit can be implemented by means of contactors and/or

relays with different arrangements of normally closed and normally open contacts. With a
break contact priority (fig. 22) the contactor or relay will not pick up when both pushbuttons S1 and S2 are pressed simultaneously; however, with a make contact priority (fig.
23), the coil will be energized. For safety reasons, the dropout priority is in most cases
preferred. Break contact circuits are often used as protection in the case of a power failure
because then they return to their initial position (OFF). According to the relevant
regulations, machines or parts of machines must not start up automatically when voltage is
again applied after a power failure. This requirement can easily be met by means of
contactor controls with self-locking circuits.
b) Make contact priority
Fig. 23: Make contact priority
34
Signal storage ranges among the so-called logic operations. In logic circuitry, self-locking is
designated as RS flipflop. Besides the one mentioned above, the most important
operations are AND and OR operations (fig. 24).
R = Reset = OFF; S = Set = ON.
Fig. 24: Logics in contact engineering
35
3.7.2
Function chart
In control engineering, comprehensive controls are represented in function charts. These

replace the circuit description.
Function charts should be drawn up taking into consideration the following aspects:
1. Arrangement of the individual components so that signal lines are short.

2. Arrows indicate the direction of the effect of the individual functions.
3. ON impulses are only represented as small squares. Such an ON impulse is illustrated
in fig. 25.
4. Signal lines are drawn as thin lines.
Function charts do not always contain momentary-contact switch as individual elements.

Especially in comprehensive machine controls, these switching elements are not drawn.
They are replaced by the following symbols which are included in the signal flow of the
relay or contactor.
Fig. 25: Illustration of a switching impulse
36
Example 1:
Circuit diagram with associated function chart
Fig. 26: Circuit diagram
For a detailed description of the illustration of function charts, see VDI guideline 3260.
The type of illustration below should help you understand the structure of a function chart.
Fig. 27: Function chart re fig. 26
37
Example 2: Signal elements
Fig. 28: Signal Element
Fig. 29: Signal element
From this, the following function chart can be derived:
Fig. 30: Function chart
This diagram could further be simplified by drawing the signal elements directly to the
function line of the 4/2-way directional valve and to omit contactor K1.
38
3.8
Momentary-contact limit switches
Momentary-contact limit switches range among so-called control switches. This group also
includes momentary-contact switches. By control switches we understand switches which
actuate control and auxiliary circuits.
While momentary-contact switches are switched off manually by the Operator, mechanical
momentary-contact limit switches are actuated e.g. by a cylinder moving a roller lever.
In fig. 31 limit switches are grouped by the type of excitation on the sensor side. They can
be classified by the type of contact output on the output side, i. e. via mechanical contacts
or via semi-conductor switches, which means without contact. In the exercises and
experiments we mainly use two types of limit switches.
Fig. 31: Categories - limit switches
Besides these mechanical momentary-contact limit switches, which have to be operated

via direct contact, there are also so-called proximity switches. According to the design,
proximity switches can be subdivided into inductive, capacitive and optical (light barriers)
proximity switches.
Limit switches are subdivided into two categories.
1. Mechanically operated limit switches with mechanical contacts.

2. Floating proximity switches with contact free output.
39
Independently of their design principle, commercially available limit switches are not only
used to restrict dangerous movements. In the case of a component failure their contact
less outputs can lead to active or passive malfunction. An additional momentary-contact
limit switch with positively mechanically opening contacts must be provided to stop the
movement.
3.8.1
Magnetic momentary-contact limit switches with reed contacts
The switching function of reed contacts is achieved by pre-loading the contacts via a small
magnet. If a stronger magnet is brought near the contact members, the pre-load is
overcome and the contact is made.
Fig. 32: Reed contact
3.8.2
Optical momentary-contact limit switches
are realized by means of light barriers. There are three possibilities:
One-way light barrier:

Sender and receiver are arranged on opposite sides. If the light beam to the receiver is
interrupted, a switching procedure is initiated.
Reflexion light barrier:

Sender and receiver are accommodated in one housing. The light beam is directed onto a
mirror and from there reflected back to the receiver.
Auto-reflection:
The object, which enters the beam path, acts as reflector (mirror).
40
3.8.3
Capacitive proximity switches
The principle of a capacitive proximity switch is based on the change in capacitance of a

capacitor. The capacitance C of a capacitor depends on the charged surface A, the plate
distance I and the dielectric constant c; the following is valid :
If a dielectric with a higher dielectric constant (glass plate, PVC plate) is brought into the
electric field of a capacitor, its capacitance increases, and with an AC voltage supply to the
capacitor, a higher charging current is applied. If the dielectric is removed from the electric
field, the process takes place in the opposite manner, i.e. the additional charging current
decreases. This additional charging current triggers off the switching process via the electronics of the proximity switch.
The reference dielectric of a capacitive proximity switch is air.
Note:
Since dirt also acts as dielectric, inadvertent incorrect operations are possible as a result of
heavy dirt deposits.
Capacitive proximity switches look similar to inductive ones.
3.8.4
Inductive proximity switches
The function principle of an inductive proximity switch is based on the disturbance of an

electromagnetic field. If a metal object is brought into the field, the latter will be changed.
This change provoques a switching process in the electronics of the inductive proximity
switch.
Fig. 33: inductive proximity switch

41
Fig. 34: Switching distances with an inductive proximity switch
Many switches of this type signal the switching process via a light emitting diode (LED).
This LED helps to determine the switching distance between the inductive proximity switch
and the metal object. In practice you will quickly find out that objects made of steel have a
larger switching distance than for example objects made of brass, aluminium or copper.
3.8.5
Example of connection of an inductive proximity switch
In general, each proximity switch comes with a connecting diagram. Nevertheless, we

would like to illustrate such a schematic diagram here:
Fig. 35: Connecting diagram
3.8.6
Momentary-contact/proximity limit switches
The function of momentary-contact/proximity limit switches-whether mechanical or contact

free is to cut current paths in or out as soon as actuating elements reach a certain position
(limiting value).
42
Momentary-contact limit switches often operate to the principle of a changeover switch.

According to standards, momentary contact switches have the following symbol:
Fig 36: Mech. momentary contact limit switch
Fig 37: Proximity switch
Depending on the circuit and the intended use, momentary-contact limit switches/proximity
switches can be normally closed or normally open. In our exercises we only use normally
open contacts.
43
3.8.7
Parallel and series connection of proximity switches
Fig. 38: Parallel connection

Logic operation OR
Fig. 39: Series connection

Logic operation AND
As mechanical contacts, proximity switches can be connected in parallel or in series. Thus,

AND and OR logic operations can be created. Naturally, proximity switches can also be
combined with mechanical contacts for logic operations.
Note:
In the experiments with the Electroprax we use inductive proximity switches.
44
3.9
Pressure switches
Pressure switches are hydraulically operated switches which switch an electric circuit when
a preset pressure has been reached.
The switching contact does not get in direct contact with the medium to be monitored such
as water, oil, etc. A change in pressure causes a sensor element (diaphragm, gaiter,
Bourdon spring (fig. 42), Bourdon tube, piston (fig. 41)) to move thereby actuating a
plunger. The switching points of the upper and lower limiting value can be varied within
predetermined ranges by adjusting the spring pretensioning rate.
In most cases, pressure switches are designed as changeover switches (fig. 40) capable of
being operated either as normally open or normally closed depending an the pin allocation.
The circuit diagram of a pressure switch is as follows:
Fig. 40: Circuit diagram - pressure switch
The sensor element determines the type and the designation of the pressure switch (e.g.
piston type pressure switch, Bourdon tube pressure switch).
45
Fig. 41: Piston type pressure switch
Fig. 42: Bourdon tube pressure switch
46
A pressure switch assumes the function of a guard. When the upper pressure limiting value
is exceeded or the pressure falls below the lower pressure limiting value, a main circuit or
an auxiliary current path can be opened or closed. As a result of two switching points, limit
switches are capable of monitoring e.g. temperatures, speeds and other variables within a
limited range.
Pressure switches have a hysteretic, i.e. the signal of the pressure switch remains in a
certain pressure range. This is caused by the spring travel in the switch as well as by
frictional forces which occur of articulated joints and dynamically loaded sealing points.
Hysteretic is the continuation of an effect whose cause no longer exists. If hysteretic is

lowered to less than a certain amount, the switching characteristics become instable. The
pressure switch becomes "too sensitive".
Fig. 43: Hysteresis of a pressure switch
47
3.10 Mechanical locking by means of momentary contacts
By means of locking circuits, current paths can be prevented from cutting in. This means
for example that a locking function avoids simultaneous switching of two or more
contactors or the timely overlap of switching processes.
The following example (fig. 44) describes a locking function with the contacts of the switch.
With a simultaneous operation of the switches the energization of the contactors becomes
impossible.
Fig. 44 Mechanical locking
The illustrated locking function is purely mechanical. The two contacts are usually
integrated into a housing and are switched by means of a lever.
When using AC solenoid valves, switches S1 and S2 must be locked in order to avoid
damage to the solenoid coil caused by simultaneous energization. With DC solenoid
valves, locking should be provided for safety reasons.
In the case of less complex circuits, mechanical locking is the more suitable solution. With
complex electrical control processes, electrical locking is to be preferred.
Most of the solenoids are fitted with a manual emergency override. Thus, they can be
operated even in the case of a power failure.
However, it must be noted that undesirable machine movements can be initiated by

actuating the manual emergency override.
48
3.11 Electrical locking by means of contactor/relay contacts
Contactors can be locked electrically by mutual switching of normally closed contacts

immediately before contactor coils. An interruption of non branched current paths provides
a disconnection priority, i.e. a safe disconnection of the contactors.
Fig. 45 Electrical locking
With cross locking functions with normally closed contacts of the contactors as illustrated
here, overlaps are possible. If the associated momentary-contact switches are operated
simultaneously, both contactors are energized simultaneously and the contactor armatures
pick up. All contacts switch for a short time (overlap).
This overlap can be excluded by providing additional mechanical locking of the switches.
3.12 Time relay
Time relays are switching relays with intended time characteristics (DIN IEC 255).
Time relays are fitted with a contact assembly which switches immediately after
energization of the coil as with a relay or a contactor, and a contact assembly, which
switches after a settable delay time. Both contact assemblies can consist of normally
closed and normally open contacts.
If the delay time starts with the de-energization of the coil, we speak of an OFF-delay relay.
There are time relays which can be changed over or have both characteristics.
49
In the switching element table, the delayed normally open or normally closed contact is
identified by the prefix v (v = delayed).
These switching elements are mainly used in auxiliary circuits of relay and contactor
controls. By a "relay" we generally understand a switching element which switches one or
several output signals with one input signal. With a time relay, the output signal is
implemented with a certain time delay. The time delay can be subdivided into three types:
3.12.1 ON-delay
(Fig. 46)
After an input signal is received, a delay mechanism is initiated. After the delay time has
elapsed, the switching contacts are operated and held in this position until the input signal
is reset. Then the contact returns to its rest Position.
Fig. 46
3.12.2 OFF-delay
(Fig. 47)
The switching contacts are actuated by the application of an input signal. When the input
signal is withdrawn, a delay mechanism is initiated. After the elapse of the delay time, the
switching contacts return to their rest position.
Fig. 47
50
3.12.3 ON- and OFF-delay

(Fig. 48)
Here, the two basic types of time delays are combined in one component.
Fig. 48
Fig. 49: Basic functions of time relays
All components for the generation of time functions have the intermediate storage of an
auxiliary variable in common. The type of intermediate storage and the suitability of a time
relay type for a certain application depends on the lengths of the time delay or interval to
be achieved, on the required and achievable accuracy, on the possibility of a variation in
the time delay or interval and the repetition frequency.
51
Type of component
Intermediate storage and auxiliary
Achievable time delay
variable
Pneumatic time relay
Air in a pneumatic damper
50 ms to 2 min.
Thermal time relay
Thermal capacitance of materials
2 s to 5 min.
Motor-driven time relay
Rotation of mechanical shafts
1 s to 50 h
Time relay with clockwork
Clockwork
1 s up to several days
Capacitor time relay
Capacitance of capacitors
1 ms to 10 s
Magnetic time relay
Inductance of reactors
5 ms to 100 ms
Electronic time relay
Capacitance of capacitors in electronic 1 ms to 20 min.

circuits
Micro-processor time relay
Digital divider circuit

Fig. 50: Delay mechanisms
52
1 ms up to several days
Experiment cross-reference
No.
Mannesmann Rexroth - Experiments Experiment
BIBB
st
(1 issue)
Experiment no.
1 Extending a cylinder by operating a push-button
2 Signal storage by electrical self-locking
Setting and resetting using a momentary-contact switch

3 Mechanical locking by means of momentary-contact switch contacts
4 Electrical locking by means of contactor contacts
5 Signal storage by means of electrical self-locking Resetting by means of
a momentary-contact switch
6 Rapid advance circuit
11, 12
7 Pressure-dependent reversing
8 Pressure switches and proximity switches
7, 10
9 Pressure-dependent sequence control
10
10 Advance control with time-dependent intermediate stop
6, 9
53
Required electrical components
Electro-hydraulics to BIBB
E1
E2
E3
E4
E5
E6
Momentary-contact
switch 1nc
Momentary-contact
switch 1 nc
Relay 4 x changeover
switch1no
Maintained-contact
E9
E10 E11
Total
Lamp 24 DC
Momentary-contact
limit switch 1no

Momentary-contact
Iimit switch1 nc
Power supply 24 DC
E8
switch 1 nc/ 1 no
Momentary-contact
E7
54
Required hydraulic components
Electro-hydraulics to BIBB
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
Total
Pressure relief valve

(direct operated)
DD1.X
Pressure switch
DD6E
Throttle valve
(adjustable) DF1.X
Throttle check valve
DF2.X
valve DW3E
Isolator valve DZ2.X
Distributor DZ4.X
valve DW4E
DZ1.X
Cylinder
4/3-way directional
Pressure gauge
(pilot operated) DS1

4/2-way directional
Check valve
(1) 2
(1)
2
1
2 (1)
Pressure hose 1000

mm with mini- mess
connection DZ25
Loading unit DW12
(AZ + loading unit)

Cylinder Z1 (Z2)
+ load unit L1 (L2) *
*
For use with Fluidprax
55
6.1
Component plates
The plate number refers to the individual component version
56
57
58
Symbols
Graphical symbols to DIN

Electrical engineering and electronics
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
Experiment 1:
Extension of a cylinder upon the Operation of a push-
button
1.
Description of the experiment
In this experiment, a double-acting cylinder is to extend and retract. The extending process
is controlled by operating a pushbutton. When the pushbutton is released, the cylinder
retracts automatically.
With this experiment, the following knowledge should be imparted:
a) How to complete a simple circuit diagram with two current circuits

b) Illustration of the difference between a control circuit and a main circuit
c) Indication of types of switching contacts and their classification figure (normally closed,
changeover switch, normally open)
d) How to draw a contact element chart
Example:
Upon the Operation of a push-button, the cylinder of a press brake extends. The work
piece (sheet steel) is bent around an edge. As the push-button is released, the cylinder
retracts automatically.
79
2.
Task
2.1
Hydraulic circuit
Supplement the circuit illustrated below so that a cylinder extends upon the operation of a
push-button. When the push-button is released the directional valve returns to its initial
position due to its spring centring and the cylinder retracts. In order to be able to vary the
extension velocity, install a throttle and limit the system pressure by means of suitable
valve.
Figure 1: Circuit diagram (hydraulic circuit)

Extending of a cylinder upon the operation of a push button
80
2.2
Electrical circuit
Supplement the electrical circuit diagram so that the solenoid coil Y1 of the 4/2-way
directional valve is energized as soon as the push-button S1 is operated. Upon releasing
the push-button, the solenoid coil is to be de-energized.
Figure 2: Circuit diagram (electrical circuit)

Extending of a cylinder upon the operation of a push button
81
3.
Preparation of the experiment
The following components should be an hand for this experiment:

3.1
Hydraulic circuit:
1 Pressure relief valve DD1.X 1 Throttle check valve DF2.X

1 4/2-way directional valve with spring return DW3E
1 Pressure gauge with distribution DZ1 or DZ25 with DZ1 .X
1 Cylinder
Pressure hoses
3.2
Electrical circuit:
1 Push-button ON S1
1 Relay K1
1 Ampere meter, voltmeter
Wander leads
Before starting the set-up of the experiment, please refer to the section "safety regulations", which can be found in chapter 1.
4.
Experiment set-up
4.1
Hydraulic circuit
Set up the hydraulic circuit and follow the steps below:
1. The isolator valve at the Hydroprax to your training rig is closed (only with Hydroprax
4).
2. Hang the pressure relief valve DD1.X, the throttle check valve DF2.X, the pressure
gauge DZ1.X and the 4/2-way directional valve with spring return DW3E onto the
component carrier and secure them.
3. Connect the individual components via hoses according to the circuit diagram.
82
4.2
Electrical circuit
Now set up the electrical circuit following the steps below:
1. The Power supply is switched off, the system is de-energized.

2. Connect the individual components using the wander leads according to the electrical
circuit diagram. Use red wander leads for positive electrical connections and black
wander leads for negative connections. This simplifies trouble-shooting in the case of
possible mistakes.
5.
How to carry out the experiment
1. Check the set up circuits.

2. Check that the flow control valve at the Hydroprax to the training rig is set to 5 LJmin.
This corresponds approximately to a setting of 1.24 on the scale of the flow control
valve (only with Hydroprax 4).
3. Make sure that the connecting hoses fit properly (verify by pulling).
4. Make sure that all four EMERGENCY OFF push-buttons (only with Hydroprax 4) are
connected to the Hydroprax, disengaged and are available at the trainings rigs.
5. Now switch the red main switch of the Hydroprax to I.
6. Switch on the power supply at the control panel by means of the key switch by turning
the key clockwise.
7. Switch the pump of the Hydroprax on by operating the yellow push-button.
8. Take care that the isolator valves on the adjacent training rigs to the Hydroprax are
closed (Hydroprax 4).
9. Open the isolator valve (only with Hydroprax 4) at the Hydroprax, to which your training
rig is connected.
83
6.
Experiment
a) Set the system pressure to 30 bar at the pressure relief valve DD1.X and turn the
throttle check valve to the central position.
b) Measure the following currents on the basis of the individual circuit diagram with activated and released push-button:
Control current (figure 3)
Valve current (figure 4)
Total current (figure 5)
Enter the measured values into the experiment chart.
c) Measure the voltage with the push-button being activated and released. Complete the
values in the chart with the measured values.
d) Close the isolator valve at the Hydroprax to your training rig (only with Hydroprax 4).
e) Switch the power supply off.
Figure 3: Control current
84
Figure 4: Valve current
Figure 5: Total current
Note:
The total current is the sum of control current plus valve current.
G = S + V (Ampre)
7.
Evaluation
Figure 6 Table
85
Experiment 2:
1.
Signal storage by electrical self-locking
Description of the experiment
A cylinder is to be extended by means of a push-button impulse. When the push-button is

released the cylinder is to continue to extend by means of signal storage until the end
position is reached. The retraction of the cylinder may only be possible when the signal
storage is reset by means of a second push-button.
The following knowledge is to be imparted:

a) Set-up of an electrical circuit with electrical signal storage
b) How to draw up a circuit diagram for signal storage
c) Supplementing and explaining a function chart
2.
Task
2.1
Hydraulic circuit
Supplement this circuit so that the cylinder can be extended and retracted by means of the
solenoid operated directional valve. The DF1.X fine throttle influences the retracting and
extending velocity of the cylinder.

Signal storage by means of electrical self-locking
86
2.2
Electrical circuit
Supplement the circuit diagram so that the solenoid coil Y1 of the 4/2-way directional valve
is energized when push-button S1 is operated. When the push-button is released power
should still be supplied to the solenoid coil. The cylinder retracts when the power supply to
the solenoid coil is interrupted by the Operation of a second push-button S2.
Note:
Connect a normally open contact relay K1 in parallel to push-button S1.
Storage of the signal from push-button S1 by K1.
Withdraw the signal provided by push-button S1 by means of push-button S2.
Figure 2: Electrical circuit

Signal storage by means of electrical self-locking
87
3.

3.1
Hydraulic circuit:
1 Pressure relief valve DD1.X

1 4/2-way directional valve with spring return DW3E
1 Throttle DF1.X
1 Pressure gauge with distribution DZ1 or DZ25 with DZ1.X
1 Cylinder
Pressure hoses
3.2
Electric circuit:
1 Push-button ON (normally open) S1

1 Push-button OFF (normally closed) S2 1 Relay K1
Wander Leads
Before starting the set-up of the experiment, please refer to the section "safety
regulations", which can be found in chapter 1.
4
Experiment set-up
4.1
Hydraulic circuit:
Set up the hydraulic circuit by following the steps below:

4).
2. Hang the various components onto the component carriers according to the experiment
set-up and secure them.
3. Connect the individual components according to the circuit diagram using the pressure
hoses.
88
4.2
Electrical circuit:
Now set up the electrical circuit by following the steps below:

2. Connect the individual components using the wander Leads according to the electrical
circuit diagram. Use red wander Leads for positive electrical connections and black
wander Leads for negative connections. This simplifies trouble-shooting in the case of
possible mistakes.
5
How to carry out the experiment:

2. Make sure that the flow control valve on the Hydroprax to the training rig is set to 51./m
in. This corresponds approximately to a setting of 1.24 on the scale of the flow control
valve (only with Hydroprax 4).
4. Make sure that all four EMERGENCY OFF push-buttons on the Hydroprax are connected and disengaged and are available at the training rigs (only with Hydroprax 4).
the key clockwise.
7. Switch on the pump of the Hydroprax by operating the yellow push-button.
Take care that the isolator valves on the adjacent training rigs are closed (only with
Hydroprax 4).
rig is connected.
89
Experiment:
a) Set the system pressure to 30 bar on the pressure relief valve DD1.X. Switch the
throttle DF1.X to position 5.
b) Briefly press push-button ON Si. The cylinder extends and remains in its end position.
Withdraw the self-locking signal by pressing push-button OFF S2. Relay K1 is now deenergized, the 4/2-way directional valve DW3E shifts and the cylinder retracts.
c) Describe the sequence of this circuit in the function chart.
d) Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4).
e) Turn the power supply off.
7
Evaluation:
Figure 3: Function chart
90
Experiment 3:
Mechanical locking by means of momentary-contact
switch contacts
1
Description of the experiment:
In this experiment, the cylinder is to approach any intermediate position in the inching
mode. By "inching mode" we understand an impulse circuit without self-locking. The
cylinder is to be locked hydraulically in any intermediate position. This can be achieved by
means of pilot operated check valve.

a) How to set up a hydraulic and electrical circuit with mechanical locking of the
momentary-contact switches
b) Mechanical locking
2.
Task
2.1
Hydraulic circuit:
Supplement this circuit so that the cylinder retracts or extends when the 4/3-way directional
valve DW4E is correspondingly controlled. During the retracting process, the check valve
must be unlocked by energizing the solenoid coil of the 3/2-way directional valve DW3E.
The pilot operated check valve DS1 (leak-free) positively isolates the cylinder in any
intermediate position.
This is not possible with the directional valve DW4E (spool valve) alone since in contrast to
poppet valves this valve is not leak-free. The cylinder would sag under external loading.
it should be possible to regulate the retracting velocity, to set the system pressure and to
monitor it via the pressure gauge.
91

mechanical locking
92
2.2
Electrical circuit:
Complete the electrical circuit diagram so that the cylinder retracts and extends in the
inching mode by the operation of two momentary contact switches S5 and S9. Switch S9
should be locked. When both switches are operated simultaneously, the retracting direction
should priority.
Figure 2
Circuit diagram (electrical circuit) mechanical locking
93
3.

3.1
Hydraulic circuit:
1 4/3-way directional valve DW4E

(A not connected by means of hoses)
1 Pilot operated check valve DS1 1 Pressure relief valve DD1.X
1 Throttle check valve DF2.X
1 Isolator valve DZ2.X
1 Loading unit Via -(1DW12Yor AZ with loading unit
1 Cross unit DZ4.X
1 Pressure gauge DZ1 with distributor or DZ4.X with DZ1.X and DZ25
Pressure hoses
3.2
Electric circuit:

1 Push-button OFF (normally closed + normally open) S9
2 Relays K1, K2 Wander leads
Wander leaders
Before starting the set-up of the experiment, please refer to the section "safety regulations", which can be found in chapter 1
94
Experiment set-up
4.1
Hydraulic circuit:

1. The isolator valve of the Hydroprax to your training rig is closed (only with Hydroprax
4).
hoses.
4.2
Electrical circuit:
1. The power supply is switched off, the system is de-energized.

2. Connect the individual components using the wander leads according to the electric
possible mistakes.
5.

2. Make sure that the flow control valve on the Hydroprax to the training rig is set to 5
Umin. This corresponds approximately to a setting of 1.24 on the scale of the flow
control valve (only with Hydroprax 4).
4. Make sure that all four EMERGENCY OFF push-buttons on the Hydroprax are
connected and disengaged and are available at the training rigs (only with Hydroprax
4).
5. Now switch the red main switch of the Hydroprax to 1.
the key clockwise.
Hydroprax 4).
rig is connected.
95
6.
Experiment:
a) Limit the system pressure to 40 bar; for this, the isolator valve DZ2.X must be closed.
After having set the pressure, open it.
b) Open the throttle check valve DF2.X.
c) Extend the cylinder. When retracting, stop at an intermediate position.
d) Draw up a function chart.
e) Retract the cylinder completely and close the isolator valve on the Hydroprax to your
training rig (only with Hydroprax 4).
f)
7.
Turn the power supply off.

Evaluation:
96
Experiment 4:
1.
Electrical locking by means of contactor contacts
In this experiment, the cylinder is to extend and retract upon the Operation of a pushbutton. The movement of the cylinder is to be controlled by means of three push-buttons
"FORWARDS", "BACKWARDS" and "STOP". it is required that the cylinder can be
stopped at any position during retracting or extending.

a) Set-up of the hydraulic and electrical circuit
b) Electrical locking
c) Combination of mechanical and electrical locking
2.
Task
2.1
Hydraulic circuit:
Work out a circuit with which the cylinder retracts and extends when a directional valve is
accordingly controlled. It should be possible to regulate the extending velocity, to set the
system pressure and to minitor it via the pressure gauge.
Figure 1: Circuit diagram: (hydraulic circuit)

electrical locking
97
2.2
Electrical circuit:
Supplement the electrical circuit diagram and the connection diagram so that the cylinder
retracts and extends when the push-buttons S5 and S6, respectively, are operated. The
individual signals are to be stored by means of self-locking. The locking contacts (normally
closed) of the relays have to lock the relay that is not used for the respective motion
sequence. By pressing push-button OFF S9, the entire power supply to the contactors is to
be interrupted and the seif-locking function of the individual push-button must be withdrawn
as long as this push-button is operated. After this, the cylinder can again be traversed
when the corresponding push-button for the relevant direction of movement is operated. By
pressing push-button OFF S9, the entire power supply to the contactors is to be interrupted
and the self-locking function of the individual push-button must be withdrawn as long as
this push-button is operated. After this, the cylinder can again be traversed when the
corresponding push-button for the relevant direction of movement is operated.
electrical locking
98
3.
Preparation of the experiment:

3.1
Hydraulic circuit:

1 Cylinder
1 Pressure gauge DZ1 with distributor
or DZ4.X with DZ1.X and DZ25
Pressure hoses
3.2
Electric circuit:
2 Push-buttons ON (normally open) S5, S6

1 Push-buttons OFF (normally closed) S9
2 Relay K1
Wander leads
4.
Experiment set-up
4.1
Hydraulic circuit:

4).
hoses.
99
4.2
Electric circuit:

possible mistakes.
5.

Umin. This corresponds approximately to a setting of 1.24 on the scale of the flow
4).
5. Now switch the red circuit breaker of the Hydroprax to I.
the key clockwise.
Hydroprax 4).
8. Open the isolator valve (only with Hydro- prax 4) at the Hydroprax, to which your
training rig is connected.
100
6.
Experiment:
a) Limit the system pressure to 40 bar by means of the pressure relief valve DD1.X. For
this, the isolator valve DZ2.X must be closed. After having set the pressure, open the
valve.
b) Bring the throttle check valve to the central position.
c) Now extend the cylinder once.
d) Retract the cylinder and stop the cylinder movement by operating the push-button OFF
S9. Take the electrical circuit diagram and try to find out how this is possible.
e) Work out a function diagram on the basis of the cylinder movement and the pushbutton positions for the extension movement of the cylinder with intermediate stop and
for the retraction movement.
f)
Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4)
g) Turn the power supply off.

7.
Evaluation of the experiment:
101
Experiment 5:
Signal
storage
by
means
of
electrical
self-locking
Resetting by means of a proximity switch

1.
Description:
This experiment is to demonstrate the function of an inductive proximity switch in practice.

The cylinder is to extend upon the Operation of a push-button and automatically return with
the help of a proximity switch.
In addition, it should be possible during the retraction movement to re-extend the cylinder
at any position by operating a push-button.
With this experiment, the following knowledge is to be imparted:
1. Set-up of an electrical and hydraulic control, in which electrical seif-locking is reset by

means of a proximity switch.
2. Function and types of proximity switches (see chapter 3.8).
2.
Task
2.1
Hydraulic circuit:
Work out a circuit, with which the cylinder retracts and extends when a directional valve is
accordingly controlled. it should be possible to regulate the extending velocity, to set the
system pressure and monitor. it via the pressure gauge.

Proximity switch
102
2.2
Electric circuit:
Complete the electric circuit diagram so that the directional valve (Y1) shifts when pushbutton S5 is operated. This switching impulse is to be stored by electrical self-locking.
The cylinder retracts automatically, when proximity switch B1 switches and thus resets the.
self-locking function.

proximity switch
103
3.

3.1
Hydraulic circuit:

1 Loading unit ailE/MDW123
or AZ with loading unit
Pressure hoses
3.2
Electric circuit:
1 Push-button ON (normally open) S5 1 Relay K1

1 Relay K2
1 Proximity switch B1
Wander leads
4.
Experiment set-up
4.1
Hydraulic circuit:
1. The isolator valve of the Hydroprax to your training rig is closed (only with Hydroprax 4)
3. Connect the individual components according to the circuit diagram via the Pressure
hoses.
104
4.2
Electrical circuit:

possible mistakes.
5.

L/min. This corresponds approximately to a setting of 1.24 on the scale of the flow
4).
the key clockwise.
Take care that the isolator valves on the adjacent training stands are closed (only with
Hydroprax 4).
rig is connected.
6.
Experiment:
a) Set the system pressure to 30 bar by means of the pressure relief valve DD1.X and
bring the throttle check valve to the central position.
b) Now start an experimental run and find out whether the cylinder acts as intended.
Complete the function chart. With this and all the following experiments do not draw the
control elements (contactor, relays) into the function chart but directly connect the
signal lines with the directional valve. This simplifies the function chart.
c) Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4)
d) Switch the Hydroprax off.
105
7.
Evaluation:
106
Experiment 6:
1.
Rapid advance circuit
This experiment deals with rapid advance circuits. They are used for example to move a
tool quickly to the required position in order to save time. The subsequent machining
process takes place at a slower rate. The cylinder must therefore extend at two different
speeds; rapid advance up to the vicinity of the work piece, then feed speed until the stroke
end is reached, then rapid return. Changes in speed and direction are initiated by a
proximity switch.
With this experiment, the following knowledge is to be imparted:

a) Set-up of an electrical and hydraulic rapid advance circuit
b) Description of possible causes of malfunction
107
Example:
Application for a drilling machine in the machinery construction sector.
2.
Task
2.1
Hydraulic circuit:
Supplement the circuit illustrated below:

In the rest position of a relevant directional valve, the oil flow is to be directed to tank at
zero pressure. At the initial phase of the cylinder stroke, the cylinder is to extend in the
rapid advance mode and then change over to throttled feed. In the rapid advance mode,
the throttle check valve is bridged by means of a second directional valve.

Rapid advance/feed circuit
108
2.2
Electrical circuit:
Complete the following circuit diagram so that proximity switch B1 switches over from rapid
advance to throttled feed, and a second proximity switch B2 initiates the return stroke of
the cylinder.
In addition, it must be possible to stop the cylinder movement at any time by operating
push-button OFF S5. By operating push-button S7 the cylinder can be moved from any
position to its initial position. The system is started by means of push-button S6.

Rapid advance/feed circuit
109
3.

3.1
Hydraulic circuit:

1 4/2-way directional valve DW3E (A and T not connected)
1 Pressure gauge with distribution DZ1 or DZ4.X with DZ1.X and DZ25
1 Loading unit fIDW14
or AZ with loading unit
2 Cross pieces DZ4.X
Pressure hoses
3.2
Electrical circuit:
2 Proximity switches B1, B2

2 Push-buttons ON (normally open) S5, S6, S7 3 Relays K1, K2, K4
1 Relay K3
Wander leads
4.
Experiment set-up
4.1
Hydraulic circuit:
1. The isolator valve of the Hydroprax to your training rig is closed (only with Hydroprax
4).
3. Connect the individual components according to the circuit diagram via the pressure
hoses.
110
4.2
Electrical circuit:

2. Install the two proximity switches B1 and B2 into the cover.
possible mistakes.
5.

4).
the key clockwise.
Hydroprax 4).
rig is connected.
6.
Experiment:
a) Limit the system pressure to 30 bar by means of the pressure reducing valve; for this,
close isolator valve DZ2.X.
b) Once the pressure is set, open the DZ2.X and bring the throttle check valve into the
central position. Start the experiment by means of push-button ON S7. (When the
cylinder is again retracted, S5 must be pressed briefly in order to be able to start
again).
111
c) Start the experiment again and stop it using the push-button OFF S5.
d) Move the cylinder into the initial position by means of push-button ON S7.
e) Draw up a function chart for the process started by operating push-button ON S5.
f)
Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4).
g) Switch the power supply off.

Explanation re function chart:
The 4/2-way directional valve and the 4/3-way directional valve are switched by means of
push-button ON S7. This is a signal branch, which is represented by a point at the branch
point.
The cylinder only extends in the rapid advance mode, when the 4/2-way directional valve
and the 4/3-way directional valve are switched. This AND logic is illustrated with a bold
oblique at the point of linkage of the two signal lines.
7.
Evaluation:
112
Experiment 7:
1.
Pressure-dependent movement reversal
In this experiment, a cylinder is to extend upon the Operation of a push-button. The

retracting movement is to be controlled by a pressure switch. The latter switches a
directional valve as soon as a certain pressure value at the piston area is exceeded and
thus reverses the cylinder's direction of movement.
1. Set-up of an electrical and hydraulic circuit for pressure-dependent movement reversal
2. Function and operating principle of a pressure switch
2.
Task
2.1
Hydraulic circuit:
Supplement the circuit so that the cylinder retracts or extends when a directional valve is
accordingly controlled. The piston is to retract when a certain pressure is applied to the
piston area and the pressure switch interrupts the electrical circuit. This causes the
contactor to drop out, and the 4/2- way directional valve to shift. The circuit is to be set up
in a manner that the system pressure can be set and monitored via the pressure gauge. it
should be possible to regulate the extending velocity of the piston.

pressure-dependent movement reversal
113
2.2
Electrical circuit:
Complete the electrical circuit diagram so that the 4/2-way directional valve DW3E
switches when the push-button ON S5 is operated. This switching impulse is to be stored
by self-locking. If a certain pressure is reached at the piston area, pressure switch DD6E
("normally closed") must switch and the cylinder must retract. Install an additional pushbutton OFF (S9) into the circuit so that the extension movement of the cylinder can be
stopped at any time and the cylinder immediately returns to the initial position.
Figure 2
Circuit diagram (electrical circuit) Pressure-dependent movement reversal
Pressure-dependent movement reversal
114
3.

3.1
Hydraulic circuit:
1 4/2-way directional valve DW3E 1 Throttle DF1 .X

1 Pressure switch DD6E
1 Pressure gauge with distribution DZ1 or DZ4.X with DZ1.X and DZ25
1 Cross piece DZ4.X
1 Cylinder
Pressure hoses
Allan key size 10
3.2
Electrical circuit:

1 Push-button OFF (normally closed) S9 1 Relay K1
Wander leads
4.
Experiment set-up
4.1
Hydraulic circuit:

1. The isolator valve of the Hydroprax to your training rig is closed (only with Hydroprax 4).
hoses.
115
4.2
Electrical circuit:
Now set up the electric circuit by following the steps below:

possible mistakes.
5.

4).
5. Now switch the red circuit breaker of the Hydroprax to I.
the key clockwise.
Hydroprax 4).
rig is connected.
116
6.
Experiment:
Task I
a) Set the system pressure to 20 bar and open fine throttle DF1.X completely.
b) Set the switching point of pressure switch DD6E to 40 bar. The switching pressure can
be adjusted to the required value at the pressure switch using the Allen key.
c) Extend the cylinder by operating push-button S5. If the pressure switch does not
respond, retract the cylinder to its initial position by operating push-button OFF S9 .
d) Increase the system pressure in steps according to table 1 using pressure relief valve
DD1.X. Proceed as described under c). Enter in table 1 the switching condition of the
pressure switch and the cylinder Position after Operation of push-button ON S5.
Task II
a) Set the system pressure to 30 bar. The throttle remains fully open.
b) Extend the cylinder by operating push-button S5. The pressure switch must not switch
as it is set to 40 bar. The cylinder does not retract.
c) Slowly increase the system pressure by turning the pressure relief valve clockwise until
the pressure switch responds and the cylinder retracts. Thus, you determined the
switching point by increasing the pressure. The switching point should be slightly above
40 bar.
d) Now reduce the system pressure by 3 bar.
e) Set the throttle to position 0.5.
f)
Extend the cylinder and measure the extension time. If the pressure switch does not
respond, retract the cylinder by operating the push-button OFF S9.
g) Open the throttle in increments of half a scale unit and proceed as described under f).
h) Record the measuring results in table 2.
i)
Close the isolator valve an the Hydroprax to your training rig (only with Hydroprax 4).
j)
Switch the power supply off.
117
7.
Figure 3: Table 1
Figure 4: Table 2
118
Experiment 8:
1.
Pressure switches and proximity switches
In the preceding experiments you have become familiar with pressure switches and
proximity switches.
In this experiment, these two switching elements are to be used in one circuit. The
experiment is based an the application example of a deep drawing press which has to
operate at different pressures. First the press has to perform the material at a lower
pressure (prepressing pressure). After a certain forming distance, the system switches
over to a higher pressure (finishing pressing pressure). After finishing pressing is
completed, a pressure switch initiates the return stroke.

a) Set-up of a hydraulic and electrical circuit
b) Use of different switching elements in one circuit
2.
Task
2.1 Hydraulic circuit:
Supplement the circuit so that after a certain distance the cylinder is pressurized at a
higher pressure by a suitable valve. In our circuit the higher pressure is indicated by a
higher traversing speed of the cylinder. When the cylinder is completely extended, the
return stroke is to be initiated by a hydraulically operated switch.
119
Figure 1 Circuit diagram (hydraulic circuit)

4/2-way directional valve type DW3E (Y2) can be replaced by

4/3-way directional valve type DW4E (see page V8 7/2.1).

with 4/3-way directional valve DW4E)
120
2.2
Electrical circuit:
Supplement the electrical circuit and the connection plan so that the cylinder extends after
Operation of the push-button. When proximity switch al is reached, the 4/2-way directional
valve DW3E (Y2) or 4/3-way directional valve DW4E is to switch the system over to a
higher system pressure. When the cylinder is in its end position, pressure switch DD6E,
which is set to the higher pressure, switches and the cylinder retracts completely. Here, the
pressure switch is used as "normally open" contact.

121
3. Preparation of the experiment:

3.1
Hydraulic circuit:

1 4/2-way directional valve DW3E 4/3-way directional valve DW4E (Y2 detail not
connected)
2 Pressure relief valves DD1.X
2 Pressure gauges with distribution DZ1 or DZ4.X with DZ1.X and DZ25
1 Loading unit Wag PA/124E or AZ with loading unit
Pressure hoses
Allan key size 10
3.2
Electrical circuit:
1 Push-button ON S5
3 Relays K1, K2, K4
1 Proximity switch 1
Wander leads
122
4. Experiment set-up
4.1 Hydraulic circuit:
1. The isolator valve at the Hydroprax to your training rig is closed

(only with Hydroprax 4).
hoses.
4.2
Electrical circuit:

2. Install the two proximity switches B1 and B2 into the cover of the loading unit (lower
drilling).
possible mistakes.
123
5.

4. Make sure that all four EMERGENCY OFF
II> push-buttons on the Hydroprax are connected and disengaged and are available at
the training rigs (only with Hydroprax 4).
the key clockwise.
Hydroprax 4).
rig is connected.
124
6.
Experiment
a) Completely unscrew the pressure relief valve DD1.X (a) and then set the pressure
relief valve DD1.X (b) to 40 bar.
b) Adjust the switching pressure of the pressure switch to 40 bar using the Allan key.
c) Start the experiment by operating push-button ON S5.
d) Draw up the function chart for the motion sequence.
e) Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4).
f)
Explanation re-function chart:
The oblique in the function line of the 4/2-way directional valve indicates that the condition
marked by this line is the precondition for the introduction of further functions. In our
experiment, the cylinder can only extend at a higher velocity as long as the spool of the
4/2- way directional valve is in position "a".
With spool position "b" the cylinder retracts.
7.
Evaluation of the experiment
125
Experiment 9:
1.
Pressure-dependent sequence control
In this experiment, two cylinders are to extend one after the other in dependence upon
certain preconditions and then retract simultaneously. With a sequence control, the
subsequent working cycle or step is initiated by the termination of the preceding cycle. This
can either be dependent on position, pressure or time. Cylinder B may only start to extend
when cylinder A is completely extended or when the proximity switch at the end of the
stroke has been reached. Both cylinders are to retract together when cylinder B has
reached its end position and a certain pressure is applied to the piston side.

a) Set-up of a hydraulic and an electrical circuit
b) Pressure and position-dependent sequence control
Example: Fixture
The first cylinder feeds the work piece. The second cylinder clamps a work piece, e.g. a
gear. For safety reasons the piston rod of the clamping cylinder must retract when the set
clamping pressure is exceeded, e.g. when the work piece is incorrectly aligned.
126
2.
Task
2.1
Hydraulic circuit:
Supplement the circuit illustrated below. For cylinder A a 4/3-way directional valve and for
cyliner B a 4/2-way directional valve is to be used. Limit the system pressure and vary the
traversing speed of the cylinder using suitable valves.

127
2.2
Electrical circuit:
Supplement the electrical circuit so that cylinder A extends when push-button ON S5 is

operated. The proximity switch is to cause cylinder B to extend. When cylinder B reaches
its end position, pressure switch DD6E switches and both cylinders retract simultaneously.
Self-locking of relay K3 can be reset by operating push-button OFF S9.
In this experiment, the pressure switch is used as a "normally open" contact.

128
3.

3.1
Hydraulic circuit:
1 4/3-way directional valve DW4E 1

4/2-way directional valve DW3E
2 Throttle check valves DF2.X
2 Pressure gauges with distribution DZ1 or DZ4.X with DZ1.X and DZ25
1 Loading unit ifileDW12!) or AZ with loading unit
1 Cylinder
Pressure hoses
Allan key size 10
3.2
Electrical circuit:

1 Push-button OFF (normally closed) S9 1 Proximity switch B1
3 Relays K1, K2, K4
Wander leads
129
4. Experiment set-up
4.1
Hydraulic circuit:
4).
hoses.
4.2
Electrical circuit:

2. Install the two proximity switches B1 and B2 into the cover of the loading unit (upper
drilling).
possible mistakes.
5.

4).
130
the key clockwise.
Hydroprax 4).
rig is connected.
6.
Experiment
a) Limit the system pressure to 40 bar; for this, isolator valve DZ2.X must be closed. After
having set the pressure, re-open the Isolator valve.
b) Set the pressure switch to 30 bar using the Allan key.
c) Open both throttle check valves.
d) Start cylinder A by pressing the push-button ON S5.
e) Observe the pressure, at which pressure switch DD6E switches, on pressure gauge
DZ1.X.
f)
Complete the function chart.
g) If you want to repeat the experiment, first press push-button OFF S9 .

h) Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4).
i)
131
7.
Evaluation of the experiment
Figure 3 Function chart
132
Experiment 10:
1.
Feed control with time-dependent intermediate stop
In this experiment, the cylinder is to be extended by a push-button impulse. Along the

stroke of the cylinder, two proximity switches (B1, B2) are fitted, the first of which stops the
piston. The dwell time at this position is controlled by means of a time relay. When the
second proximity switch is reached, the cylinder's direction of stroke is reversed. The
cylinder returns to its initial position without an intermediate stop.
1. Set-up of a hydraulic and an electrical circuit comprising proximity switches and time re
lays
2. Function principle of a time relay
2
Task
2.1
Hydraulic circuit:
Work out a circuit with which the cylinder retracts or extends when a directional valve is
accordingly controlled. It should be possible to regulate the extension - speed and to adjust
the system pressure.
133

Time relay
134
2.2
Electrical circuit:
Supplement the electrical circuit so that the cylinder extends after the switch-on impulse
from the push-button ON S1 to the first proximity switch B1 and rests there for a certain,
adjustable time. This dwell time is set via the time relay K9T. Then, the cylinder moves
further to the second proximity switch B2. This causes the 4/3-way directional valve to shift,
and the cylinder retracts without intermediate stop.

Time relay
135
3. Preparation of the experiment:

3.1
Hydraulic circuit:
1 Pressure relief valve DD1 .X

1 Loading unit kt DW1 2) or AZ with loading unit
1 Pressure gauge DZ1 with distribution or DZ4.X with DZ1.X and DZ25 Pressure hoses
3.2
Electrical circuit:

1 Push-button OFF (normally closed) S2
2 Proximity switches B1, B2
3 Relays K1, K2, K3
1 Time relay K9T
Wander leads
136
4.
Experiment set-up
4.1
Hydraulic circuit:
4).
hoses.
4.2
Electrical circuit:

possible mistakes.
5.

2. Make sure that the flow control valve on the Hydroprax to the training stand is set to 5
4).
the key clockwise.
137
Hydroprax 4).
rig is connected.
6.
Experiment:
a) Limit the system pressure to 30 bar. For this, isolator valve DZ2.X must be closed.
Once the pressure is set, open the isolator valve.
b) Now set the dwell time of the cylinder at the time relay by turning the rotary knob to
position B (approx. 2 seconds switching time delay).
c) Extend the cylinder. The isolator valve DZ2.X is open.
d) When the cylinder is completely retracted, operate the reset push-button S2 (pushbutton OFF) in order to withdraw the self-locking function of relay K3.
e) Complete the function chart.
f)
Close the isolator valve on the Hydroprax to your training rig (only with Hydroprax 4).
g) Switch the power supply off.
138
7.
Figure 3 Function chart
139
Explanation re function chart:
The delay time of 2 s provided by the time relay is illustrated by means of the following
signal line.
140

EE060 Electro Hydraulic Controls TP Inst

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SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL EDUCATION

ELECTRICAL and ELECTRONIC

MCE Industrietechnik Linz GmbH & Co

Safety regulation ............................................................................................................5

Safety regulations Electrics ...................................................................................5

Safety regulations Hydraulics................................................................................7

Foreword to the trainer's manual ...................................................................................8

Basic principles of electro-hydraulics...........................................................................10

Electric current ................................................................................................10

Electric voltage ................................................................................................12

Electric resistance ...........................................................................................12

Electric power ..................................................................................................13

Basic circuits .......................................................................................................13

Series connection ............................................................................................13

Parallel connection ..........................................................................................14

Measuring of current I and voltage U ..................................................................16

Current measurement .....................................................................................16

Voltage measurement .....................................................................................16

Electro-hydraulic valves ..................................................................................18

Direct operated directional valves ...................................................................21

Pilot operated directional valves......................................................................23

Extending a cylinder by pressing a push-button..................................................24

Time and current characteristics .....................................................................26

Breaking procedure .........................................................................................27

Main circuit and control circuit .........................................................................29

Symbols of the most important switching elements.........................................31

Designation of contacts at contactor/relay.......................................................31

Electrical self-locking Suppression by means of a momentary-contact switch ...33

Signal storage .................................................................................................34

Momentary-contact limit switches .......................................................................39

Magnetic momentary-contact limit switches with reed contacts ......................40

Optical momentary-contact limit switches .......................................................40

Capacitive proximity switches .........................................................................41

Inductive proximity switches ............................................................................41

Example of connection of an inductive proximity switch..................................42

Momentary-contact/proximity limit switches ....................................................42

Parallel and series connection of proximity switches ......................................44

Pressure switches ...............................................................................................45

Mechanical locking by means of momentary contacts ........................................48

Electrical locking by means of contactor/relay contacts ......................................49

ON- and OFF-delay .....................................................................................51

Required electrical components ..................................................................................54

Required hydraulic components ..................................................................................55

Component plates ...............................................................................................56

Extension of a cylinder upon the Operation of a push-button..................79

Signal storage by electrical self-locking...................................................86

Mechanical locking by means of momentary-contact switch contacts ...91

Electrical locking by means of contactor contacts ...................................97

Signal storage by means of electrical self-locking Resetting by means of

Rapid advance circuit ...........................................................................107

Pressure-dependent movement reversal ..............................................113

Pressure switches and proximity switches ............................................119

Pressure-dependent sequence control.................................................126

Feed control with time-dependent intermediate stop.........................133

VDE 0105 part 1 describes:

VDE 0105 part 12 describes:

Unterrichtsrumen" (special regulations for experimenting with electrical energy in

Safety regulations Hydraulics

General guidelines for working with hydraulic systems

The electrics may only be serviced by a specialist !

Working with the training stand

Check all quick-release couplings for proper fit by pulling.

Hoses must not be excessively bent or curved (risk of bursting).

Foreword to the trainer's manual