UNIVERSITY OF NAIROBI

DEPARTMENT OF ELECTRICAL AND INFORMATION

ENGINEERING

CONTROL LAB MANUAL

ELECTROPNEUMATIC INSTALLATION

April, 2018
Contents
1 OBJECTIVES.................................................................................................................................... 3
2 PREPARATORY QUESTIONS ON ELECTRO-PNEUMATIC CONTROL ................................. 4
3 GENERAL CONSIDERATIONS ..................................................................................................... 6
3.1 INTRODUCTION ..................................................................................................................... 6
3.2 ELECTRIC DIAGRAMS .......................................................................................................... 7
3.3 ELECTROPNEUMATIC DIAGRAMS .................................................................................... 9
4 ELEMENTARY LOGIC FUNCTIONS USING FUNCTIONAL ELECTRIC DIAGRAMS ....... 10
5 TECHNIQUES OF ELECTROPNEUMATIC CONTROL ............................................................ 14
5.1 Control of a cylinder through monostable solenoid valve ....................................................... 14
5.2 Control of a cylinder through bistable solenoid valve ............................................................. 16
5.3 Control of a cylinder through monostable solenoid valve and self-holding circuit ................. 18
5.4 Bistable solenoid valve with Pulse Relay ................................................................................ 20
5.5 Permanent binary counter for circuits with monostable solenoid valve .................................. 20
5.6 Control for sliding door ............................................................................................................ 22
5.7 Semi-automatic control of a double-acting cylinder with monostable solenoid valve ............ 23
5.8 Semi-automatic control of a double-acting cylinder with bistable solenoid valve .................. 23
5.9 Control of a cylinder with monostable solenoid valve and excitation-delayed timer .............. 25

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1 OBJECTIVES

1. To understand the basic principles of pneumatics and electro-pneumatic control.

2. To understand the advantages and limitations of pneumatic control systems
3. Learn how to interpret and connect simple circuits used in electro-pneumatic control and describe
how the circuits achieve the control.
a. Understand the various circuit components: identify actuators, push buttons, different types
of valves and relays, and associate these with their function in the circuits.
b. Implement elementary logic functions using functional electric diagrams
4. To understand the constructional and functional differences between the monostable solenoid and
the bistable solenoid.
5. To understand the principles and operation of directional control valves

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2 PREPARATORY QUESTIONS ON ELECTRO-PNEUMATIC CONTROL

Read the document “Pneumatic Systems” as well as other material and answer the following questions.
NB: you are expected to come with written answers to the lab as part of your preparation

1. List six advantages of using pneumatic systems.

2. State the limitations of using pneumatic systems.

3. What are the components that regulate the pressure?

4. State the difference(s) between a single acting cylinder and a double acting cylinder.

5. State the functions and classification of directional control valves.

6. What are the basic functions of a pneumatic control system?

7. Draw the following symbols of the pneumatic components:

Type Symbol Type Symbol

(a) Compressor (h) Manual control

valve

(b) Cylinder (i) Push button

control valve

(c) Filter (j) Vertical piston

lever control
valve
(d) Single acting cylinder (k) Pulley lever
control valve

(e) Double acting cylinder (l) Non-return valve

(f) 3/2 directional control (m) Flow control

valve valve

(g) 5/2 directional control

valve

8. Draw a signal inversion circuit.

9. Draw a pneumatic circuit with memory function.

10. Draw a pneumatic circuit of a double cylinder with its piston staying at the end of the cylinder.
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5
3 GENERAL CONSIDERATIONS

3.1 INTRODUCTION

Most of the power pneumatic circuits used industrially, utilizes electricity as

energy source to control the circuits. These circuits are called
electropneumatic.

The educational aids described in this handbook permit the study of and the
experimentation on power and sequential electropneumatic circuits used
industrially.

LIST OF MODULAR PANELS FOR ELECTROPNEUMATIC INSTALLATIONS

item Object
AZ-10 Panel-type fuse holder 6x30 - 6.3 A
AZ-15 Single-phase transformer 72 VA - 220/12-24 V
AZ-42 Delay timer - motor 24 V-50 Hz
AZ-43 Auxiliary relay for industrial use
coil 24 V-50 Hz
AZ-44 Push-buttons for industrial use
AZ-80 Pneumatic power supply
AZ-81 Double-acting cylinder with electric limit-switches
AZ-82 5/2 monostable solenoid valves – 24 V-50 Hz
AZ-83 5/2 bistable solenoid valve – 24 V-50 Hz
AZ-84 Pulse relay (single-pole two-way switch)
coil 24 V – 50 Hz

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3.2 ELECTRIC DIAGRAMS

The electric diagrams present in this handbook are recommended by C.E.I.

(Italian Electrotechnic Commettee). The relevant symbology is here below
listed.
a) Codes
Normally-open contact NA
Normally-closed contact NC
Start push-button PM
Stop push-button ALT
Pulse-control push-button PJ
Limit-switch FC
Auxiliary-contact relay XYZ
Pulse-control relay J
First timer relay 1T
Second timer relay 2T
Codes are written at the right hand or under the element. b)

Electric symbology

Conductor

Flexible conductor

Conductor cross without electric connection

Conductor electrically connected

Relay coil (general symbology).

Coil of excitation-delayed timer

Lamp

Coil of solenoid valve

Coil of drop-out-delayed timer.

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c) Control elements

Contact with push-button control, open at rest position,

spring return.

Contact with push-button control, closed at

rest position, spring return.

Double contact with push-button

control. Both contacts open at rest position, spring
return.

Double contact with push-button

control. Both contacts closed at rest position, spring
return.

Auxiliary contact, open at rest position. Generai

symbology.

Auxiliary contact, closed at rest position. General

symbology.

Switch (general symbology).

SPDT switch.

Limit-switch contact, closed at rest position.

Limit-switch contact, open at rest

position.

Closed auxiliary contact, excitation delayed

(a), drop-out delayed (b).

Open auxiliary contact, excitation delayed

(a), drop-out delayed (b).

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Electric diagrams are always supplied with “functional patterns” and, when possible, “assembly patterns”
of the power electric plate. The main standards for the construction of functional diagrams are:
• horizontal lines up and down represent the power supply common to the
different circuits;
• each vertical line (with the relevant devices) is a circuit;
• elements belonging to the same device have the same code thus pointing
out the operating simultaneity.

3.3 ELECTROPNEUMATIC DIAGRAMS

Pneumatic diagrams are divided into two circuits: the power circuit and the
control circuit.
In the case of electropneumatic diagrams, the power pneumatic circuit is
separated from power electric circuit.
The connection between the two circuits is given by the symbol representing
the control of the main directional control valve.

Electropneumatic directional
control valve 5/2 (electric controls
by solenoid valves, one winding).

Electric control by solenoid valve,

to be inserted in the functional
electric diagram.

This symbol is represented with the letter corresponding to the cylinder (A, B,
C...) or the sign “+“ or “-’ according to the fact that the electric control drives
the main directional control valve making its piston move out or retract.

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4 ELEMENTARY LOGIC FUNCTIONS USING FUNCTIONAL ELECTRIC DIAGRAMS

i. Identity function (YES) U=A

Functional equation

A U
0 0
1 1
Truth table

Electric diagram

ii. Inversion function (NOT) U = A’

Functional equation

A U

0 1

1 0
Electric diagram Truth table

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iii. Addition function (inclusive-OR) U=A+B
Functional equation

A B U

0 0 0

0 1 1

1 0 1
Electric diagram
1 1 1
Truth table

iv. Exclusive-OR
U=A⊕B
Functional equation

A B U
0 0 0
0 1 1
1 0 1
1 1 0
Electric diagram Truth table

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 v. Product function (AND) U=A·B
Functional equation

A B U
0 0 0
0 1 0
1 0 0
1 1 1
Electric diagram Truth table

vi. Inhibition function

A B U
0 0 0
0 1 0
1 0 1
1 1 0
Truth table

Electric diagram

U=A·B
Functional equation

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vii. Examples of logic equations

Electric diagrams

(A+B)·C=U (A+B)·C·D=U

Functional equations
5 TECHNIQUES OF ELECTROPNEUMATIC CONTROL

5.1 Control of a cylinder through monostable solenoid valve

Figure 5.1 shows the diagram of the power pneumatic circuit and the functional diagram of the power
electric circuit concerning the control of a cylinder through monostable solenoid valve.
Note that the directional control valve has combined control by solenoid and pilot directional valve.

Pressing push-button PM, solenoid valve A+ excites. Being this the solenoid valve which controls the
directional control valve, it causes its switching and the piston moves out.
Now, releasing the push-button, the solenoid valve de-energizes, the spring repositions the main
directional control valve and the piston retracts.
Figure 5.2 shows the assembly diagram built up with the modules concerning the functional diagram of
Figure 5.1.

Figure 5.1 Control of a cylinder through monostable solenoid valve

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Figure 5.2

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5.2 Control of a cylinder through bistable solenoid valve

Figure 5.3 shows the power pneumatic circuit and the control electric circuit of this electropneumatic
control.
Pressing the first push-button (1PM) even shortly (bistable solenoid valve), the solenoid valve A+ excites
and the cylinder moves out.

Pressing the second push-button (2PM), even shortly, the solenoid valve A- excites and the cylinder
retracts. What happens whether the two push-buttons are pressed at the same time?

Figure 5.4 shows the assembly diagram of the pattern of Figure 5.3.

Figure 5.3 Control of a cylinder through bistable solenoid valve

When controlling a cylinder through monostable solenoid valve, self-holding circuit is often used (see
Figure 5.5). In fact, to keep the monostable directional control valve switched, it is necessary to have
always the switching signal.
Referring to Figure 5.5 parallel connected to the magnet X, there is the solenoid valve A+ of the
directional control valve.

Acting on the push-button A, magnets X and A+ excite and the piston moves out.
When releasing A, the piston keeps its position, since both A+ and X are excited by the self-holding
produced by the contact 1X belonging to the magnet X.

Now, acting on push-button B, current flow stops, both magnets de-energize, the contact 1X opens and
the piston retracts.

Q2.2a. What happens if both push-buttons are activated at the same time?

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Figure 5.4

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5.3 Control of a cylinder through monostable solenoid valve and self-holding circuit

Figure 5.5 shows the “self-holding circuit”: fundamental circuit in the use of relays.

Figure 5.5 Self-holding circuit

As it should be noted from the figure, the magnet X can be excited acting on the normally-open contact
A. Parallel connected to contact A, there is the normally-open contact of the magnet X (coded with 1X).
This contact, due to the pickup of the magnet, closes and remains closed even when contact A is released.

In fact, in the new position, current flows with continuity and passing through the contact 1X keeps the
magnet excited. This magnet, at its turn, keeps the contact X closed. So, to obtain the initial condition, it
is necessary to break (even shortly) the continuous flux of current. This can be done acting on the
normally-closed push-button B.

Figure 5.7 shows the assembly diagram of the circuit of Figure 5.6.

Figure 5.6 Control of a cylinder through monostable solenoid valve and self-holding circuit

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Figure 5.7

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5.4 Bistable solenoid valve with Pulse Relay

Figure 5.8 shows a pulse relay (module AZ 84) controlling a bistable solenoid valve.

In this electric circuit, memory is called “permanent” since, with lack of current, the coil of relay J de-
energizes but does not cause the switching of the relevant exchange contact.

Of course, with lack of current, the cylinder keeps its last position. Figure 5.9 shows the assembly
diagram of the circuit of Figure 5.8.

N.B. Before testing, identify the normally-closed contact AZ 84 (relay J).

Figure 5.8 Permanent binary counter for circuits with bistable solenoid valve

Questions:
Q2.4: Press the push-button five times at intervals of say 3 seconds. Describe the observed behaviour
of the cylinder and explain how the circuit effects that operation

5.5 Permanent binary counter for circuits with monostable solenoid valve

Questions:

Q2.5a. Draw and implement a simple circuit (using a monostable solenoid valve) which effects the
same behaviour as in the previous section (Section 5.4) when the push-button is pressed five times at
intervals of 3 seconds.

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Figure 5.9

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5.6 Control for sliding door

Figure 5.10 shows an application of the previous exercises. It is the electric circuit for a sliding door.

The door must be controlled from two different positions, that is, by two control push-buttons.

Q2.6a. Describe the behaviour of the piston as observed when the two push-buttons are pressed in turn.
Explain how the circuit effects the observed behaviour.

Q2.6b. What happens when each of the buttons is pressed for a long time (long activation) e.g. for 5
seconds?

Q2.6c. This circuit implements a failsafe property which constitutes a safety condition that is common
in many applications. Explain what the failsafe property is in this situation.
Hint: what happens to the monostable solenoid valve when the supply is disconnected abruptly?

Figure 5.10 Control for sliding door

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5.7 Semi-automatic control of a double-acting cylinder with monostable solenoid valve

Figure 5.11 shows the electropneumatic circuit for the semi-automatic control of a double-acting cylinder
through monostable solenoid valve.

Figure 5.12 shows the assembly diagram of Figure 5.11.

Q2.7a. Describe the behaviour of the piston as observed when the push-button is pressed once (short
activation). Explain how the circuit effects the observed behaviour.

Q2.7b. What happens when the push-button is pressed for a long time (5 seconds)?

Q2.7c. With a lack of current what happens to the monostable solenoid valve regardless of its position?

Figure 5.11 Semi-automatic control of a double-acting cylinder with monostable solenoid valve

5.8 Semi-automatic control of a double-acting cylinder with bistable solenoid valve

Q2.8a. Design and implement a simple circuit to effect the same operation of the piston as in the previous
exercise but using a bistable solenoid valve instead of a monostable solenoid valve.

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Figure 5.12

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5.9 Control of a cylinder with monostable solenoid valve and excitation-delayed timer

Figure 5.13 shows the control electric diagram for the semi-automatic movement of a double-acting
cylinder power supplied by a monostable solenoid valve. Particularly, the semi-automatic control
potentiometer can be regulated to give on excitation delay (in this case).

Implement the circuit.

Q2.9a. Describe the operation observed when push-button PM is activated and explain how the circuit
effects the observed operation.

Figure 5.13 Control of a cylinder with monostable solenoid valve and excitation-delayed timer

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