Electro Pneumatics Sytems

33
Chapter 2 – Electro-pneumatics
Introduction:
Electro-pneumatics systems combine electric, electronic and pneumatic technologies.
Most of the industrial applications are operated by inexpensive and reliable electro-pneumatics
components and systems.
Pneumatic systems with no electric or electronic components are usually used in places where
electricity is forbidden, such as gas factories, fuel stations etc.
Electro-pneumatics components replace mainly the pneumatics components in the control field –
from control valves, limit switches and sensors to complex control systems.
The components can be defined by families:
1. Electro-pneumatics components such as valves.

2. Electric components such as relays, switches, limit switches and sensors.
3. Electronic components such as timers, AND gates, OR gates and PLC controllers.
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Experiment 2.1 – Controlling a Single Acting

Cylinder with a Solenoid/Spring Valve
Equipment Required:
 TPS-3810/B + PNE-381H
 PNE-381B – Single acting cylinder 80mm + flow control valve module
 PNE-381Z – 3/2 way solenoid valve, normally closed, spring return
 PNL-3810 – Electronic board including: 3 pushbuttons, 3 switches, 4 relays
 12V power supply
 Banana wires
 A compressor
 4mm flexible tubes
Discussion:
Some systems are electrically connected or operated. A pneumatic system or circuit can be operated
by pressing a pushbutton or getting an electric operating signal.
In this experiment, we will learn about some electro-pneumatic and electric components.
The first component we use is a N.C. (Normally Close) 3/2 single solenoid valve.
A R
P
Figure 2-1
This is a spring-return valve. The square with the diagonal line (next to the lever) indicates an
electric coil. Current flowing through this coil activates the valve, thus air flows from input P to
output A.
Figure 3-2 describes a circuit that includes a single acting cylinder operated by a 3/2 single solenoid
valve. The electric circuit described in figure 3-3 operates the valve.
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We usually design electro-pneumatic circuits in two stages:
a) Designing the pneumatic system.

b) Designing the electric system. The conventional way of planning an electric circuit in
the electro-pneumatic field is called a Ladder Diagram. This method enables us to plan
the circuit in a simple and organized way.
A+
SV+
Figure 2-2 Operating a Single Acting Cylinder with a Solenoid/Spring Valve
In figure 3-3 you can see a simple ladder diagram. This ladder diagram describes the operation of
the solenoid SV1 by the pushbutton switch PB1. Pressing PB1 closes the circuit and current flows
to the coil in the SV1 valve. The current causes the valve to change its state exactly as in a similar
valve operated by air.
- +
BP SV1
Figure 2-3 The Electric Circuit that Operates the Valve
The control circuit is built in the shape of branches which remind us of a ladder. This is why this
kind of electric circuit is called a ladder diagram.
The two perpendicular lines (on both sides of the diagram) indicate the voltage supply lines (the
positive and negative).
The valve's solenoid coil is called SV (Solenoid Valve). In figure 3-3, one of the coil's terminals is
connected to the positive line of the power supply and the other terminal is connected to the
negative line via a pushbutton switch.
The power supply's negative pole connects to the solenoid's coil and operates the valve when the
pushbutton is pressed.
The voltage supply lines can be replaced without affecting the system's behavior.
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Procedure:
Note:
Ensure that the valve in the air supply is closed, and that there is no pressure in the pipes.
Step 1: Install the electric component module PNL-3810 on the system's panel.
Step 2: Install the 80mm single acting cylinder module on the system's panel.
Step 3: Install the 3/2 single solenoid valve module.
Step 4: Check the 3/2 single solenoid valve and identify the air input (P) and the air output (A).
Also identify the air release gate (usually covered with a filtering net) and the banana
sockets for connecting the voltage to the coil.
Step 5: Implement the pneumatic system described in figure 3-2.
Step 6: Implement the electric system described in figure 3-3.

SV1
N.O.
COM
+
L1
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
L3 COM ON/OFF Switches
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
Relay K4 Pushbutton Switches
Step 7: Adjust the air pressure on the air supply regulator to 2 ATM.
Step 8: Connect the 12V power supply to the power inlet socket on PNL-3810.
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Step 9: Press the pushbutton.
The piston should pop out.
Step 10: Release the pushbutton.
The piston should pop back in.
Step 11: Replace the pushbutton with the S1 switch.
Step 12: Raise and lower the switch and observe the system's behavior.
Questions:
1. What operates the electric switch?
2. Give two examples were a pushbutton should be used.
3. Give two examples were a toggle switch should be used?
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Experiment 2.2 – Electric Conditioning Circuits

(OR, AND)
Equipment Required:
 TPS-3810/B + PNE-381H
 Banana wires
 A compressor
Discussion:
Control machines such as an electric paper cutting machine or an electric press and other machines
that perform dangerous actions sometime require safety control. To operate an electric paper cutting
machine a worker has to press two separate pushbuttons so his hands will not be near the cutting
place.
This condition for operating the machine (two pushbuttons are pressed) is called AND operation.
A+
SV+
Figure 2-4 Operating a Single Acting Cylinder with a Solenoid/Spring Valve
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- +
PB1 PB2 SV1
Figure 2-5 Electric Circuit Creating "AND" Conditioning
Only if PB1 and PB2 are pressed at the same time, SV1 will be activated.
Sometimes, a certain operation can be performed from two places or more. For example, operating
a system by pressing one pushbutton or another one.
This condition is called OR operation and its electric circuit is as follows:
- +
PB1 SV1
PB2
Figure 2-6 Electric Circuit Creating "OR" Conditioning
SV1 will be activated if PB1 or PB2 or both are pressed.
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Procedure:
Note:
SV1
N.O.
COM
+
L1
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
Step 8: Press the PB1 pushbutton.
Check the piston's behavior.
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Step 10: Press both pushbuttons.
Step 11: Release the pushbuttons.
SV1
N.O.
COM
+
L1
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
Step 15: Press both pushbuttons.
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Step 16: Release the pushbuttons.
Questions:
1. In the following two tables describe how the two electric circuits (OR and AND) are operated:
"OR" Circuit "AND" Circuit
Switch 1 Switch 2 Operate Switch 1 Switch 2 Operate

Yes/No Yes/No
Not pressed Not pressed Not pressed Not pressed
Not pressed Presses Not pressed Presses
Presses Not pressed Presses Not pressed
Presses Presses Presses Presses
2. If the input operational state (the manual valve) and the output operational state (the piston) is
defined a '1' and the not activated state is defined as '0', fill in the following AND function
truth table:
A B Y
0 0
0 1
1 0
1 1
3. If the input operational state (the manual valve) and the output operational state (the piston) is
defined a '1' and the not activated state is defined as '0', fill in the following OR function truth
table:
A B Y
0 0
0 1
1 0
1 1
4. Give two additional examples for using each circuit.
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Experiment 2.3 – Operating a Single Acting

Cylinder Using a Relay
Equipment Required:
 TPS-3810/B + PNE-381H
 Banana wires
 A compressor
Discussion:
Various consumers with different currents and voltages are needed to operate many electro-
pneumatic systems in the industry.
For example, a solenoid valve needs various voltages according to its size. A regular solenoid valve
needs a current above 2A, while a small solenoid valve need a current of 200mA-1A. This is why
we need components such as relays which can be operated with low currents and in turn can operate
a solenoid valve which is operated with high currents.
A+
SV+
Figure 2-7
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- +
PB1
R1
R1 SV1
N.O.
Figure 2-8
The relay is composed of an electromagnet (a coil with an iron core) and three contacts which
create two switches with a common contact. One switch is Normally Close (N.C.) and the second
one is Normally Open (N.O.). When current flows in the electromagnet coil, the switches change
their state.
R1
The symbol of the relay's coil is:
N.O.
The symbols of the connections are: a) Normally Open connection:
N.O.
b) Normally Close connection:
The relay's electric circuit is dismantled into two branches. The first branch includes the relay's coil
and the second branch includes the relay's switch.
The relay's coil R1 is connected (in its own circuit) to the pushbutton switch PB1.
The relay's coil R1 is used as a Normally Open (N.O.) switch which operates the solenoid valve's
coil SV1.
The connection between the two branches is because of the name R1 which appear on the relay's
coil and on the relay's switch. When the coil is operated, the switch is also operated.
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Procedure:
Note:
SV1
N.O.
COM
+
L1
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
The K1 relay should be activated and in turn operates the valve's coil. The valve should
flow air into the piston which pops out.
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The whole process will be inverted and the piston will pop in.
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Experiment 2.4 – Operating a Single Acting

Cylinder Using a Self-Holding Relay
Equipment Required:
 TPS-3810/B + PNE-381H
 Banana wires
 A compressor
Discussion:
We wish to operate the single acting cylinder (located in the following pneumatic system) using one
pushbutton without the need to press it all the time. The system's operation will stop by using
another pushbutton.
A+
SV+
Figure 2-9
We will use an electric circuit that operates a self-holding relay for a continuous operation of the
solenoid valve.
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- +
2 1
R1
R1
R1
SV1
R1
Figure 2-10
Pressing switch 1 for a short time operates the relay.
Operating the relay causes switch R1 (N.O. – Normally Open) to close and keep the relay operating
even after the pushbutton is released. Switch R1 also operates the solenoid valve's (SV1) coil. This
state is called "self-holding".
The function of switch 2 (N.C. – Normally Close) is to allow the relay to be released. Pressing
switch 2 stops the current from flowing into the relay, thus releases it and the piston.
There is no N.C. pushbutton in the electric circuit we have. We can implement this kind of
pushbutton using a N.O. pushbutton and a relay as described in the following electric diagram.
- +
PB1
R2
R1
R1
R1
SV1
R1
PB2
R2
Figure 2-11
R2
The symbol indicates the N.C. switch of relay R2.
Pressing pushbutton PB2 causes its N.C. switch to open and stop the current to relay R1.
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Procedure:
Note:

SV1
N.O.
COM
+
L1
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
The K1 relay should be activated and in turn operates the valve's coil. The valve should
flow air into the piston which pops out.
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No change occurs in the system and the piston stays out.
The K2 relay should be activated and in turn opens the branch of relay K1, which in
turn stops the current to the valve, which causes the piston to pop in.
Step 11: Press switches 1 and 2 simultaneously and observe the results.
Step 12: Release switches 1 and 2 simultaneously and observe the results.
Questions:
1. Why the control circuit is called a self-holding circuit?
2. Why pressing switches 1 and 2 simultaneously causes the system to not be operate?
3. Does the self-holding circuit represent a memory unit?
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Experiment 2.5 – Operating a Double Acting

Cylinder Using a Solenoid Valve
Equipment Required:
 TPS-3810/B + PNE-381H
 PNE-381A – Double acting cylinder 100mm + flow control valves module
 PNE-381Y – 5/2 way double solenoid valve
 Banana wires
 A compressor
Discussion:
The following system operates the double acting cylinder using a 5/2 double solenoid valve.
A+ A-
+ -
SV+ SV-
Figure 2-12
The double valve includes two non-return electric control inputs (SV+ and SV–). Moving from one
state to another is done by an electric signal given to the control inputs. Sending an electric signal to
a control input causes the valve to change its state and to not return to its previous state even if the
voltage at the input is stopped.
A state change occurs when an electric signal is send to another input.
Each electric input has two terminals connected to the solenoid's coil.
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The piston is activated using the following electric circuit:
- +
PB1 SV+
PB2 SV-
Figure 2-13
Pressing pushbutton PB1 operates the valve which in turn operates A+ and pops the piston out.
Pressing pushbutton PB2 operates the valve which in turn operates A– and pops the piston in.
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Procedure:
Note:
Step 2: Install the 100mm double acting cylinder module on the system's panel.
Step 3: Install the 5/2 double solenoid valve module.
SV-
N.O.
COM
+
L1
SV+
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
The valve coil SV+ should be activated and in turn flows air to A+, thus the piston pops
out.
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The valve coil SV– should be activated and in turn flows air to A–, thus the piston pops
in.
Step 11: Press switches 1 and 2 simultaneously and observe the results.
Step 12: Release switches 1 and 2 simultaneously and observe the results.
Step 13: Press pushbutton PB1 and release it, and while the piston pops out press pushbutton
PB2.
Observe the system's behavior.
Step 14: While the piston moves, press both pushbuttons and observe the system's behavior.
Questions:
1. What will happen if the pushbutton is pressed for a long time?
2. What will happen if the pushbutton is pressed for a short time?
3. What will happen if both pushbuttons are pressed simultaneously?
4. What will happen if one pushbutton is pressed and released, and while the piston moves the
other pushbutton is pressed?
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Experiment 2.6 – Operating a Double Acting

Cylinder Using Limit Switches
Equipment Required:
 TPS-3810/B + PNE-381H
 PNE-381A – Double acting cylinder 100mm + flow control valves module
 PNE-381X – Two limit switch module
 PNE-381Y – 5/2 way double solenoid valve
 Banana wires
 A compressor
Discussion:
We enhance the previous system so it will operate a double action cylinder using electric limit
switches.
A+ A-
MS1 MS2
+ -
SV+ SV-
Figure 2-14 A Double Acting Cylinder Operated Electrically
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First we operate the system using two pushbuttons (as in the previous experiment) with one
difference – we add a main switch (S1). When switch S1 is open, PB2 can cause the piston to pop
in; however, PB1 cannot pop the piston out until switch S1 is closed.
- +
S1 PB1 SV2+
PB2 SV2-
Figure 2-15 Operating a Solenoid Valve Using Pushbuttons
We can replace pushbuttons PB1 and PB2 with limit switches. The limit switches are pressed
alternately every time the piston reaches the end of its course. When switch S1 is closed, the system
operates automatically.
- +
S1 MS1 SV2+
MS2 SV2-
Figure 2-16 Operating a Solenoid Valve Using Limit Switches
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Procedure:
Note:
Step 2: Install the 100mm double acting cylinder module on the system's panel.
Step 3: Install the 5/2 double solenoid valve module.

SV-
N.O.
COM
+
L1
SV+
N.C. -
Relay K1
N.O.
L2 COM
N.C.
Relay K2
N.O. S1 S2 S3
N.C.
Relay K3
N.O.
L4 COM
PB1 PB2 PB3
N.C.
Step 8: Activate switch S1.
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Step 9 Press the PB1 pushbutton.
The valve coil SV+ should be activated and in turn flows air to A+, thus the piston pops
out.
The valve coil SV– should be activated and in turn flows air to A–, thus the piston pops
in.
Step 12: Press pushbutton PB1 and release it, and while the piston pops out press pushbutton
PB2.
Observe the system's behavior.
Step 13: While the piston moves, press both pushbuttons and observe the system's behavior.
Step 14: While the piston is out, open switch S1.
Does this operation affect the system?
Step 15: While switch S1 is open, press pushbutton PB2.
Does the piston pop in?
Step 16: While switch S1 is open, press pushbutton PB1.
Does the piston pop out?
Step 17: Disconnect the wires from the pushbutton and connect them to the limit switches as
described in figure 3-16.
Step 18: How does the system behave when switch S1 is open?
Step 19: How does the system behave when switch S1 is close?
Step 20: Exchange the wires connected to the limit switch.
How does the system behave now?
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Questions:
1. Does switch S1 affect the operation of pushbutton PB1?
2. Does switch S1 affect the operation of pushbutton PB2?
3. How does the system behave when the limit switch are connected instead of the pushbuttons
according to the state of S1?
4. If we change the wires operating SV+ and SV–, how it will affect the system's operation?
5. If we exchange the wires connected to the limit switches, how it will affect the system's
operation?
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33

The components can be defined by families:

1. Electro-pneumatics components such as valves.

Experiment 2.1 – Controlling a Single Acting

We usually design electro-pneumatic circuits in two stages:

a) Designing the pneumatic system.

Figure 2-2 Operating a Single Acting Cylinder with a Solenoid/Spring Valve

Figure 2-3 The Electric Circuit that Operates the Valve

Step 3: Install the 3/2 single solenoid valve module.

Step 5: Implement the pneumatic system described in figure 3-2.

Step 6: Implement the electric system described in figure 3-3.

Step 9: Press the pushbutton.

The piston should pop out.

Step 10: Release the pushbutton.

The piston should pop back in.

Step 11: Replace the pushbutton with the S1 switch.

2. Give two examples were a pushbutton should be used.

3. Give two examples were a toggle switch should be used?

Experiment 2.2 – Electric Conditioning Circuits

Figure 2-4 Operating a Single Acting Cylinder with a Solenoid/Spring Valve

PB1 PB2 SV1

Figure 2-5 Electric Circuit Creating "AND" Conditioning

This condition is called OR operation and its electric circuit is as follows:

Figure 2-6 Electric Circuit Creating "OR" Conditioning

SV1 will be activated if PB1 or PB2 or both are pressed.

Step 3: Install the 3/2 single solenoid valve module.

Step 4: Implement the pneumatic system described in figure 3-4.

Step 5: Implement the electric system described in figure 3-5.

Step 8: Press the PB1 pushbutton.

Check the piston's behavior.

Step 9: Press the PB2 pushbutton.

Check the piston's behavior.

Step 10: Press both pushbuttons.

Check the piston's behavior.

Step 11: Release the pushbuttons.

Check the piston's behavior.

Step 12: Implement the electric system described in figure 3-6.

Step 13: Press the PB1 pushbutton.

Check the piston's behavior.

Step 14: Press the PB2 pushbutton.

Check the piston's behavior.

Step 15: Press both pushbuttons.

Check the piston's behavior.

Step 16: Release the pushbuttons.

Check the piston's behavior.

"OR" Circuit "AND" Circuit

Switch 1 Switch 2 Operate Switch 1 Switch 2 Operate

4. Give two additional examples for using each circuit.

Experiment 2.3 – Operating a Single Acting

Step 3: Install the 3/2 single solenoid valve module.

Step 4: Implement the pneumatic system described in figure 3-7.

Step 5: Implement the electric system described in figure 3-8.

Step 8: Press the PB1 pushbutton.

Step 9: Release the pushbutton.

Experiment 2.4 – Operating a Single Acting

Pressing switch 1 for a short time operates the relay.

Step 3: Install the 3/2 single solenoid valve module.

Step 4: Implement the pneumatic system described in figure 3-9.

Step 5: Implement the electric system described in figure 3-11.

Step 8: Press the PB1 pushbutton.

Step 9: Release the pushbutton.

No change occurs in the system and the piston stays out.

Step 10: Press the PB2 pushbutton.

3. Does the self-holding circuit represent a memory unit?