Making Things Dojo Textbook

ものづくり教科書 Company
members only

Electric Sequence (Elementary Version)

Mitsubishi Motors Corporation

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 Revision history
Prepared on April 1, 2008
Prepared by S. Ozaki, Dojo Master
(Mizushima)
Dojo Name Maintenance Dojo
Rev. No. Rev. Date Reason for Revision/Revised Contents Revised by Dojo Name Rev. Page
Rev. 1 Month/day/year
Rev. 2 Month/day/year
Rev. 3 Month/day/year
Rev. 4 Month/day/year
Rev. 5 Month/day/year
Rev. 6 Month/day/year
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Rev. 8 Month/day/year
Rev. 9 Month/day/year
Rev. 10 Month/day/year
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Rev. 12 Month/day/year
Rev. 13 Month/day/year
Rev. 14 Month/day/year

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 Making Things Dojo Training Schedule
Training Name Sequencer Circuit Total of Training Time 16.0H
1. Training item Contents of Training Required time
1 Basic knowledge of relay circuits 0.5H
2 Crimping terminal and terminal connection 0.5H
3 Major electric devices 0.5H
4 Practice of combining electric circuits 13.0H
5 How to use circuit testers (measurement of resistance, DC/AC voltage)
6 How to use low-tension voltage detector
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2. Training 1) Dojo Textbooks and Training Materials
method
2) MY4 relay, 3 sockets, 3 push-buttons, 1 plug, This textbook

1) Place 2 indicators, 1 timer, 1 socket,

2) Training 1 keep relay, 1 socket,
materials
3) Method Others (slight materials for wiring installation, crimping
nippers)
3) Consider, create, and practice combining circuits
3. Method for
judging the
completion of 1 According to questions, Create circuits that fulfill conditions
training (What 2 Create circuits to function according to questions, To actually practice combining circuits
and how to be
achieved) 3

4. Job of Judging Job and Job Name Required time

judging the
completion of 1 Create, combine, and check function of circuits according to questions 1.5H
training 2

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 Basic knowledge of relay circuits
Purpose

1. Currently, sequencers have been majorly used, but it is

impossible to understand the function of equipments
unless the wiring connection of the hardware circuits are
understood.
Therefore, design the basic hardware circuits (contact
circuits), and then practice combining the circuits.

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 Basic knowledge of relay circuits
Safety
1. There is always a danger of electrical shock during the
electric work. Never touch the live part.
2. If the common wires are short-circuited due to defectively
created circuits and excessive current is supplied, cables
will be burnt, which may cause burn injury.
Be sure to always wear safety gloves.
3. Be sure to conduct the power-on/off operation of NFB in
the front with a hand opposite to your heart.
4. If you should find any operator who receives electrical
shock, firstly cut off NFB to keep the operator away from
the source of electrical shock.
Never hastily touch the operator with bare hands.
5. Make emergency contact to rescue the operator’s life
when necessary.
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 Basic knowledge of relay circuits
What are Contact “a” and Contact “b”?
Circuit diagram
Mark tube: Distinct numbers have been
given on respective cables to avoid
a
doubling of numbers. This tube is
attached to cable, those numbers
being stamped.

Contact “a” is a point of contact which allows the electricity to be supplied because the
continuity is possible when relays, push-buttons, etc. are activated. (To understand contact
“a” and contact “b” by checking the continuity, referring to how to use circuit testers)
Contact “b” is a point of contact which allows no electricity to be supplied, providing no
continuity when activated, which is an opposite function to the above
Symbol marks of relay contacts
Symbols shown at right are typical
Contact “a”:
relay symbols. Be careful that
Contact “b”: these are different respectively in
other devices (push-buttons, timer
contact,
6
etc.).
 Basic knowledge of relay circuits
Matching of electric circuits and actual objects
Check for actual objects in the electric circuit shown below.
Circuit diagram

PB1 PB2 CR1

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 Crimping terminal and terminal connection
When installing electric circuits, conduct wiring installation with crimping
terminal connected to cables.
Let’s briefly practice on how to crimp.
Explanation of crimping terminal types

R-type round YAS-type Ring sleeve

terminal
Mainly used for power lines.
Having the advantage that it
is not be easily taken off
due to the loosened
tightening screw, but cannot
be replaced unless screws
are completely removed
when replacing devices.
Y-shaped terminal (large/medium/
small)
Used for normal connection of Used when connecting many cables
terminals.
Having the advantage that
cables can be taken off only by
loosening screws.
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 Crimping terminal and terminal connection

Practice on how to crimp

① Use the ② Fit the slit of

position crimping terminal
corresponding to the convex side
to the cable size

③ Too much space ⑤ Good

example 
between covering
 Bad
and crimping
example
④ Too much ③ ④
coming-out of
bare wire
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 Crimping terminal and terminal connection
Cautionary points on terminal connection

① Never connect more than three

cables to one terminal.
Reason: Tend to be easily loosened
because it is not completely
tightened
② Never nip the mark tube
when connecting
Reason: Cause faulty contact

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 Major electric devices

Explanation of relay
Currently, less frequently used
because a miniature relay is
Point of substituted.
contact
Replace with the same spec.
ones (in case of replacement)
because there are various types
according to contact
arrangement, coil voltage, etc.
Coil connection
terminal e.g.: ４ a AC100V
Electric symbols Coil voltage
Coil Four contacts “a”
Contact “a”: e.g.: 3a1 ｂ AC100V
Contact “b”: CR Three contacts “a”
One contact “b”
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 Major electric devices

Explanation of magnet relay

Used for OFF-OFF operation of
Point of electric motor’s power circuits.
contact The type of magnet relay differs
according to the magnitude of
electric motor’s load current.
Contact arrangement: 3a, 1a1b,
etc.
Coil connection Since the worn condition at the
Electric symbol terminal point of contact has been
Coil periodically inspected, the ones
having the abnormally worn
Contact “a”:
point of contact are replaced or
Contact “b”: MG
only the point of contact is
replaced according to types.
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 Major electric devices

Explanation of miniature relay

Contact arrangement has been stamped on this surface.
Select according to where to be used
because there are contacts for minute
electric current, etc.

Since the contact arrangement has

been stamped on the surface of
socket, be sure to connect without fail.
Also be careful to replace this relay
because it has various coil voltages.
Electric symbol Insert this portion into the socket
Coil Since the numbers have been given on
Contact “a”: the wiring connection area of the
socket, be sure to check the number
Contact “b”: CR and the number of the above-
mentioned contact arrangement to be
13 connected
 Major electric devices

Explanation of keep relay

Contact arrangement has been stamped on this surface.

Easily replaced because it is used with

plugged into the socket.
The production of this type is
currently ceased, but shown here to
learn about the latch function.
Check how the set/reset changeover
contact is activated.
Insert this portion into the socket.
Electric symbol Coil Since the numbers have been given on
the wiring connection area of the socket,
be sure to check the number and the
Contact “a”: KR
number of the above-mentioned contact
Contact “b”: arrangement to be connected.

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 Major electric devices

Explanation of timer
Using this dial, the Contact arrangement has been stamped on this surface.
set values of timer
can be changed.
Easily replaced because it is used
with plugged into the socket.
Since there are various types
according to coil voltage, timer
setting-possible range, etc., record
the setting of actual product, etc. to
replace the same product.
Never change the set values of
Electric symbol timer when the coil power supply is
Coil ON. (to prevent wrong operation)
Contact “a”:
TR
Contact “b”:
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 Major electric devices

Explanation of detector (limit SW)

Mainly used for checking the

operations of conveyor, jig, etc.
It is necessary to inspect (and then
replace) the lever because it is
worn.
Besides the standard type, there
Lever are special ones such as spatter-
resistant type, high-sensitive type,
Electric symbol etc.

Contact “a”:
Take off the lid to check the internal
mechanism when the lever is
Contact “b”: ON/OFF.

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 Major electric devices

Explanation of detector (proximity SW)

Used for various places because it

is free from any mechanical wear
by detecting in noncontact, not
detecting in the work’s contact with
the detector.
Not only iron but glass, etc. can be
detected.
Use the ones corresponding to the
Electric symbol
proper detecting conditions
because there are the ones that
have various detecting distances.
Using this symbol, Mizushima Engineering
Section has given PX*** as names of the d
evices, but be careful that there are other v
arious symbols.
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 Major electric devices
Explanation of detector (photoelectric SW)
Electric symbol
Using this symbol, Mizushima Engineering
Section has given PH*** as names of the de
vices, but be careful that there are other var
ious symbols.
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Used in pairs of photoemitter and pho
toreceiver, if any object that blocks th
e photo exists in the space between t
hose, this detector detects and its out
put turns ON or OFF according to its
setting.
There are various types according to
the set distance of photoemitter/photo
receiver or the size of object possible
to be detected.
In addition, there are also any ones n
ot having photoreceiver and allowing i
nstallation of reflector (mirror), whose
name is reflector type, etc.
 Major electric devices

Explanation of push-button SW

SW operated by an operator to turn

on the controlled power supply or
move any object.
There are selective push-button
type, illuminating-lamp button type,
etc.
Check how the contact is activated
when the actual push-button is
pushed.

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 Combining electric circuits
Explanation of electric circuits and
practice of combining circuits
Measure the voltage
Combining electric circuits applied to the coil,
Check for AC100V referring to the page on
existence or how to use a circuit
otherwise of tester.
charging,
referring to
the page on PB ON 1
how to use
a low-
tension Explanation of function
detector.
1) If the PB ON is pushed, the electric current is supplied in the arrow direction
shown as ①, and then a voltage of AC100 is applied to CR1 coil to turn on CR-1.
2) If the PB ON is released, the electric current is no longer supplied to turn off CR1.

Then, after the change of circuits, check if the circuits have been short-circuited
to turn on the power supply, referring to the page on how to use a circuit tester.
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 Combining electric circuits
Explanation of self-holding circuits’ function
and practice of combining circuits
AC100V
Self-holding circuit

PB ON 1

Explanation of function 2
1) If the PB ON is pushed, the electric current is supplied in the arrow direction
shown as ① to turn on CR-1.
2) Then, if the PB ON is released, the electric current is supplied in the arrow
direction as ② to continue turning on CR1.
3) To turn off CR1, push the PB OFF.
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 Combining electric circuits

Explanation of interlocking circuits’ (relays’) function

and practice of combining circuits

If the PB1 is pushed, CR1 turns on. In such situation,

CR2 does not turn on even if the PB2 is pushed (turns
on).
Reason: The electric current is not supplied at the point
of contact “b” of CR1.
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 Combining electric circuits

Explanation of interlocking circuits’ (buttons’) function

and practice of combining circuits

On the previous page, you have learned the interlocking function of the
relays’ contact, also in case of the push-button PB1 and PB2, the
circuit that will not turn on the other while the one is being pushed is
called “interlocking circuit”, having been incorporated into circuits at
various places.
In addition, there are various methods for circuit description.
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 Combining electric circuits
Select necessary parts from circuits, combine and
check function ①

Based on this circuit diagram, collect necessary parts and

combine circuits. Then, if the PB1 turns on, CR1 turns on.
Then, if the PB2 is pushed, CR2 turns on.
After then, consider how the PB1 & 2 are pushed will turn
off both of CR1 &2.
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 Combining electric circuits
Select necessary parts from circuits, combine and
check function ②

Red lamp (“R” of RED is indicated inside the circle)

As with the previous page, a timer (TR2) exists in this circuit.

Actually combine circuits to check how this circuit functions.
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 Combining electric circuits

Explanation of timer’s function

PB1
TR1
10 sec.
10 sec.
9.9 sec.
Time chart

PB1 ON

TR1 Coil ON
Will not turn on.
TR1 Contact “a” Reason:
The setting is 10 sec.,
but the time for the coil
TR1 Contact “b”
voltage ON is only 9.9
26 sec.
 Combining electric circuits

Select necessary parts from circuits, combine and

check function ③

ＴＲ１

As with the previous page, a timer (TR1) exists in this circuit.

Actually combine circuits to check how this circuit functions.

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 Combining electric circuits
Select necessary parts from circuits, combine and
check function ④

As with the previous page, a timer (KR1) exists in this circuit.

Actually combine circuits to check how this circuit functions.

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 Combining electric circuits

Explanation of keep relays’ function

Set coil

Reset coil

Time chart Once the PB1 turns

on, there will be no
PB1 ON change in ON/OFF
condition of contact
until the PB2 turns
PB2 ON on.

Contact “a” * As it keeps the

condition, it is
often called “keep
relay” or “latch
Contact “b” relay”.

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 Combining electric circuits
According to questions, consider circuits to be combined ①

1) Create the circuits in which the lamp turns on when any one of PB1, PB2, and PB3 turns on.
2) Create the circuits in which the lamp turns on only while all of PB1, PB2, and PB3 are
pushed simultaneously.
3) Create the circuits in which the lamp turns on only while any one of PB1, PB2, and PB3 is
pushed. The lamp will not turn on when any two of those are pushed.
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 Combining electric circuits

Consider circuits ①

Q1: Create the circuits in which the cylinder returns in 10 seconds

after the cylinder forwards and then the forward motion
limitation LS1 turns on when the PB1 turns on.
Forward

Cylinder
LS1

For reference circuits, see the next page.

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 Combining electric circuits

Consider circuits ① - 1

Complete the circuits so as to function as specified in the

previous page.
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 Combining electric circuits
Verify the functions of actual product
and electric circuits (1)

Forward

Backward motion
limitation
Forward motion
limitation

Forward

If the PB1 is pushed while the cylinder is at the backward motion limitation, the SOL1
turns on, and then the cylinder moves in the forward direction and the LS2 turns on at
the forward motion limitation. Therefore, referring to the circuits and mechanical
diagram, read out that the forward command is terminated and then the cylinder returns.
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 Combining electric circuits
Verify the functions of actual product
and electric circuits (1)
Forward

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 How to use a circuit tester ①
Outside view Name and applications
<1> Name
- Pointer
- Pointer zero-point adjusting screw
- Zero Ω adjusting VR
- Change SW for measuring range,
etc.
- Test pin joint area

<2> Applications
- Measurement of low-tension voltage
- Know the target values for
resistance, etc.

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 How to use a circuit tester ②
How to measure resistances Order of measurement
①Set a range SW to the value
covering a resistance you wish to
measure.
② Short-circuit the red and black test

pins.
③ Set the indication to 0 with Zero
Ω adjusting VR.
④ Put the test pins to the lead wire
of resistance.
⑤ Read the value where the pointer
indicates.
⑥ Read the scale as a range SW is
magnified by 100.
⑦ As the pointer indicates the value
of “2”, it means 200Ω.
Note: Be sure to carry out the item
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 How to use a circuit tester ③
How to measure DC voltage Order of measurement
① Check the zero indication of
DCV: Direct-current voltage
pointer. (If failed, set to 0 by
ACV: Alternating-current voltage turning an adjusting screw.)
② In this case of measuring the
battery (DC 1.5V), set the select
SW to DC10V. (In case of unclear

voltage, temporarily measure with

the maximum voltage select to

set the select SW to the proper
Never measure the voltage in the value.)
resistance range. ③ Read the value where the pointer
* Or, the circuit tester will be burnt. indicates. (The value in a column
where the value selected in ②
has been stamped as a maximum
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 How to use a circuit tester ④
Order of measurement
How to measure AC voltage
①Check the zero indication of pointer.
(If failed, set to 0 by turning an
adjusting bolt.)
② Set the select SW to 1000V.
Putting the test pins to the portion
to be measured, read the
approximate voltage and then select

the range to the measuring voltage

greater than the value by about
20%.
③ Put the test pins to the portion to be
measured.
Never measure the voltage in the ④ Read the value of the range
resistance range. selected.

* Or, the circuit tester will be burnt. Note: To read the measuring value
by 75% of full scale, not
deflecting out the pointer in ②.
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 How to use a detector

Outside view Name and applications

① Name
- Contact portion
- Neon lamp

② Applications
Check by the neon lamp ON
condition if the electric circuit has
There are some detectors that been charged or not.
contact this portion to the covering
of cables.

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 How to use a detector
Sketch of measurement
How to use
① Hold the opposite side to the end
of the detector body with a hand.
② Put the end of the detector to the
charging portion.
③ If the neon lamp comes on, the
portion where the end of the
detector is put has been charged.
Never touch directly with hands.

Note: Practice so that you may judge

Use a high-tension
voltage detector for high
voltage (3300V).
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the light emission of 100V,
200V, 400V, or induction
phenomenon, depending on
the degree of the neon lamp’s
luminance.
 Revision history
Reason for Revision/Revised Contents Approved Reviewed Prepared
Rev. No. Rev. Date by by by

Ver 1.0 Established Ozaki

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