Chapter 6

Introduction to Electro-pneumatic
Introduction to Electro Pneumatics
Electro-Pneumatics
Definition :
 Electro-pneumatic term is defined from the words of
electro which means electrical and pneumatic which
means pressurized air.
 The electro-pneumatics equipments and system is an
integration of electrical and mechanical components
with compressed air source.
 Electro pneumatic is a pneumatic control system where
air pressure and direction of valve are controlled by an
electrical current.
Introduction to Electro Pneumatics
Other Definition of Electro-Pneumatics
Pneumatics is a method to transfer energy from one point to
another using actuators which are driven by fluids under
pressure (definition of pneumatic).
Pneumatics restricts itself to gaseous fluids while hydraulics
uses liquids to transfer the energy.
Pressure of the pneumatic system can be controlled by
 manually opening a valve,
 automatically by detecting its pressure,
 sending an electrical signal.
The control of pneumatic components by electrical
impulses (electrical signal) is known as electro-pneumatics.
Introduction to Electro Pneumatics
Signal flow and component of an pneumatic control
system
Introduction to Electro Pneumatics
Signal flow and component of an Electro-Pneumatic
control system
Introduction to Electro Pneumatics
Pneumatic power section

Solenoid actuated Directional control valves form

the interface between the signal control section
(electrical) and the pneumatic power section in an
Electro-pneumatic system.
Introduction to Electro Pneumatics
Electrical signal control section

Solenoid valve
Introduction to Electro Pneumatics
Advantages of using Electro-Pneumatics
1. Lesser wear-off parts. Lesser installation jobs.
i.e., Electrical control valve, Electrical switches
2. Replace tube in pneumatic system to electrical wire in
electro-pneumatic
3. Less parts are used  Reduce working space.
4. Sensor and Controller (such as PLC) can be included in
the system
E-260

Electrical signal
input (switch
panel)
Push Button
 Basic Electrical Device
Seven basic electrical devices commonly used in the control of
fluid power systems are
1. Manually actuated push button switches
2. Mechanical Position Sensor (Limit switches)
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

Other devices used in electro pneumatics are

1.Proximity sensors
2.Reed switch
2. Electric counters
(A) Push Button Switch
Push buttons are of two types
i) Momentary push button (return to unactuated position when release)
ii) Maintained contact or detent push button (has a latching mechanism to
hold it in the selected position)
Push Button Switch
Example :
Normally Open (N.O) and Normally Close (N.C)
In pneumatic circuit :
For example : 3/2-way Push button (valve)

Normally Open Normally Close

In electrical circuit :
For example : Push button switch

Normally Open Normally Close

(B)Mechanical Position sensor (limit
switch)(Pneumatic)
3/2-way N.C valve with roller (Limit switch)

(Electro-Pneumatic)
Mechanical Position sensor (Limit switch)
 Limit Switch
Any switch that is actuated due to the position of a fluid power
component (usually a piston rod or hydraulic motor shaft or the position
of load) is termed as limit switch.

There are two types classification of Limit switches depending upon

method of actuations of contacts
a) Lever actuated contacts
b) Spring loaded contacts

In lever type limit switches, the contacts are operated slowly. In spring type
limit switches, the contacts are operated rapidly.
(C) Proximity sensor
 Proximity sensor contain a transistor which conducts and
switches (trigger ON) when something comes near to the
sensors.
 Some of the proximity sensor only work with steel
material components － Inductive proximity sensor
Proximity sensor – Symbol and Sample Circuit

Proximity Sensor

Question :

1. Name the switch type used for START and STOP button.
2. What is the different between A1 and A2 in Electrical circuit?
(D) Processing element - Relay
 Relay is an electrically actuated switch, contains a coil and a
contactor switch or multiples contactors.
 When power is applied to relay coil, the core magnetizes,
drawing the contact assembly in.
 This will change the state of all the contacts in the relay (i.e.,
N.O contact becomes closed or N.C contact becomes open).
 Relay uses small amount of power to control switching
(advantage). The voltage applied to the coil doesn’t have to be
the same as that in control circuit.
 Relay is used to allow low voltage control systems to switch
large current/ high voltage
 Sample circuit
Contactor
E-140

Coil

When Toggle switch 1S3 is pressed, power is supplied to Relay

(K1) coil which result to the all contactors in relay change their
state (open  close or close  open). Solenoid valve 1Y1
activate to ON
N.O and N.C wire / cable connection

Normally Close (N.C)

Example : Pin 21  22
Normally Open (N.O)
Example : Pin 41  44
Animation (Relay OFF)

Source : UniKL Electro-Pneumatic Lecture Note, 2008

Animation (Relay ON)
More about Relays

 Relay has a few functions as a safety device:

1. The high voltage output (i.e. 240V) can be switched ON
through a contactor using relay with low voltage (i.e.
24V) supplied to a coil.
2. The high current output can be switched ON through a
contactor using relay with low current supplied to a coil.
3. Functioned as Safety control circuit for emergency
power cut-off (EMERGENCY START and STOP button)
to the whole circuit.

Use in automation process  Switching more than one

outputs simultaneously using relay with a coil and multiple
contactors.
To control ON and OFF of various outputs sequences using
several Relay.
(E) Solenoid DCV
 Solenoid valve is an electro-mechanical device that built-in
with a coil (solenoid) and a pneumatic Directional control
valve.
 Directional control valve (DCV) solenoid operated use
electrical signals to control pneumatic valves.
 They are used to start, to stop and/or to change the
direction of air flow.
 There are 2 types operated of directional control valve
using solenoid:
1. Directly operated valve
2. Pilot operated valve
1. Directly operated valve
Flow is releases to the consuming device via armature of the solenoid. In order to
obtain a sufficient cross section of opening, a comparably large armature is required.
This consequently requires a powerful return spring and the solenoid to generate a
high force. It is therefore of a large design with high power consumption.

2. Pilot operated valve

The valve piston is moved via an air duct from pressure port 1. This only requires a
Low flow so that a comparatively small armature with minimal actuating force can
be used. A minimum supply pressure is required in order to actuate the piston
against the spring force. Solenoid can be configured in a small design and the
power consumption and heat emission is thus reduced.
3/2 DCV single solenoid operated with spring
return

The cross sectional view of 3/2 way single solenoid valve in the normal
and actuated positions are shown in Figure. In the normal position, port 1
is blocked and port 2 is connected to port 3 via back slot (details shown in
the circle) When the rated voltage is applied to coil, armature is pulled
towards the centre of the coil and in the process the armatures is lifted
away from the valve seat. The compressed air now flows from port 1 to
port 2, and ports 3 is blocked. When the voltage to the coil is removed, the
valve returns to the normal position.
5/2 DCV single pilot operated single solenoid
with spring return
The cross section view of 5/2 way single solenoid in the normal and
actuated positions are shown in Figure. In normal position, port 1 is
connected to port 2, port 4 is connected to port 5, and port 3 is blocked.
When the rated voltage is applied to coil 14, the valve is actuated
through an internal pilot valve. In actuated position, port 1 is connected
to port 4 , port 2 is connected to port 3, and port 5 is blocked. The valve
returns to the normal position when the voltage to the armature coil is
removed.
 5/2 DCV double pilot operated double
solenoid

The cross section view of 5/2 way double solenoid in the normal and
actuated positions are shown in the Figure when the rated voltage is applied
to coil 14, the valve is actuated to a one switch in position with port 1
connected to port 4, port 2 connected to port 3, and port 5 blocked. When the
rated voltage is applied to the coil 12, the valve is actuated to the other
switching position with port 1 connected to port 2, port 4 connected to port 5
and port 3 blocked.
The symbols for the various solenoid/pilot actuated valves
are given in below

3/2 DCV single solenoid with manual

override with spring return

3/2 DCV single pilot operated single

solenoid with manual override with spring
return

5/2 DCV single solenoid with single manual

override with spring return

5/2 DCV double solenoid with double

manual override with spring return

5/2 DCV double pilot operated double

solenoid with double manual override
Solenoid DCV
5/2-DCV double pilot operated
double solenoid

5/2-DCV Single pilot operated

single solenoid with spring
return

3/2-DCV Single pilot operated

single solenoid with spring
return
Sample circuit

Pneumatic Power Component --- cylinder

Final Control element --- Solenoid valve

Symbol in Electrical circuit

Solenoid

When Pushbutton switch (SW1) is pressed, power is applied to

Solenoid S1 which then change the electrical signal to pneumatic
signal and allow air flow to cylinder A (single acting with spring
return) for rod to extend.
Sample Circuit connection

Red cable is a connection

from 24V line.
Blue cable is a connection to
GND (0 V).
Supply / Power component
In Electro-Pneumatic system, the supply or power
source component is divided into two, based on the
system component.
1. Pneumatic － Compressor
2. Electrical － AC / DC power supply
Symbol for 24V DC
IEC Standard JIC Standard
Direct control in electro-pneumatics
Direct control is the control of an electro-pneumatic valve without using
intermediate components such as a relay, a contactor or an industrial computer
(PLC). The valve is connected directly to electric switch as shown in Fig. below

Advantages of direct control

•Simple and easy
•Less wiring
•Cheap.

Disadvantages of direct control

•Remote control is not possible
•Switching more than one valve at a time is
not possible
•Latching is not possible
•Design improvement is not flexible.
Indirect control in electro pneumatics
Indirect control is the control of an electro-pneumatic valve using intermediate
components such as relays, contactors or programmable logic controllers (PLC).

Advantages of indirect control systems

•Remote control is possible
•Switching more than one valve at a time is possible
•Latching is possible.
•Flexible design improvement and development.
•Incorporating logic operating conditions (OR, AND conditions)

Disadvantages of direct control

•Complicated
•More wiring
•More cost involved
Direct Control of Single Acting Cylinder

Forward stroke: The circuit is closed

when push button PB closes. A magnetic
field is produced in the coil Y. The
armature in the coil opens the passage for
the compressed air. The compressed air
flows from 1 to 2 of the 3/2 DCV to
cylinder, which travels to the final forward
position.

Return stroke: When the push button PB is released, the circuit is interrupted.
The magnetic field at coil Y collapses, the 3/2 way valve switches back to its
original position as shown in Figure 1.27. The compressed air in the cylinder then
exhausts through port 3 of the DCV and the cylinder travel to the final rear
position.
Indirect Control of single acting cylinder
Forward stroke: The circuit is closed
when push button PB closes. Closing
of Push button PB energises a relay
K1. The coil Y is energised via
normally open contact K1 (indirect
energising).
A magnetic field is produced in
armature of the coil Y opens the
passage for the compressed air. The
compressed air flows from 1 to 2 of the
3/2 DCV to cylinder, which travels to
the final forward position.

Return stroke: When the push button PB is released, the circuit is interrupted.
Opening of Push button PB de-energises a relay K1. The magnetic field at coil Y
is collapses due to the opening of contact K1 the 3/2 way valve switches back to
its original position as shown in Figure. The compressed air in the cylinder then
exhausts through port 3 of the DCV and the cylinder travel to the final rear
position.
Direct Control of Double Acting Cylinder

Forward stroke: The double acting

cylinder is controlled by 5/2 way valve.
When the pushbutton PB is pressed, coil Y
is energised and the directional control
valve is activated by compressed air via
pilot control. The piston travels to the final
forward position.

Return stroke: When the push button PB is released, the circuit is interrupted. The
magnetic field at coil Y collapses, the return spring of 5/2 becomes active and the
5/2 way valve switches back to its original position as shown in Figure 1.29. The
compressed air in the cylinder then exhausts through port 5 of the 5/2 DCV and the
cylinder travel to the final rear position.
Indirect Control of double acting cylinder
(using 5/2 way, single solenoid)

Forward stroke: The circuit is closed

when push button PB closes. Closing of
Push button PB energises a relay K1.
The coil Y is energised via normally
open contact K1 (indirect energising).
A magnetic field is produced in
armature of the coil Y opens the
passage for the compressed air through
internal pilot. The compressed air flows
from 1 to 4 of the 5/2 DCV to cylinder,
which travels to the final forward
position.
Return stroke: When the push button PB is released, the circuit is interrupted.
Opening of Push button PB de-energises a relay K1. The magnetic field at coil
Y is collapses due to the opening of contact K1 the 5/2 way valve switches back
to its original position as shown in Figure 1.30. The compressed air in the
cylinder then exhausts through port 5 of the DCV and the cylinder travel to the
final rear position.
Indirect Control of double acting cylinder (using 5/2 way, double
solenoid)

Forward stroke: when push button

PB1 is pressed, coil Y1 is energised
and 5/2 way directional control valve
changes over. The piston travels out
and remains in the final forward
position until a signal is applied to coil
Y2. The 5/2 directional control valve
will remain in the last position because
it is double solenoid valve and has no
return spring.

Return stroke: When the push button PB1 is released and PB2 is pressed. Opening
of Push button PB1 de-energises a relay K1. The magnetic field at coil Y1 is
collapses due to the opening of contact K1. Closing of PB2 energises Y2 and the
piston returns to its original position as a result of changeover of the 5/2 way valve.
The 5/2 way directional control valve will not switch over if there is an active
opposing signal. For example, if Y1 is switched on and a signal is given to Y2, there
will be no reaction as there would be an opposing signal
 Control of Double Acting Cylinder OR Logic (Parallel Circuit)

The piston of a double acting cylinder is to travel out when either one of two
pushbutton switch is pressed. It is to return when both are released. When push
button PB1 or PB2 are pressed. Coil Y1 is energised. The directional control valve
switches over and the piston travels to the final forward position. When both the
push button switches are released, the signal is removed from Y1 and the cylinder
travels back to its original position.
 Control of Double Acting Cylinder AND Logic

The piston of a double acting cylinder is to travel out when either one of
two pushbutton switch is pressed. It is to return when both are released.
When push button PB1 or PB2 are pressed. Coil Y1 is energised. The
directional control valve switches over and the piston travels to the final
forward position. When both the push button switches are released, the
signal is removed from Y1 and the cylinder travels back to its original
Latching circuits
Definition of latching: It is a process where the relay contacts
remain on without keeping the relay coil energized. In other
words, it is required somethings to keep the circuit powered for
a certain function even though a pushbutton switch is released
to the open position
 Latching Circuit with Dominant OFF

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the
circuit goes to OFF position/relay coil is not energised , then such a circuit is called
Dominant OFF latching circuit. Refer to Figure ,
a) When we press START push button PB1 is pressed and released , following
operations occurs:
1. Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes
2. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel to
PB1. This NO contact of K1 latches the start push button. Therefore even if the PB1 is
released, NO contact of K1 in branch 2 keeps coil K1 energised.
3. There is another NO contact in branch 3, which is connected to Y1. When push
button PB1 is pressed this also remain closed, as a result cylinder moves forward and
remains there until stop button PB2 is pressed.
b) When we press STOP push button PB2 is pressed momentarily and released ,
following operations occurs:
1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens
2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open. This
NO contact of K1 no more latches the start push button.
3. NO contact in branch 3 is also open now, which is de-energises. As a result cylinder
moves back to its home position and remains there until start button PB1 is pressed
again.
Latching Circuit with Dominant OFF
 Latching Circuit with Dominant ON

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the
circuit goes to ON position/relay coil is energised , then such a circuit is called
Dominant ON latching circuit. Refer to Figure,
a) When we press START push button PB1 is pressed and released , following
operations occurs:
1.Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes
2. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel to
PB1 and in series with PB2. This NO contact of K1 latches the start push button.
Therefore even if the PB1 is released, NO contact of K1 in branch 2 keeps coil K1
energised.
3. There is another NO contact in branch 3, which is connected to Y1. When push
button PB1 is pressed this also remain closed, as a result cylinder moves forward and
remains there until stop button PB2 is pressed.
b) When we press STOP push button PB2 is pressed momentarily and released ,
following operations occurs:
1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens
2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open.
This NO contact of K1 no more latches the start push button.
3. NO contact in branch 3 is also open now, which is de-energises. As a result
cylinder moves back to its home position and remains in home position until start
button PB1 is pressed again.
Latching Circuit with Dominant ON
Direct Control of Automatic Return of a Double Acting Cylinder
Indirect Control of Automatic Return of a Double Acting Cylinder
( double solenoid)
Oscillating motion of a double acting cylinder (Forward )
Oscillating motion of a double acting cylinder (Return )