Exercise 2-3

Basic Electrically-Controlled Hydraulic System

EXERCISE OBJECTIVE

• To describe the function and operation of a magnetic proximity switch;

• To describe the purpose of a holding relay contact;
• To assemble and test a one-cycle reciprocation system.

DISCUSSION

Reciprocation of cylinders

Many industrial applications require that a hydraulic cylinder be extended and

retracted automatically after an operator presses a START pushbutton. This is
called reciprocation of a cylinder, and an electrical control circuit can be used to
perform this sequence. While the cylinder provides the muscles, or power, to do
work, the electrical control circuit provides fast and accurate control of a directional
valve to reciprocate the cylinder.

Reciprocation involves a change in the direction of the cylinder. Automatic reversal

is achieved by using the electrical signal provided by a sensing device, such as
a magnetic proximity switch, mechanical limit switch, or photoelectric switch, to shift
the directional valve when the cylinder becomes fully extended or retracted.

One-cycle reciprocation system

As an example, Figure 2-16 shows a ladder diagram providing one-cycle

reciprocation of a hydraulic cylinder. One-cycle reciprocation means that when
started by an operator, the cylinder rod extends fully, automatically retracts without
attention of the operator, and stops, which makes a complete cycle.

Automatic retraction is achieved with a solenoid-operated directional valve

activated by a magnetic proximity switch, PX1, placed at the end of the extension
stroke. The switch contact is normally closed (N.C.) in the deactivated condition.

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Basic Electrically-Controlled Hydraulic System

START
(+) PB1 PX1, N.C. (-)

1 CR1
P
HOLD T
CR1-A
RETRACTED
SOL-A

CR1-B SOL-A
2
L1 PX1 (DEACTIVATED)

a) Initially, the cylinder rod is retracted.

(+) PX1 (-)

PB1

1 CR1
P
T
CR1-A SOL-A
EXTENDS

CR1-B SOL-A
2
L1 PX1 (DEACTIVATED)

b) Pressing a pushbutton starts cylinder extension.

(+) PB1 PX1 (-)

1 CR1
P
T
CR1-A SOL-A
EXTENDS

CR1-B SOL-A
2
L1 PX1 (DEACTIVATED)

c) The cylinder continues to extend after the pushbutton is released.

(+) PB1 PX1 (-)

1 CR1
P
T
CR1-A
RETRACTS
SOL-A

CR1-B SOL-A
2
L1 PX1 (ACTIVATED)

d) Retraction is automatic when the rod activates a magnetic proximity switch.

Figure 2-16. One-cycle reciprocation of a cylinder.

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Basic Electrically-Controlled Hydraulic System

a. In the normal condition of the system, the cylinder rod is retracted, as illustrated
in Figure 2-16 a). Relay coil CR1 is deactivated because an open circuit
condition exists on ladder rung 1 by the open condition of N.O. contacts PB1
and CR1-A. Therefore, directional valve solenoid SOL-A is de-energized and
the valve is in the crossed-arrows condition.

b. When pushbutton PB1 is pressed, as illustrated in Figure 2-16 b), the current
flows from the + terminal of the power supply, through contacts PB1 and PX1
in rung 1, to energize relay coil CR1. This closes relay contacts CR1-A and
CR1-B. Contact CR1-B in rung 2 causes solenoid SOL-A and lamp L1 to
energize. This causes the directional valve to shift to the straight-arrows position
and extend the cylinder rod. Contact CR1-A in rung 1 provides another path in
parallel with contact PB1 for the current to flow to relay coil CR1, and is called
a holding, or seal-in contact.

c. When pushbutton PB1 is released, as illustrated in Figure 2-16 c), the current
continues to flow to relay coil CR1 through the alternate path provided by
holding contact CR1-A being closed. Therefore, solenoid SOL-A stays energized
and the cylinder rod continues to extend to full stroke.

d. When the cylinder rod becomes fully extended, magnetic proximity switch LS1
is activated by the magnetic piston inside the cylinder. This is illustrated in
Figure 2-16 d). This opens N.C. contact PX1 in rung 1, de-energizing relay
coil CR1. This causes relay contact CR1-B in rung 2 to open, de-energizing
solenoid SOL-A and lamp L1. This causes the directional valve to return to the
crossed-arrows condition and retract the cylinder. When the cylinder rod is fully
retracted, it stops and waits for the operator to start another cycle.

Magnetic proximity switches

In the circuit described above, automatic reversal of the cylinder is achieved by

using the electrical signal provided by a magnetic proximity switch to shift a
directional valve when the cylinder rod becomes fully extended. Magnetic proximity
switches are widely used in industrial hydraulic systems to sense the position of a
cylinder piston. They can be easily and quickly mounted anywhere within the piston
travel range.

Your Hydraulics Trainer comes with two magnetic proximity switches of the Reed
type. As Figure 2-17 shows, each switch consists of two mechanical reeds (contact
points) that open and close by touching and separating, and of an internal relay coil
controlling a set of N.O. and N.C. contacts of the single-pole, double-throw
(SPDT) type. The + and  terminals on top of the switch are to be connected to a
24-V dc power supply. The three other terminals provide access to the SPDT
contacts.

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Basic Electrically-Controlled Hydraulic System

REED
CONTACTS COIL
OPEN DEENERGIZED
+

CR

N.O.
CONTACTS
COM DEACTIVATED
HYDRAULIC DIAGRAM SYMBOL
N.C.

REED
N.O. TERMINAL
CONTACTS COIL
CLOSED ENERGIZED COMMON TERMINAL
+ N.C. TERMINAL

CR
LADDER DIAGRAM SYMBOL

MAGNETIC N.O.
PISTON CONTACTS
COM ACTIVATED
N.C.

Figure 2-17. Magnetic proximity switch of the Reed type with SPDT contacts.

When the magnetic piston of a cylinder comes within proximity of the switch, the
magnetic field pulls the switch reeds together, allowing the current to flow from the
+ terminal of the switch to energize the internal relay coil. This causes the switch
SPDT contacts to activate. The N.O. contact goes closed while the N.C. contact
goes open.

When the magnetic piston moves away from the switch, the switch reeds separate
again, de-energizing the relay coil. This causes the switch contacts to return to their
normal, deactivated state.

Procedure summary

In this exercise, you will assemble and test the one-cycle reciprocation system
described in the DISCUSSION section of the exercise.

– In the first part of the exercise, you will clamp the 3.8-cm (1.5-in) bore cylinder
to the work surface and mount a magnetic proximity switch at the end of its
extension stroke. Then you will assemble the circuit.

– In the second part of the exercise, you will verify that the electrical control circuit
operates properly. The purpose of this verification is to isolate problems such as
wiring errors in a systematic, controlled manner before turning on the hydraulic
power unit. Verification of the electrical control circuit is particularly important

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Basic Electrically-Controlled Hydraulic System

when working on electrically-controlled hydraulic systems because the functions

being performed by this circuit may not be readily apparent to the operator, and
unpredictable cylinder motion may occur at anytime.

– In the third part of the exercise, you will test system operation.

EQUIPMENT REQUIRED

Refer to the Equipment Utilization Chart, in Appendix A of this manual, to obtain the
list of equipment required to perform this exercise.

PROCEDURE

Setting up the system

* 1. Get the 3.8-cm (1.5-in) bore cylinder from your storage location. Clamp the
cylinder to the work surface. Connect the two ports of the cylinder to the
power unit return line port through a manifold.

* 2. Get a magnetic proximity switch from your storage location. Mount the
switch on the 3.8-cm (1.5-in) bore cylinder so that the switch is activated
when the cylinder rod is fully extended. To so do, perform the following
steps:

– Manually retract the cylinder rod completely.

– Loosen the set screw on the magnetic switch until the clamp is loose
enough to slip over the cylinder tie rod. Position the switch at the rod
end of the cylinder, then tighten the set screw.

– Connect the circuit shown in Figure 2-18. Notice that the magnetic
switch, PX1, is to be wired normally open. Also, notice that the switch
+ and  terminals are to be connected to the corresponding terminals
of the 24-V dc power supply.

– Turn on the 24-V dc power supply. Pilot lamp L1 should be off,

indicating that the magnetic switch is deactivated.

– Manually extend the cylinder rod completely. Pilot lamp L1 should now
be on, indicating that the magnetic switch is activated. If L1 is off,
loosen the set screw on the switch and reposition the switch until L1
turns on. Then, tighten the set screw.

– When you have finished, retract the cylinder rod completely. Turn off
the 24-V dc power supply.

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Basic Electrically-Controlled Hydraulic System

TO POWER UNIT
RETURN LINE PORT

MAGNETIC PROXIMITY
SWITCH MOUNTED AT
THE ROD END OF THE
CYLINDER

3.8 cm (1.5-in)
(+) (-) BORE CYLINDER

L1 24-V dc
PX1, N.O. POWER SUPPLY

1 +

PILOT
LAMPS

LADDER DIAGRAM CONNECTION DIAGRAM

LEGEND: HYDRAULIC HOSE

ELECTRICAL LEAD

Figure 2-18. Mounting a magnetic proximity switch at the rod end of the 3.8-cm (1.5-in) bore
cylinder.

* 3. Disconnect and store all hoses and electrical leads.

* 4. Connect the one-cycle reciprocation system shown in Figure 2-19. As you

do this, be careful not to modify the mounting of the cylinder and magnetic
switch (PX1). Notice that PX1 is now to be wired normally closed. The +
and  terminals of this switch are to be connected to the corresponding
terminals of the 24-V dc power supply.

Note: The directional valve solenoid is not polarized, which

means that it does not matter which solenoid terminal is
connected to relay contact CR1-B and which solenoid terminal is
connected to the  terminal of the 24-V dc power supply. Either
way, the solenoid will still energize and shift the valve spool.

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GAUGE A

SUPPLY

START EXTENDED
(+) PB1 PX1, N.C. (-)

1 CR1

HOLD P 3.81-cm (1.5-in)

CR1-A P A BORE CYLINDER

T B

CR1-B SOL-A RETURN T

2
SOL-A
L1

PX1

ELECTRICAL SECTION HYDRAULIC SECTION

a) Schematic diagram

PX1

b) Connection diagram
LEGEND: HYDRAULIC HOSE

ELECTRICAL LEAD

Figure 2-19. Schematic diagram of a one-cycle reciprocation system.

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Basic Electrically-Controlled Hydraulic System

Testing the electrical control circuit

* 5. Turn on the 24-V dc power supply. Do not turn on the hydraulic power unit
yet.

* 6. Momentarily press pushbutton PB1. If the circuit is working, pilot lamp L1

should turn on to indicate that directional valve solenoid SOL-A is
energized. Is this your observation?

* Yes * No

* 7. Verify that directional valve solenoid SOL-A is energized. Get your

multimeter from its storage location and set it to read dc volts. Connect the
multimeter probes across the + and terminals of the solenoid. The voltage
reading on the multimeter should be about 24 V, indicating that the
solenoid is energized. Does the multimeter read 24?

* Yes * No

* 8. Leave the multimeter probes connected across the solenoid. Turn off the
24-V dc power supply. Remove the electrical wire connecting N.C. switch
contact PX1 to the + side of relay coil CR1. This will simulate activation of
magnetic switch PX1. Turn on the power supply. You should observe that
lamp L1 is off and that the voltage across the solenoid is about 0 V. Is
lamp L1 off and voltage reading 0 V?

* Yes * No

* 9. When all the above conditions are met, the electrical control circuit is
operational. Turn off the 24-V dc power supply. Reconnect N.C. switch
contact PX1 to the + side of relay coil CR1, as Figure 2-19 shows. Turn on
the 24-V dc power supply, then proceed to the next part of the exercise.

CAUTION!

Do not proceed with the exercise if any of the above

requirements are not met. Instead turn off the 24-V dc power
supply and check the circuit connections. Modify the circuit
connections as required, then turn on the power supply and
test circuit operation.

Testing the one-cycle reciprocation system

* 10. Before starting the hydraulic power unit, perform the following start-up
procedure:

a. Make sure the hydraulic hoses are firmly connected.

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Basic Electrically-Controlled Hydraulic System

b. Check the level of the oil in the power unit reservoir. Oil should cover,
but not be over, the black line above the temperature/oil level indicator
on the power unit. Add oil if required.
c. Put on safety glasses.
d. Make sure the power switch on the power unit is set to the
OFF position. Plug the power unit line cord into an ac outlet.
e. Open the pressure relief valve completely by turning its adjustment
knob fully counterclockwise.

CAUTION!

Ensure that the electrical leads and components are not

placed in a position where they may become wedged or
confined between rigid parts of the trainer when the cylinder
rod extends. Damage to the operator and the trainer could
result.

* 11. Turn on the hydraulic power unit.

* 12. With the directional valve solenoid de-energized, the valve is in the
crossed-arrows condition and the oil from the pump is directed to the rod
end of the cylinder. Since, however, the cylinder rod is fully retracted, the
pumped oil is blocked at the cylinder piston and is now being forced
through the pressure relief valve. Adjust the relief valve adjustment knob
so that the system pressure at gauge A is 1400 kPa (200 psi).

* 13. Start the cylinder cycle by momentarily pressing pushbutton PB1. Record
below what the cylinder rod does.

* 14. Does the cylinder rod cycle more than one time or does it stop after one
cycle?

* 15. Start another cycle by momentarily pressing PB1. Is retraction automatic

when the cylinder rod becomes fully extended? Why? Explain by referring
to the ladder diagram in the electrical section of Figure 2-19.

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Basic Electrically-Controlled Hydraulic System

* 16. Start another cycle by momentarily pressing PB1. Does the cylinder
continue to extend when you release PB1? Why? Explain by referring to
the ladder diagram in the electrical section of Figure 2-19.

* 17. What would happen to circuit operation if relay contact CR1-A in rung 1
were removed? Would you still be able to extend the cylinder? Explain.

* 18. Turn off the power unit. Open the pressure relief valve completely by
turning its adjustment knob fully counterclockwise.

* 19. Turn off the 24-V dc power supply and the multimeter.

* 20. Disconnect and store all hoses and electrical leads. Wipe off any hydraulic
oil residue.

* 21. Remove and store all electrical and hydraulic components. Wipe off any
hydraulic oil residue.

* 22. Clean up any hydraulic oil from the floor and the trainer. Properly dispose
of any towels and rags used to clean up oil.

CONCLUSION

In this exercise, you tested the operation of a one-cycle reciprocation system. You
saw that a cylinder can be made to retract automatically by using a magnetic
proximity switch. You learned that a relay contact can be used to maintain a closed
circuit to an output load, allowing a pushbutton to act as a maintained contact
switch.

You also learned that it is a good practice to test the electrical control circuit before
putting the whole system into operation. This is particularly important when working
on electrically-controlled hydraulic systems because the functions being performed

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Basic Electrically-Controlled Hydraulic System

by a control circuit may not be readily apparent to the operator, and unpredictable
motion may occur at any time.

REVIEW QUESTIONS

1. What is meant by “one-cycle reciprocation”?

2. What is the purpose of a magnetic proximity switch in a one-cycle reciprocation

system?

3. In the ladder diagram of Figure 2-19, what is the purpose of holding

contact CR1-A in ladder rung 1? Explain.

4. What will the cylinder rod do in the system of Figure 2-19 if N.C. contact PX1
in ladder rung 1 is changed for a N.O. contact? Explain.

5. What will the cylinder rod do in the system of Figure 2-19 if N.O. contact CR1-B
in ladder rung 2 is changed for a N.C. contact? Explain.

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