Electrical and Electronic

Control Devices

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Basic electrical devices used in FPS

Push button Solenoid Timer

Limit switch Relay switch
switch switch switch

Pressure Temperature
switch switch

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Switches

Switches are used for breaking and making electrical connections.

Normally Open (NO): no electric current can flow through the switching element until the switch
is actuated.

Normally Closed (NC). Electric current can flow through the switching element until the switch is
actuated.

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Push-button switch
• Used mainly for

• Starting and stopping the operation of

machinery

• Providing manual override when an emergency

arises

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Limit switches
• Actuated either at the end of the retraction or
extension strokes of hydraulic or pneumatic cylinders.

• Basically, limit switches perform the same functions

as push-button switches. The difference is that they
are mechanically actuated rather than manually
actuated.

• Actuators can be cams, levers, rollers, and plungers.

• However, the symbols used for limit switches do not

indicate the type of actuator used.

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Pressure switches
• Pressure switches open or close their contacts based

on system pressure.

• They generally have a high and a low-pressure setting.

• For example, it may be necessary to start or stop a Symbol used in electrical circuits

pump to maintain a given pressure.

• Low-pressure setting would start the pump, and

• The high-pressure setting would stop it.

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Relays switches
• Relays are switches whose contacts open or close
when their corresponding coils are energized.

• Commonly used for the energizing and de-energizing

of solenoids (i.e. operate at a high current level). So it
protects manual operator.

• The use of relays also provides interlock capability,

Which prevent burnout of solenoids by eliminating
accidental energizing of two solenoids at the opposite
ends of a valve spool.

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Solenoid switches
• Solenoids are electromagnets that provide a push or
pull force to operate fluid power valves remotely.

• When a solenoid (an electric coil wrapped around an

armature) is energized, the magnetic force created
causes the armature to shift the spool of the valve
containing the solenoid.

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Timer switches
• Time delay devices are used to control the time
duration of a working cycle. In this way a dwell can
be provided where needed.

• For example, a dwell can be applied to a drilling

machine operation, which allows the drill to pause for
a predetermined time at the end of the stroke to clean
out the hole.

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Temperature switches
• Automatically senses a change in temperature and

opens or closes an electrical switch when a

predetermined temperature is reached.

• Temperature switches can be used to protect a fluid

power system from serious damage when a

component such as a pump or strainer or cooler

begins to malfunction.

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Circuit diagrams
• When drawing electrohydraulic or electropneumatic circuits, a separate circuit is drawn for the fluid system and a
separate circuit is drawn for the electrical system.

• Each component is labeled to show exactly how the two systems interface. Electrical circuits use ladder diagrams
with the power connected to the left leg and the ground connected to the right leg. It is important to know the
symbols used to represent the various electrical components.

• The operation of the total system can be ascertained by examination of the fluid power circuit and electrical
diagram, as they show the interaction of all components.

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Ladder diagram
• Ladder diagrams are specialized schematics commonly
L1 L2
used to document industrial control logic systems.
Rungs
• They are called “ladder” diagrams because they resemble
a ladder, with two vertical rails (supply power) and as
many “rungs” (horizontal lines) as there are control
circuits to represent.

• The “L1” and “L2” designations refer to the two poles of

a 120 VAC supply unless otherwise noted. L1 is the

Rails “hot” conductor, and L2 is the grounded (“neutral”)

conductor.

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Ladder diagram
• Inputs: External control actions such as a push button
being pressed or a limit switch being triggered. The
inputs are actually hardwired to the PLC terminals and
represented in the ladder diagram by a normally open
(NO) or normally closed (NC) contact symbol. (switch)
A simple ladder diagram showing a lamp
that is controlled by a hand switch. • Outputs: External devices that are being turned on and
off, such as an electric motor or a solenoid valve. The
outputs are also hardwired to the PLC terminals and are
represented in the ladder diagram by a relay coil symbol.
(lamp)

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How it works?
• Here the switch is normally open so, if ‘A’ is actuated
then ‘Y’ will be energized.

• Otherwise ‘Y’ stays off.

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How it works?
• If both ‘A’ and ‘B’ actuated ‘Y’ will get energized.

• If either ‘A’ or ‘B’ actuated ‘Y’ will get energized.

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How it works?

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How it works?

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 Electro-Pneumatic
and
Electro-Hydraulic circuits

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Control of cylinder using single limit switch

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Control of cylinder using single limit switch cont.…
• When the START button is pressed momentarily, coil 1-CR is energized, so the cylinder extends.

• Even though the START button is released, the solenoid stays energized as long as the circuit un-broken.

• When 1-LS is actuated by the piston rod cam or STOP button is pushed, it opens to de-energize coil 1-CR. This
reopens the contacts of 1-CR to de-energize solenoid A. Thus, the valve returns to its spring-offset mode and the
cylinder retracts.

• This closes the contacts of 1-LS, but coil 1-CR is not energized because the contacts of 1-CR and the START
button have returned to their normally open position.

• The cylinder stops at the end of the retraction stroke, but the cycle is repeated each time the START button is
momentarily pressed.

• The STOP button is actually a panic button. When it is momentarily pressed, it will immediately stop the
extension stroke and fully retract the cylinder.
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Reciprocation of cylinder using pressure switches.

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Reciprocation of cylinder using pressure switches.

• Each of the two pressure switches has a set of normally open contacts.

• When switch 1-SW is closed, the cylinder reciprocates continuously until 1-SW is opened.

• Assuming solenoid A was last energized: The pump is turned on, and oil flows through the valve and into the

blank end of the cylinder.

• When the cylinder has fully extended, the pressure builds up to actuate pressure switch 1-PS. This energizes SOL

B to switch the valve. Oil then flows to the rod end of the cylinder.

• On full retraction, the pressure builds up to actuate 2-PS.

• Once pressure is removed the switch returned to NO position by spring.

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Reciprocation of cylinder using limit switches.
• Exact same control capability
except each pressure switch is
replaced by a normally open limit
switch as illustrated.

• Observe that switches are always

shown in their unactuated mode in
the electrical circuits.

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Dual-cylinder sequence circuits

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 Dual-cylinder sequence circuits
• When the START button is pressed momentarily, SOL A is energized to allow flow through valve V1 to extend cylinder 1.
Actuation of 1-LS de-energizes SOL A and energizes SOL B. Note that limit switch 1-LS is a double pole, single-throw type. Its
actuation opens the holding circuit for relay 1-CR and simultaneously closes the holding circuit for relay 2-CR. This returns
valve V1 to its spring-offset mode and switches valve V2 into its solenoid-actuated mode. As a result, cylinder 1 retracts while
cylinder 2 extends. When 2-LS is actuated, SOL B is de-energized to return valve V2 back to its spring-offset mode to retract
cylinder 2. The STOP button is used to retract both cylinders instantly.

• The complete cycle initiated by the START button is as follows:

1. Cylinder 1 extends.

2. Cylinder 2 extends while cylinder 1 retracts.

3. Cylinder 2 retracts.

4. Cycle is ended.
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Counting, timing, and reciprocation of cylinder

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Counting, timing, and reciprocation of cylinder

1. A momentary push button stops the cylinder motion immediately, regardless of the direction of motion. It also

unloads the pump.

2. A second momentary push button starts a cycle in which a hydraulic cylinder is continuously reciprocated.

3. If the START button is pressed after the operation has been terminated by the STOP button, the cylinder will

continue to move in the same direction.

4. An electrical counter is used to count the number of cylinder strokes delivered from the time the START button

is pressed until the operation is halted via the STOP button. The counter registers an integer increase in value

each time an electrical pulse is received and removed.

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Counting, timing, and reciprocation of cylinder

5. An electrical timer is included in the system to time how long the system has been operating since the START

button was pressed. The timer runs as long as a voltage exists across its terminals. The timer runs only while the

cylinder is reciprocating.

6. Two lamps (L1 and L2) are wired into the electric circuit to indicate whether the cylinder is extending or

retracting. When L1 is ON, the cylinder is extending, and when L2 is ON, the cylinder is retracting.

7. The cylinder speed is controlled by the pressure- and temperature-compensated flow control valve.

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