M11LAP2 Basic Control Devices

ELEcrRO·FLUID
LEARNING

POWER SYSrEMS ACTIVITY

PACKET

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BB861·XA02XEN
 LEARNING ACTIVITY PACKET 2

BASIC CONTROL DEVICES

INTRODUCTION
The ladder diagram is the standard method used to represent electrical relay control
circuits. In this LAP, you are going to learn the basic rules for creating ladder diagrams
and the main basic input/output devices found in almost all circuits: manual switches and
indicator lights.

ITEMS NEEDED
Amatrol Supplied
For Pneumatics Curriculum
1 85-EP Electro-Pneumatic Relay Control System or
85-EF Electro-Fluid Power Relay Control System
1 85-BP Basic Pneumatics System
1 16019 Electric Power Supply
For Hydraulics Curriculum
1 85-EH Electro-Hydraulic Relay Control System or
85-EF Electro-Fluid Power Relay Control System
1 85-BH Basic Hydraulic System, 850 Bench (either 850-Cl or 850-Hl)
1 85-HPS power supply or an 850-Cl bench (either 850-Cl or 850-Hl)
1 16019 Electric Power Supply

School Supplied
1 79-921 Air Compressor or equivalent
1 Adjustable wrench
1 Set of Allen wrenches
1 Flat head screwdriver
1 Digital Multimeter

SECOND EDITION, LAP 2, REV. A

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, 1ST, lTC, VEST, and Technovate are trademarks or registered trademarks of Amatrol,
Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 2010 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic,
optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and
retrieval system, without written permission of the copyright owner.
Amatrol, Inc., 2400 Centennial Blvd., Jeffersonville, Indiana 47130 USA, Phone 812-288-8285, FAX 812-283-1584

BB861-XA02XEN BASIC CONTROL DEVICES 2

Copyright © 2010 Amatrol, Inc.
TABLE OF CONTENTS
SEGMENT 1 LADDER DIAGRAMS 4
OBJECTIVE 1 Describe the function of a ladder diagram
OBJECTIVE 2 Describe the function of the four components of a ladder diagram
OBJECTIVE 3 Describe ten ladder diagram drawing rules
SKILL 1 Draw a ladder diagram given a pictorial of a control circuit
OBJECTIVE 4 Describe how to determine the operation of a circuit given a ladder diagram
SKILL 2 Determine the operation of a circuit given a ladder diagram
SKILL 3 Connect and operate a logic circuit given a ladder diagram
SKILL 4 Design a ladder diagram using one or more logic elements

SEGMENT 2 INDICATORS 22
OBJECTIVE 5 Describe the function of an indicator lamp and give an application
OBJECTIVE 6 Describe the operation of an indicator lamp and give its schematic symbol
SKILL 5 Connect and operate an indicator lamp given a ladder diagram

SEGMENT 3 PUSH BUTTONS ..............•............................................. 29

OBJECTIVE 7 Describe the function of a pushbutton and give an application
OBJECTIVE 8 Describe the operation of a pushbutton switch and give its schematic symbol
OBJECTIVE 9 Describe three types of pushbutton switch operators and give an application of each
SKILL 6 Connect and operate a pushbutton switch given a ladder diagram

SEGMENT 4 SELECTOR SWiTCHES 38

OBJECTIVE 10 Describe the function of a selector switch and give an application
OBJECTIVE 11 Describe the operation of a selector switch and give its schematic symbol
SKILL 7 Connect and operate a selector switch given a ladder diagram

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Copyright © 201 0 Amatrol, Inc.
 OBJECTIVE 1

Until now we have drawn electrical control circuits using pictorial diagrams.
While this type of circuit is fine for simple controls, designers long ago found that
this type of diagram becomes very complicated and hard to read for more complex
circuits, like those used to control most automatic sequences. As an example,
consider the pictorial diagram shown in figure 1.
This diagram shows a circuit used to control a fluid power valve. When the
operator presses 1PB, solenoid A energizes, causing the valve to shift and extend
the cylinder. When the cylinder becomes fully extended, it actuates a limit switch,
causing the switch to close and turn on the lamp.
Although this circuit only involves a few components, it is difficult to read
because the components are not placed in the diagram in any order and the elec-
trical control lines cross over each other.

LIMIT
SWITCH

POWER
SOURCE
+

RETRACT
~B

, /

L
/ ,

Figure 1. Pictorial-Schematic Scheme

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Copyright © 2010 Amatrol, Inc.
 To make electrical control circuits easier to read, the LINE DIAGRAM or
LADDER DIAGRAM was developed. This type of diagram arranges the electrical
wires in orderly rows like rungs on a ladder with components located on each of
these rungs. Shown in figure 2 is the corresponding ladder diagram for the circuit
shown in figure 1.

LADDER DIAGRAM (CONTROLS ONLY)

POWER
SUPPLY

L1 L2

EXTEND
--1...1£'B SOLA
RUNG 1 ••• ~O
3 2
EXTEND
RETRACT
-UE'B SOLB
4 2
RUNG 2 ••• ~O RETRACT

EXTENDED
1LS
RUNG 3 ••••• -C).. 5
EXTENDED

PICTORIAL POWER DIAGRAM

CYLINDER

LIMIT
SWITCH,ILS

2--F=;;;~ ---.ar===t---4
3--b::~....E ......5!~1---2

Figure 2. Ladder Diagram and Power Diagram

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 2

The four components of a ladder diagram represent the four basic components
of an electrical circuit, as shown in figure 3. These are:
• Power Supply
• Input Device
• Output Device
• Conductors

t
POWER POWER \
UPPLY (+) SUPPLY (-)

L1 1PB
CONDUCTOR
(WIRES) 7 L2

RUNG 11Un-i-
1 _ 3 ~ R 2

INPUT
(POWER BUnON
DEVS SWITCH)
-~T D~'CE
(INDICATOR LAMP)

Figure 3. Basic Components of a Ladder Diagram

Power Supply
All electrical circuits must have a power supply to allow the control logic
circuit to energize the output devices. The power supply in a ladder diagram is
represented by the two vertical lines, or ladder side rails. The vertical line on the
left is the hot or positive side of the power supply and is labeled Ll. The vertical
line on the right is the ground or return side of the power supply and is labeled N
(for neutral), or L2. With an AC power supply, the supply rails can either come
from a control transformer or directly from the main power lines. If the supply is
from a control transformer, the rails are often not labeled.

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Copyright © 2010 Amatrol, Inc.
 Conductors
Conductors are the electrical wires that connect the components of the control
circuit. They form the rungs of the ladder running between the power rails. The
input and output device symbols are placed on these rungs.

Input Devices
All input devices, such as switches, are used to perform the logic functions
that control the outputs. Input devices are usually connected between the left side
of the power supply and the output devices. Some of the various symbols for input
devices are shown in figure 4.

Output Devices
Output devices are the components that perform the machine operation. Output
devices are usually connected between the input devices and the right side of the
power supply. Figure 4 shows the schematic of an indicator lamp output device.

PUSHBUTTON PUSHBUTTON
NORMALLY NORMALLY
OPEN CLOSED

.....l-
1PB
2PB
-0 0- -Q...L.Q-
(INPUT DEVICE) (INPUT DEVICE)

SELECTOR SWITCH INDICATOR

3- POSITION LAMP

(INPUT DEVICE)
~/ ,
(OUTPUT DEVICE)

Figure 4. Ladder Diagram Symbols of Common Input and Output Devices

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 3

There are ten basic rules to follow when drawing or interpreting ladder
diagrams. These include:
-All Components Labeled - Each component in a ladder diagram should be
labeled with its function (i.e. start) and an abbreviation identifying what it
is (i.e. PBI).
-All Conductors (wires) Numbered - The wires connecting the components
should be numbered left to right and top to bottom. Notice that LI and L2
are both numbered.
Any wires that are connected to LI or L2 all should have the same numbers.
All of the conductors connected to Ll should be numbered 1. All conductors
connected to L2 will be numbered 2.
Also, conductors that are joined together directly should have the same
numbers.
-All Rungs Numbered - A rung is considered any circuit path between L I and L2.
These paths are represented by horizonta1lines.

L1 START L2
-L!.£'B STOP
3PB
3 4
RUNG 1
START
~B
RUNG 2
START
~B ,
5
RUNG 3
L- r. ~J ,~---/~.----~

INPUT DEVICES OUTPUT DEVICES

AND LOGIC

Figure 5. Structure of a Ladder Diagram

-Control Devices Only - A ladder diagram shows only control devices such as
switches, solenoids, and relays. It does not show power devices such as
valves, motors and cylinders. These are shown on a separate diagram called
a Power Diagram.

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 -Only One Load Per Rung - A load is an output device such as an indicator lamp.
Loads should never be wired in series on the same rung. They should be
wired in parallel on different rungs as shown in figure 6.

INCORRECT CORRECT

L1 1PB L2

RUNG
1

RUNG
2 r --1-~",
,,
,
R

G
,

Figure 6. Wiring of Multiple Loads

-Output Devices Located On the Right - Output control devices include sole-
noids, lamps, and control relays. They should be located on the right side of
the ladder rung with one terminal directly connected to L2.
- Input Devices Located On the Left - Input devices such as push buttons and limit
switches should be located on the rungs between the output devices on that
rung and the hot side Ll. This places them on the left side of the diagram.
-At Least One Switch Per Line - If there were no switches on a rung and only
an output device, the output would always be on. The purpose of the circuit
represented by the ladder diagram is to control a machine. This means that
the outputs must be able to be turned on and off at specific points during
the machine's operation. To do this requires manual and automatic input
switches wired in between the hot side and each output in order to switch the
outputs on and off.
- Only Contacts Actually Used are Shown - If an input switch or relay has several
contacts that are unused in a circuit, they should not be shown in the ladder
diagram for that circuit. This helps avoid clutter in the diagram.
-Vertical Lines Represent Power - Regardless of the type of power used, AC or
DC, the ladder diagram should always be drawn with vertical and horizontal
lines. The vertical lines on the left and right sides of the diagram shall always
represent the source of control power.
The ladder diagram method helps you interpret the operation of the circuit
more easily because it unravels the lines and allows the diagram to be read in an
orderly fashion. By looking at the closed/open status of the inputs on the left side
of a rung of a ladder diagram, you can determine whether the output on the right
side is on or off. Each rung usually contains a single output device. If the ladder
diagram is used to perform a sequence of steps, the rungs are often arranged so that
the outputs are located from top to bottom in the order in which they are energized.

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Copyright © 2010 Amatrol, Inc.
 SKILL 1

Procedure Overview
In this procedure, you will be given a pictorial of a control circuit and
asked to draw the ladder diagram that corresponds to it. An example is given
first, then you will do it yourself.

o 1. Study the circuit diagram in figure 7. Locate the power supply, any input
devices, any output devices, and the conductors. In the next few steps, you
will draw a ladder diagram of this circuit.

ELECTRICAL CONTROL MODULE POoYER ij

•
ONKlFF

SELECTOR PUSHBUTTON INOICATOA

SWITCH SWITCHES lAMPS
L' l2
,.,NG

• •
1-55 '-PS
NO.

Figure 7. Pictorial Circuit Diagram for Skill

o 2. On a separate sheet of paper, perform the following sub steps to draw the
ladder diagram symbol for a power supply.
A. Draw two vertical lines about 2 inches long and 3 inches apart.
B. Label the left-hand line L1.
C. Label the right-hand line L2.
o 3. Perform the following substeps to draw the inputs.
A. Draw the symbol for a N.O. pushbutton switch to the right of LIon your
diagram.
B. Label the symbollPB.
o 4. Draw the symbol for a red indicator lamp to the right of IPB.
o 5. Draw the symbol for a green indicator light to the right of the red indicator
lamp.

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 o 6. Perform the following sub steps to draw the conductors.
A. Draw a straight horizontal line from L1 to the pushbutton symbol. Label
this line 1.
B. Draw a straight horizontal line from L2 to the right side of the green indi-
cator lamp. Label this line 2.
C. Draw a straight horizontal line from the pushbutton symbol to the red
indicator lamp symbol. Label this line 3.
D. Draw a straight horizontal line between the red lamp and green lamp.
Label this line 4.
Your drawing should look like figure 8.

L1 L2

1rL~3 o-~---{

Figure 8. Ladder Diagram

o 7. Determine if the diagram and circuit follow all of the ladder diagram rules
discussed in the previous objective.
Circuit Problems:

You should notice that this circuit violates the rule "Only One Load Per
Rung." You will connect this circuit later and learn why this is an important
rule.

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 o 8. Draw the ladder diagram that corresponds to the pictorial in figure 9.

ELECTRICAL CONTROL MODULE ij

•
POW'R
Otl'OFF

SElECTOR PUSHBunON INDICATOR

SWITCH SWITCHES lAMPS
L1 1.2

• •
AUNG
1-PS
NO.

~ 0

Figure 9. Control Circuit #2

9. Draw the ladder diagram that corresponds to the pictorial in figure 10.

ELECTRICAL CONTROL MODULE ''''''R ij

•
ONIOI'F

SELECTOFI PUSHBUTTON INDICATQA

SWITCH SWITCHES lAMPS
Ll 1.2
AUNG
NO.

Figure 10. Control Circuit #3

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Copyright © 201 0 Amatrol, Inc.
 OBJECTIVE 4 RERATI
GRAM

The best method of reading a ladder diagram is to start at the upper left comer
of the diagram at the first input on the first rung. Then work your way across the
rung horizontally before moving down to the first input on the next rung. This is
true whether you want to determine the sequence of operation of the circuit repre-
sented or construct an actual circuit from the diagram.

L1 N

START 1
STOP 1 ---1..- , /
cr------~R ~~-e

START 2
STOP 2 ---1..-

/ ,

Figure 11. Method for Reading a Ladder Diagram

To determine the sequence of operation of a ladder diagram circuit, first deter-

mine the state of all outputs when all inputs are in their deenergized, or normal,
states. Keep in mind that in order for an output to be energized, there must be a
complete circuit from the left power rail, through any inputs, through the output,
and on to the right power rail.
Start with rung 1 and trace the circuit from left to right to determine the initial
states of any outputs on that rung. Then move along any branches to determine if
there is a complete circuit along rung 1 to any outputs on lower rungs. Continue
to the next rung, checking outputs on this rung first, then moving up or down any
branches.
Once you have determined the initial state of all the outputs on the diagram,
the next step is to determine the states of all outputs as each of the inputs is ener-
gized. For example, determine which indicator lamps come on or go off as each of
the buttons are pressed.

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Copyright © 2010 Amatrol, Inc.
 SKILL 2

Procedure Overview
In this procedure, you will use a ladder diagram to determine the operation
of a control circuit. This is a key skill that will help you to troubleshoot machine
controls.

o 1. Perform the following substeps to describe the operation of the ladder

diagram circuit shown in figure 12.

START
L1 1PB L2
STOP
3PB
-L
3 4
RUNG 1
START
2PB
-L
RUNG2
START
~B
5
RUNG 3

Figure 12. Ladder Diagram Schematic

A. Determine the initial status of the circuit shown in figure 12.

Red Lamp _ (On/Off)

Green Lamp (On/Off)

B. Determine the status of the red and green lamps if IPB is pressed and
held.

Red Lamp _____________________________ (On/Off)

Green Lamp (On/Off)

C. Determine the status of the red and green lamps if 2PB is pressed and
held.
Red Lamp (On/Off)

Green Lamp (On/Off)

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 D. Determine the status of the red and green lamps if 4PB is pressed and
held.
Red Lamp (On/Off)

Green Lamp (On/Off)

E. Determine the status of the red and green lamps if IPB and 3PB are
pressed and held.
Red Lamp (On/Off)

Green Lamp (On/Off)

o 2. Perform the following substeps to determine the operation of the ladder
diagram circuit shown in figure 13.
A. Determine the status of the red and green lamps if IPB is pressed and
held.
Red Lamp Status (On/Off)

Green Lamp Status (On/Off)

L1 1PB L2
--L
3
RUNG 1

2PB
--L
RUNG 2

Figure 13. Ladder Diagram Schematic

B. Determine the status of the lamps if 2PB of figure 13 is pressed and held.
Red Lamp (On/Off)

Green Lamp ___________________________ (On/Off)

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Copyright © 2010 Amatrol, Inc.
 SKILL 3

Procedure Overview
In this procedure, you will connect a circuit using a ladder diagram as a
reference. This is one of the most commonly used skills in industry.

o 1. Set up the Amatrol 850 Electro-Fluid Power trainer.

o 2. Perform the sub steps to supply power to the trainer
A. Connect the #16019 24 VDC power supply to the Electrical Control
Module.
B. Plug the power supply plug-in connector cable #16179 into the jack on the
front of the trainer.
C. Turn on the main switch on the 24 VDC power supply.
D. Turn the control power switch to the off position (switch down).
o 3. Connect the circuit shown in figure 14 using the ladder diagram as a reference.
Remember, read a ladder diagram from left to right, top to bottom.

ELECTRICAL CONTROL MODULE

SELECTOR PUSHBUTTON INDICATOR
SWITCH SWITCHES lAMPS
L1 L2
RUNG
NO.

L1 L2

1 r.Y3
11
o-=-----{

Figure 14. Two Lamps Connected in Series

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Copyright © 2010 Amatrol, Inc.
 o 4. Turn on the control power switch.
Power should now be supplied to the jacks under L1 on the Electrical Control
Module. Record the initial status of the circuit.
RedLamp (OlliOff)

Green Lamp (On/Off)

Both lamps should be off because the N.O. PBl breaks the path of the
electricity.
o 5. Perform the following sub steps to test the operation of this series control
logic circuit.
A. Press and hold IPB and observe the lamps.
Red Lamp Status (On/Off)

Green Lamp Status (On/Off)

Both should be ON because IPB is closed, thereby creating a complete
path for the electricity to flow.
B. With IPB held, notice and record the intensity of the lamps as they are
connected in series.

You should observe that the intensity is low because the lamps are each
getting only half the voltage.
C. Release IPB and observe the lamps.
Red Lamp Status (On/Off)

Green Lamp Status (On/Off)

The lamps should be off because the circuit is open.
o 6. Turn off the control power switch.
o 7. Reconnect your circuit so that the indicator lamps are wired in parallel as
shown in figure 15.

L1 L2
1PB
--L.
3
, /
2
RUNG 1 1
/
R
,
, /
2
/
G
,
LADDER DIAGRAM

Figure 15. Ladder Diagram with Two Lamps Wired in Parallel

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 o 8. Turn on the control power switch (move to up position).
o 9. Perform the following substeps to test the operation of this parallel control
logic circuit.
A. Press and hold IPB and observe the lamps.
Red Lamp Status (On/Off)

Green Lamp Status (On/Off)

With IPB pressed and held, both lamps should be on.
B. With IPB pressed and held, notice the intensity of the lamps as they are
connected in parallel. How does the intensity of the lamps wired in parallel
compare with the intensity of the lamps wired in series?

You should have noticed that the intensity of the lights wired in series is
less than the intensity of the lights wired in parallel. This is because when
the lights are wired in series, the total voltage across each lamp is split.
When the lights are wired in parallel, each lamp gets the total voltage
across each one.
C. Release IPB and observe the lamps.
Red Lamp Status _ (On/Off)

Green Lamp Status (On/Off)

The lamps should be off because the circuit is open.
010. Perform the following substeps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the power switch on the 24 VDC Power Supply.
C. Remove the test leads.

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 Procedure Overview
In this procedure, you will design a ladder diagram to perform a specific
function using one or more control logic elements. You will then connect and
test the circuit based on your ladder diagram.

o 1. Solve the following design problem:

£..
~~ Design a control logic circuit to perform the following functions. Draw your
circuit on a separate piece of paper.
Functions
• When power is supplied to the circuit, the red and green lamps are both off.
• When IPB is pushed, both lamps come on.
• When both IPB and 2PB are pushed, the red light stays on but the green
lamp goes off.
o 2. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.
o 3. Perform the substeps to supply power to the trainer
A. Connect the #16019 24 VDC power supply to the Electrical Control
Module.
B. Plug the power supply plug-in connector cable #16179 into the jack on the
front of the trainer.
C. Turn on the main switch on the 24 VDC power supply.
D. Turn the control power switch to the off position (switch down).
o 4. Connect the circuit you designed in step 1.
o 5. Turn on the control power switch.
o 6. Perform the following substeps to test the circuit you designed.
A. With power supplied to the circuit, record the status of the red and green
lamps.

Red Lamp (On/Off)

Green Lamp (On/Off)

With power supplied to the circuit, both lamps should be off.
B. Press and hold IPB and record the status of the lamps.

Red Lamp (On/Off)

Green Lamp (On/Off)

Pressing IPB causes the red lamp to come on. The green lamp remains
off.

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Copyright © 2010 Amatrol, Inc.
 C. Release IPB and record the status of the lamps.
RedLmnp (OlliOm

Green Lamp (On/Off)

The red indicator lamp should go off.
D. Press and hold IPB and 2PB. Record the status of the lamps.
Red Lamp (On/Om

Green Lamp (On/Off)

When both IPB and 2PB are pressed, only the red lamp comes on. The
green lamp remains off.
E. Release IPB and 2PB.
o 7. Perform the following sub steps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the power switch on the 24 VDC Power Supply.
C. Remove the test leads.

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Copyright © 2010 Amatrol, Inc.
 SEGMENT 1

1. The line diagrams used to represent electrical control circuits are called

2. The side, or vertical rails in the "line" diagrams represent the

3. The four components of the "line" diagram are: _ _

____ ,and _

4. Output devices should always be located on the _

side of the rung on a "line" diagram.

5. When determining the sequence of operation of a circuit from a "line"

diagram, first determine the state of all outputs when all inputs are in
their state.

6. Input devices should always be located on the side

of the rung on a "line" diagram.

7. The wires connecting the components in a "line" diagram should be

numbered from to and from top
to bottom.

8. A "line" diagram shows only devices such as

switches, solenoids, and relays.

9. A load should never be wired in on the same rung in a

"line" diagram.

10. An additional diagram is needed with the "line" diagram to show the
connections of the hoses that connect the valve to a cylinder, motor,
or other power device. This diagram is called the _
diagram.

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 5

The most basic output device is an indicator lamp. It is available in many sizes,
shapes and types.
Indicator lights are used by electrical control systems to tell the operator at
a glance the operating status of the machine. They have many industrial uses,
including indicating that power to a machine is ON, a cycle has begun or ended, a
sensor has sensed an input, and so forth.

Figure 16. Indicator Lamps Used to Indicat the Status of a Machine's Operator

Indicator lights can be mounted anywhere on a machine but are most often
located on the front panel of the operator station as panel mounted units.

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 5

The most basic output device is an indicator lamp. It is available in many sizes,
shapes and types.
Indicator lights are used by electrical control systems to tell the operator at
a glance the operating status of the machine. They have many industrial uses,
including indicating that power to a machine is ON, a cycle has begun or ended, a
sensor has sensed an input, and so forth.

.1
",,,,If.:'
,

Figure 16. Indicator Lamps Used to Indicat the Status of a Machine's Operator

Indicator lights can be mounted anywhere on a machine but are most often
located on the front panel of the operator station as panel mounted units.

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Copyright © 201 0 Amatrol, Inc.
 OBJECTIVE 6 DE I AT

The basic operation of all indicator lamps is the same: the lamp turns on when
electrical current runs through it.
Indicator lamps are available in three basic designs:
• Full Voltage
• Resistor
• Transformer
The full voltage indicator bulbs carry the full load voltage across the filament
of the bulb. The resistor and transformer types use less power, typically running on
6-8 volts, and are the most frequently used. The 6 to 8 volts is generated by drop-
ping down the supply voltage through a built-in resistor or transformer.
Indicator lamps are available for control circuit voltages of all types including
24 VDC and 120 VAC. Be sure to check the voltage rating of an indicator lamp
before you use it. For example, 24 VDC indicators are not compatible with 120
VAC circuits.

Figure 17. Construction of Indicator Lamp on 850 Series Electro-Fluid Power

Trainer

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 The green indicator used with the 850 series system is shown in figure 18
along with its ladder diagram symbol. The letter inside the symbol is used to indi-
cate the color of the indicator. In this case, the "G" indicates a green lamp.

SCHEMATIC SYMBOL INDUSTRIAL INDICATOR LAMP

TERMINALS<

I
LETTER
INDICATES COLOR

Figure 18. Indicator Lamp Used with 850 Electro-Fluid Power Trainer and Ladder Diagram Symbol

Figure 19 shows how a simple indicator is wired into a circuit and its corre-
sponding ladder diagram. When the switch contacts close, current runs through the
filament of the lamp, causing the lamp to illuminate.

+~~:_----....;;3:.....------*1
L1
LADDER DIAGRAM L2

ACTUAL WIRING DIAGRAM

L1 L2

,.........--'- ..•.... 1PB

Figure 19. Indicator Light Used with 850 Electro-Fluid Power Trainer and Ladder
Diagram Symbol

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Copyright © 2010 Amatrol, Inc.
 There are many lens colors available for indicator lamps. Each color represents
a different status, as the table in figure 20 shows.

Red Danger, Abnormal Voltage applied, cycle

Condition, Fault Condi- in automatic, faults in
tion air, water, lubricating
~ / , or filtering systems,
ground detector cir-
cuits.
Amber Attention Motors running,
(Yellow)
-o-,/
machine in cycle, unit
or head in forward
position

Green Safe End of cycle, unit or

Condition(Security) head returned, mo-
~ / , tors stopped, motion
stopped, contactors
open.
White or Normal Condition Normal pressure of air,
Clear
-s-
, /
water, lubrication

Figure 20. Indicator Lamp Lens Color Codes

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Copyright © 201 0 Amatrol, Inc.
 SKILL 5
DIAG

Procedure Overview
In this procedure, you will connect and operate a control circuit to control
an indicator lamp.

£...o
~~
1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer, as
shown in figure 21.

INDICATOR
LAMPS

Figure 21. Electrical Control Module

o 2. Locate the two indicator lamps on the Electrical Control Module and examine
their construction.
o 3. Unscrew the lens of one of the indicators and record below what is inside the
indicator.

o 4. Screw the lens back on.

o 5. Examine the back side of the indicator lamp. Notice the two terminals.

BB861-XA02XEN BASIC CONTROL DEVICES 26

Copyright © 201 0 Amatrol, Inc.
 o 6. Perform the substeps to supply power to the trainer.
A. Connect the #16019 24 VDC power supply to the Electrical Control
Module.
B. Plug the power supply plug-in connector cable #16179 into the jack on the
front of the trainer.
C. Turn on the main switch on the 24 VDC power supply.
D. Turn the control power switch to the off position (switch down).
o 7. Connect the logic circuit shown in figure 22.

L1 L2

STOP
2PB
RUNG 1

Figure 22. Ladder Diagram for Skill

o 8. Turn on the control power switch (switch up).

o 9. Record the initial status of the circuit.

Red Lamp (On/Off)

Green Lamp (On/Off)

In the initial state of the circuit, both lamps should be off.
010. Press and hold IPB. Record the status ofthe red and green lamps.

Red Lamp (On/Off)

Green Lamp (On/Off)

When IPB is pushed, the lamps should become energized.
011. Release IPB.
012. Perform the following substeps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the power switch on the 24 VDC power supply.
C. Remove the test leads.

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Copyright © 201 0 Amatrol, Inc.
 SEGMENT 2

1. The indicator lamp is the most basic (input!

output) device.

2. Indicator lights are used by electrical control systems to tell the operator
at a glance the of the machine.

3. A red indicator light on a device would typically indicate a

_________ (normal, security, fault, safe) condition.

4. A yellow indicator light on a device would typically indicate a

_________ (normal, attention, fault, safe) condition.

5. Indicator lamps can be mounted anywhere on a machine but are most

often located on the _

BB861-XA02XEN BASIC CONTROL DEVICES 28

Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 7
AP
Pushbutton switches are used in control systems to manually send input signals
to the controller to cause it to perform functions such as starting and stopping the
machine. Pushbutton switches are typically designed to be panel mounted on the
front of an enclosure as shown in figure 23.

Figure 23. Push buttons on Operator Station

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 8 D

A pushbutton switch consists of two basic parts:

• Operator
• Contact Blocks (one or more sets)
Pushing the operator causes the contacts to open or close, depending on their
normal state. If the operator is released, most pushbuttons have a spring inside to
return the operator and contacts to their original or normal condition. The basic
construction of a pushbutton is shown in figure 24.

PUSHBUTTON
OPERATOR

Figure 24. The Construction of a Pushbutton Switch

Pushbutton switches can be either momentary or maintained. A momentary

switch contains a spring that causes the operator to return to its original posi-
tion and the contacts to return to their normal states once the person releases the
operator. One application of a momentary pushbutton switch is the horn on an
automobile.

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Copyright © 2010 Amatrol, Inc.
 A maintained pushbutton operator stays pushed in and holds the contacts in
the actuated state after the person releases the operator button. To de-actuate the
contacts, the person must pull out the operator button.
An application that commonly uses the maintained pushbutton is an emer-
gency stop function. The maintained operator provides an added degree of safety
by requiring the person to pull out the operator head before the machine can be
restarted after it has been shut down. A maintained pushbutton and its ladder
diagram symbol are shown in figure 25.

N.O. CONTACTS

N.C. CONTACTS

0+0
I

INDICATES POSITION OF SWITCH

IS MAINTAINED IN EITHER POSITION

Figure 25. Maintained Pushbutton and Ladder Diagram Symbol

NOTE
Pushbuttons are assumed to be momentary unless otherwise stated.

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Copyright © 201 0 Amatrol, Inc.
 Many industrial-type pushbuttons are designed so that more than one set of
contact blocks can be attached to an operator. This allows the pushbutton to control
several outputs. These contact blocks can have either normally open or normally
closed contacts depending on the needs of the application. The pushbuttons on the
Amatrol 850 series electro-fluid power training system have two sets of contacts,
one normally open and one normally closed.

PUSHBUTTON
OPERATOR

NORMALLY CLOSED PUSHBUTTON

CONTACTS / OPERATOR

01---
/,0
NORMALLY OPEN
CONTACTS

Figure 26. Industrial-Type Pushbutton Used on the Amatrol 850 Series Electro-Fluid Power Training Sys-
tem and Ladder Diagram Symbol

Figure 27 shows examples of pushbuttons in a ladder diagram circuit. Notice

the multiple sets of contacts associated with IPB. A dashed line is shown connecting
the sets of contacts so that a person reading the diagram can see that they have a
common operator. Pushbutton 2PB is a normally open (N.O.) pushbutton. In order
to begin operation of this circuit, the operator would have to push both IPB and
2PB. Also, notice that 3PB, the STOP pushbutton, uses a normally closed (N.C.)
pushbutton. While 3PB is in the de-energized state, current is allowed to flow.
Pushing 3PB causes the circuit to open.

L1 L2

STOP 1PB 2PB

3PB 3.....L4.....L. 5
RUNG 1 •••• --1~---.O.-;.-O I 0---;...-0 e>---=----{
I
I
I
I
I
RUNG2 •••• --------~~o_-6~----------~

Figure 27. Examples of Push buttons in Ladder Diagram

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 9

Pushbuttons are available with a variety of operator types and colors to provide
easy operation and identification. Figure 28 shows some of the types of operators
available. Each of these is best suited to particular applications as follows:

Mushroom Head
This operator is designed so that the operator can quickly locate and press
the button. This type of operator is reserved for functions such as EMERGENCY
STOP. The mushroom head operator is considered "unguarded" because its oper-
ator can be actuated from a variety of angles.

Extended Button
The color of this operator can be seen at all angles and can be actuated easily
because the pushbutton extends up beyond the body of the operator. This operator
type is also considered "unguarded".

Flush Button
The flush button is the most common of all. It requires the operator to be
located in front of it to see its color and to place a finger directly on the button
to actuate it. It is the best type of operator to avoid accidental actuation and is
required for functions such as START. This type of pushbutton is considered "fully
guarded".

MUSHROOM
HEAD

EXTENDED FLUSH
BUTTON BUTTON

Figure 28. Pushbutton Operator Types

BB861-XA02XEN BASIC CONTROL DEVICES 33

Copyright © 2010 Amatrol, Inc.
 SKILL 6

Procedure Overview
In this procedure, you will connect a circuit using a ladder diagram as a
reference. This will familiarize you with the operation of pushbutton switches.

o 1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

o 2. Perform the substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 3. Connect the circuit shown in figure 29. This is the same circuit used as an
example in the previous objective.
Remember, to understand how a circuit works, read a ladder diagram from
left to right, top to bottom.

L1 L2

1PB 2PB
....L.. -L
I 0 3 0 4
RUNG 1
I
I
I
I
I
RUNG2.-1-o~o---5----------------~

Figure 29. Examples of Push buttons in Ladder Diagram

BB861-XA02XEN BASIC CONTROL DEVICES 34

Copyright © 2010 Amatrol, Inc.
 o 4. Turn on the control power switch (move to up position).
Power should now be supplied to the jacks under LIon the Electrical control
Module.
o 5. Record the initial status of the red and green lamps.
RedLamp (OwOff)

Green Lamp (OWOff)

With power supplied to this circuit, the red lamp should be off and the green
lamp is on.
o 6. Press and hold IPB. Record the status of the red and green lamps.
Red Lamp (On/Off)

Green Lamp (On/Off)

The green lamp should go off when IPB is pressed.

o 7. Release IPB.
o 8. Press and hold IPB and 2PB. Record the status of the lamps.
Red Lamp (On/Off)

Green Lamp (OWOff)

The red lamp should come on only when both IPB and 2PB are pressed.
When IPB is pressed, the green lamp goes off.
o 9. Release IPB and 2PB.
010. Turn off the control power switch.
011. Disconnect the leads from the Electrical Control Module.
012. Connect the circuit shown in figure 30.

L1 l2

1PB
---L 2PB
I 3 4
RUNG 1
I
I I
I I
I I

I ---L
1 5 6
RUNG 2

Figure 30. Ladder Diagram Circuit for Skill

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Copyright © 201 0 Amatrol, Inc.
 CJ 13. Turn on the control power switch.
014. Perform the following substeps to test the operation of the ladder diagram
circuit shown in figure 30. Record the initial status of the circuit.

Red Lamp (On/Off)

Green Lamp (On/Off)

With power supplied to the circuit, the red and green lamp should both be off.
015. Press and hold IPB. Record the status of the red and green lamps.
Red Lamp (On/Off)

Green Lamp (On/Off)

When IPB is pressed and held, the red lamp should come on.
016. Release IPB.
017. Press and hold 2PB. Record the status of the red and green lamps.
RedLamp (On/Off)

Green Lamp (On/Off)

When 2PB is pressed and held, the green lamp should come on.
018. Press and hold IPB and 2PB. Record the status of the red and green lamps.
Red Lamp (On/Off)

Green Lamp (On/Off)

When IPB and 2PB are both pressed and held, neither lamp should be
energized. The red lamp stays off because 2PB opens the circuit on rung 1.
The green lamp stays off because IPB opens the circuit on rung 2.
018. Release IPB and 2PB.
019. Perform the following substeps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the power switch on the 24 VDC power supply.
C. Remove the test leads.

BB861-XA02XEN BASIC CONTROL DEVICES 36

Copyright © 201 0 Amatrol, Inc.
 SEGMENT 3

1. Pushbutton switches are used in control systems to manually send

____ (input/output) signals to the controller.

2. The two basic parts of pushbutton switches are the and the
contact blocks.

3. Pushbutton switches are assumed to be (momentary/

maintained) unless otherwise stated.

4. The "Mushroom" head type operator is reserved for

____ functions.

5. The "Extended" type operator is considered to be (guarded!

unguarded).

BB861-XA02XEN BASIC CONTROL DEVICES 37

Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 10 5 " TION OF

.1'hi. A selector switch is a type of manual switch that operates its contacts by
."
lit : rotating the operator into a position. It is most often used to change the mode of
operation of a machine. Typical applications include On/Off, Manual! Automatic,
Run/Jog and ForwardlReverse.

SELECTOR
SWITCHES

Figure 31. Selector Switches on Operator Station

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Copyright © 201 0 Amatrol, Inc.
 -~-s<-,,-- --....,....,."'"I""7"'7'':~t·'7~~~;.~~-~}'''':~~7~~~,

OBJECTIVE 10 Y:DE~C.. BE-T· ." . . liON,

;'.,.

A selector switch is a type of manual switch that operates its contacts by

rotating the operator into a position. It is most often used to change the mode of
operation of a machine. Typical applications include On/Off, ManuaII Automatic,
Run/Jog and ForwardlReverse.

SELECTOR
SWITCHES

Figure 31 . Selector Switches on Operator Station

BB861-XA02XEN BASIC CONTROL DEVICES 38

Copyright © 201 0 Amatrol, Inc.

--------.-----
 OBJECTIVE 11 DE ION 0 IVE I

A selector switch consists of a rotary-actuated operator and one or more sets of

contacts. Rotating the operator into a position will cause the contacts to be opened
or closed. Shown in figure 32 is the 2-position selector switch supplied with the
Amatrol 850 series electro-fluid power training system and its ladder diagram
symbol. This selector has a rotary operator that is maintained in either position. It
also has one contact block containing a set of normally open contacts and a set of
normally closed contacts.

SELECTOR SWITCH

Y-
ROTARY OPERATOR
OPERATOR

O :,0-
LI NORMALLY
NORMALLY I OPEN
CLOSED I CONTACTS
CONTACTS

NORMALLY CLOSED
CONTACTS
I
NORMALLY
OPEN
CONTACTS

Figure 32. A Typical Selector Switch

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Copyright © 201 0 Amatrol, Inc.
 Selector switches, like pushbutton switches, can be momentary or maintained.
The maintained types stay in the position you set after you remove your hand while
the spring return, or momentary types, return to another position when you release
them. Maintained types are most often used to select a mode of operation for the
machine, because they will hold their position after being released. The momen-
tary types are commonly used for jogging, because they will stop the actuator
when the person releases the operator.
Figure 33 below shows examples of selector switches in a ladder diagram
circuit. If a selector switch contains multiple contacts, a dashed line is drawn on the
ladder diagram connecting these contacts to indicate that the same operator actu-
ates all the contacts. The direction of the solid arrow (right or left) on the selector
switch symbol indicates which position the switch is in when its contacts are in the
states shown on the diagram. For example, when ISS in figure 33 is in the right
hand position, the contacts on rungs 1 and 4 are open and the contacts on rung 3
are closed. Switching the selector to the other position will close the contacts on
rungs 1 and 4 and open the contacts on rung 3.

L1 L2

SOL-A
3 4 2

SOL-B
5 2
2

, /
POWER
2
3
I
I
/ , ON

-L
4 0
7
a,
/
2 POWER
OFF

Figure 33. Selector Switch Examples in a Ladder Diagram

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Copyright © 2010 Amatrol, Inc.
 Three-position selector switches follow the same conventions as two-position
types. However, three-position selector switches require additional information on
the ladder diagram next to each set of contacts to indicate in what positions the
contacts are closed or open. This information is most often presented in the form
of a CAM CHART or TARGET TABLE, as shown in figure 34.
A CAM chart consists of a box for each position of the switch. Each of these
boxes has inside it either an "X" or an "0". The "X" indicates that the contacts
are closed when the switch is in the position represented by the box. The "0"
indicates that the switch is open. As shown in figure 34, there are three boxes for a
three-position switch. For the contacts on rung no. 1, the boxes show "OXO". This
means that the contacts are open in the left and right positions and closed in the
center position. Each set of contacts has its own separate chart.
This chart is called a CAM chart because a cam is the mechanism used inside
the selector switch to create the contacts conditions for each position.

2
L1
AUTTOFF
1 MAN

I / -,:
3 L2

I 1 2 3 3
, /
2
I
I @EI£l / ,
I
I

4
, /
2
2
~ / ,
5
, /
2
3
@E0 /
,

Figure 34. Operation of a Three-Position Selector Switch

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Copyright © 201 0 Amatrol, Inc.
 Another convention for representing the positions of the contacts is shown in
figure 35. An L for left hand or an R for right hand is placed next to the contact.
This indicates that when the switch is in the designated position, the contact is
closed. In figure 35, when the switch is in the left-hand position, the first contact
is closed and the motor moves in the reverse direction. When the switch is in the
right hand position, the second contact closes and the motor moves in a forward
direction.

O.L.
T1
L1

F O.L.
T2
L2

F O.L.
T3
L3

H2 H1

X1 X

SS1

1REV~oRN __ D 3~ ~

L : ~

4
2 F
R

Figure 35. Wiring Diagram of a Three Phase Motor Connected to Power Through
a Motor Starter

An excellent feature of three-position switches is the cam on the selector is

available in many different styles so that you can have different cam charts for each
set of contacts.

BB861-XA02XEN BASIC CONTROL DEVICES 42

Copyright © 2010 Amatrol, Inc.
 SKILL 7

Procedure Overview
In this procedure, you will use a ladder diagram as a reference to either
connect a circuit or interpret a circuit containing a selector switch.

o 1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

4',
6.
'K
o
i.•..
o 2. Perform the substeps to supply power to the trainer.
A. Connect the portable #16019 24 VDC power supply to the Electrical
Control Module.
B. Plug the power supply plug-in connector cable #16179 into the jack on the
front of the trainer.
C. Turn on the main switch on the 24 VDC power supply.
D. Turn the control power switch to the off position (switch down).
o 3. Connect the circuit shown in figure 36.

L1 L2
STOP
1PB 2PB
yS1 ----L ----L
1 0 3 4 5
RUNG 1 010 0
1 1
1 1
1 I
I I
1 I
1 7
RUNG 2

Figure 36. Example of a Selector Switch in a Ladder Diagram

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Copyright © 201 0 Amatrol, Inc.
 o 4. Place the selector switch SS! in the left position.
o 5. Turn on the control power switch.
Power should now be supplied to the jacks under LIon the Electrical Control
Module.
Examine the initial status of the circuit.
Red Lamp (On/Off)

Green Lamp (On/Off)

With power supplied to this circuit and the switch in the left-hand position,
the red lamp should be off and green lamp should be on.
o 6. Test the operation of this selector switch control logic circuit by moving SS 1
to the right position. Record the status as indicated.
RedLamp (On/Off)

Green Lamp (On/Off)

Turning the switch to the right hand position causes the green light to go off.
The red light also stays off because IPB is not pressed.
o 7. Now with the switch still in the right-hand position, press and hold IPB and
2PB.
RedLamp (On/Off)

Green Lamp (On/Off)

With the selector switch in the right-hand position, IPB and 2PB pressed, the
red lamp is on. The green lamp is off.
o 8. Release IPB and 2PB.
o 9. Return the selector switch to the left hand position.
010. Perform the steps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the power switch on the 24 VDC power supply.
C. Remove the test leads.

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Copyright © 2010 Amatrol, Inc.
,-

011. Perform the following sub steps to interpret the operation of the circuit shown
in figure 37. This circuit uses a 3-position selector switch.

L1 L2
••
51I
I
SS1
3

I !RIQI2I
I

--L
I

@mI

Figure 37. Examples of a 3-Position Selector Switch in a Ladder Diagram

A. Describe the initial status of the circuit when power is supplied (switch in
right hand position):
Red Lamp (On/Off)

Green lamp (On/Off)

With the switch in the right hand position and the power supplied to the
circuit, both the red and green light are off.
B. Describe the status of the red and green lamps. When the switch is moved
to the middle position.
Red Lamp (On/Off)

Green lamp (On/Off)

With the switch in middle position, the green light is off and the red light
is on.
C. Describe the status of the red and green lamps when the switch is moved
to the left hand position.
Red Lamp _ (On/Off)

Green lamp (On/Off)

With the switch in left hand position, the green light is on and the red light
is off.

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Copyright © 201 0 Amatrol, Inc.
 SEGMENT 4

1. A selector switch consists of a -actuated operator and one

or more sets of contacts.

2. (MaintainedIMomentary) type selector switches are

commonly used to jog an actuator to a desired position.

3. A line on a ladder diagram indicates the multiple contacts of

a selector switch.

4. Three position selector switches use a chart next to

each set of contacts to indicate in what positions the contacts are closed
or open.

5. Typical selector switch applications include ON/OFF, Forward!

Reverse, Run/Jog, and _

BB861-XA02XEN BASIC CONTROL DEVICES 46

Copyright © 2010 Amatrol, Inc.