PRACTICAL TUTORIALS

1. You are provided with a schematic of a boom control electrohydraulic system, as shown in
Figure 1, that is used for lifting and positioning operations. The system includes a hydraulic
power unit, a directional control valve, two double-acting cylinders, flow control valves,
and return lines.
Tasks:
a). Identify key components (Source of oil energy, DCV, flow valves if applicable,
cylinders).
b). Identify key electrical components (Source of electrical energy, relay, time on
delay relay, push button switches, limit switches).
c). Actuate the system and state if it is running or not running.
d). What is the function of the limit switches in your circuit?
e). State the function of 1V, 2V, 3V, 1A1 and 1A2 components.
f). State the possible causes of fault in the system operation.

1 A1 1 A2

F=0 F=10
+24V 1 2 3 4

3
3
B B S1
K1 3
3
4
2 V 3 V K1 K1
4
4
A A 4

1 5

T1
1 V A B
2

1Y
P T A1
A1
B T1 10
K1 1Y
A2
A2

A
M
P T

0V

Ts

2 1
3
4

Figure 1: Boom control electrohydraulic system

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 2. Double acting cylinder is used to perform to and from operation. Cylinder has to move
forward when Start button is pressed and continue to and from motion till 10 cycles of
operations is performed. Start button used to reset the counter and stop button is used as an
emergency.
Tasks:
a). Draw the pneumatic circuit
Answer;

L1 L2

A1

V1 V2

V0 4 2

SL1 SL2
5 3
1

b). Draw an electrical wiring diagram for PLC

Answer;

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 +24V 1 3 4 5

3 3 3 3

START STOP L1 L2

4 4 4 4

+24V

24V I1 I2 I3 I4 I5 I6 I7 I8

0V Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

0V

SL2
SL1

0V

c). Prepare a ladder logic diagram (LAD) control for the operation in the TIA Portal
software.
Answer;

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 d). State the possible causes of the system's fault.
Answer;
‒ If V1, and V2 are fully clogged
‒ If solenoids on the V0 are not receiving enough 24V
‒ If the compressor is not delivering enough pressure to the system
e). Using a PLC, implement and test your LAD for the system. (LAB WORKS)
3. You are provided with a schematic of a boom control hydraulic system, as shown in Figure
1, that is used for lifting and positioning operations. The system includes a hydraulic power
unit, a directional control valve, two double-acting cylinders, flow control valves, and
return lines.
Tasks:

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 a). Identify key components (DCV, flow valves, and cylinders)
b). State the function of 1V, 2V, 3V, V4, V5, V6, V7, 1A1 and 1A2 components.
c). Explains the function of the flow rate valves in the circuit.
d). Actuate the system and state if it is running or not running.
e). What happens if valves V4, V5, V6 and V7 in the circuit are fully clogged?
f). Explain possible causes of fault in the circuit.

L1 L2
L3

A1
A2
B B +24V 1 2 3 4 5 7 8 9
B B
V4 V5
V6 V7 3
3 3 3
3 3
A A 3
K1 L2 K2
A A K1 K3
K2
V2 4 4 4
A B A B 4 4 4
V3 4

SL1 SL2 SL3

P T P T
1
1
L1
K2 L3
B 2
2

V1
A A1 A1 A1
Z0 P T
K1 K2 K3 SL1 SL3 SL2

A2 A2 A2

Ts

0V

2 1 4 9
7 8

Figure 2: Boom control hydraulic system

4. Double acting cylinder is used to perform continuous to and from motion. Cylinder has to
move forward when start button PB1 is pressed and retract after 10 seconds, it should
continue to and from motion till stop button PB2 is pressed. Limit switches are used for
end position sensing.
Tasks:
a). Draw the pneumatic circuit
Answer;

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 L1 L2

A1

V1 V2

V0 4 2

SL1 SL2
5 3
1

b). Electrical wiring diagram for PLC

Answer;
+24V 1 3 4 5

3 3 3 3

START STOP L1 L2

4 4 4 4

+24V

24V I1 I2 I3 I4 I5 I6 I7 I8

0V Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

0V

SL2
SL1

0V

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 c). Prepare a ladder logic diagram (LAD) control for the operation in the TIA Portal
software.
Answer

d). State the possible causes of the system's fault.

Answer

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 ‒ If V1, and V2 are fully clogged
‒ If solenoids on the V0 are not receiving enough 24V
‒ If the compressor is not delivering enough pressure to the system
e). Using a PLC, implement and test your LAD for the system. (LAB WORK)

5. You are provided with a schematic of a boom control hydraulic system, as shown in Figure
1, that is used for lifting and positioning operations. The system includes a hydraulic power
unit, a directional control valve, two double-acting cylinders, flow control valves, and
return lines.
Tasks:
a). Identify key components (DCV, flow valves, and cylinders)
b). Explains the function of the flow rate valves in the circuit.
c). Actuate the system and state if it is running or not running.
d). What happens if valves 1V3 in the circuit is fully clogged?
e). Explain possible causes of fault in the circuit.

S0 S1
2M
1A

B +24V 1 2 3 4 5 6 7 8 9

1 V3
13 14 14 24 34 24
1Z 3
3
A ST K1 S1 K3 K1 K2 K3
S2
K2
14 11 11 21 31 21
4
4

1
1 V1 A B 2 V1 A B
S0

1Y 1 1Y 2 2Y 2
12 22
P T P T
K2 K2
B
11 21

A1 A1 A1 1Y 2
1Y 1
A
K1 K2 K3 2Y
P T
A2 A2 A2
0V

Ts
2 1 4 6
7 5 8 9

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