Pneumatic Systems

Module 2: Direct and Indirect Control in

Electro-pneumatics

PREPARED BY

IAT Curriculum Unit

August 2008

© Institute of Applied Technology, 2008

AT0000 – Pneumatic Systems

2 Module 2: Direct and indirect control in electro-pneumatics

 AT0000 – Pneumatic Systems

Module 2: Direct and Indirect Control in

Electro-pneumatics

Module Objectives

The students will be familiar with:

1- Electrically actuated directional control valves (solenoid valves).
2- Direct control in electro-pneumatics.
3- Indirect control in electro-pneumatics.
4- Advantages and disadvantages of direct and indirect control
techniques.
5- Simple electric circuits.

Module Contents

1 Electrically actuated directional control valves P4

(solenoid valves)
2 Direct control in electro-pneumatics P6
3 Experiment 1 P7
4 Experiment 2 P9
5 Assignments P11
5 Indirect control in electro-pneumatics P13
6 Experiment 3 P14
7 Experiment 4 P16
8 Assignments P18

Module 2: Direct and indirect control in electro-pneumatics 3

AT0000 – Pneumatic Systems

Electrically actuated directional

control valves (DCV) - Solenoid
valves.
+24V
An electro-pneumatic control system
works with two forms of energy.

• Electrical energy in the signal control Coil solenoid

section.

• Compressed air in the power section. Valve Spool

0V
Electrically actuated DCVs are switched
with the aid of a coil that is called a
solenoid. The coil attracts or repels the
a) Solenoid coil is not powered.
valve spool, see Fig. 2.1-a.

• When the pushbutton is pressed,

current flows through the solenoid
coil, the solenoid is energized causing 24 V
the valve spool to move, which in
turn will switches the valve to the
second position where the air flows to
fill the cylinder and cylinder piston will
advance, see Fig 2.1 –b.

• Releasing the pushbutton will cut the OV

current flow, this will de-energize the
solenoid and the DCV moves back to
its normal position. b) Solenoid coil is powered.

Fig. 2.1: Actuation of a DCV

with a solenoid.

4 Module 2: Direct and indirect control in electro-pneumatics

 AT0000 – Pneumatic Systems

Solenoid valves are divided

into two groups:

1. Single solenoid valve with a

spring return.
The valve remains in the actuated
position as long as the current
flows through the solenoid.

Example

5/2 DCV with single solenoid and

spring return, Fig.2.2.

2. Double solenoid valves.

The valve will keep and maintain

the last switched position even
when no current flows through the
solenoid. It is sometimes called Fig. 2.2: I.S.O. Symbol 5/2 DCV,
memory valve. Single solenoid, Spring return

Example

5/2 DCV, with double solenoid,

Fig. 2.3.

Fig. 2.3: I.S.O. symbol 5/2 DCV,

Double Solenoid.

Module 2: Direct and indirect control in electro-pneumatics 5

AT0000 – Pneumatic Systems

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).

Advantages of direct control

• Simple and easy.

• 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.

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Experiment # 1

Title

Direct control of a double acting cylinder by

using 5/2 DCV, single solenoid.

Solenoid coil
Objectives Spring

Students to be familiar with:

• 5/2 DCV, single solenoid, with spring

return.
• Electro-pneumatic equipments.

Background

A direct control circuit is used to control a

5/2 DCV single solenoid by using a push
button switch. Pressing the pushbutton will
energize the coil (solenoid) which in turn
will actuate the valve.

Required components

SR. Name Qty.

1 Double–acting cylinder 1
2 5/2 way valve, single solenoid 1
3 Power supply 1
4 Switches 1

Module 2: Direct and indirect control in electro-pneumatics 7

AT0000 – Pneumatic Systems

Procedure

1- Connect the pneumatic circuit

according to the pneumatic circuit
a).
2- Connect the electric circuit according
to the electric circuit b).
3- Check that all parts are connected
properly with each other. 4 2
4- Switch the power on from the power
Y1
supply and open the service unit.
5 3
1
5- Press switch S1. Explain what
happens to the cylinder.
...................................................
...................................................
...................................................
a) Pneumatic circuit
...................................................
6- Release switch S1. Explain what
+24V
happen to the cylinder.
...................................................
...................................................
................................................... 3
7- Replace switch S1 with a detent
switch, repeat the steps above and S
1
explain what happen to cylinder. 4
...................................................
...................................................
................................................... Y1
...................................................
8- Turn the power off and close the
service unit. 0V
9- Dismantle and tidy up.
b) Electric circuit
Conclusion
............................................................................................................
............................................................................................................
............................................................................................................
............................................................................................................
............................................................................................................
............................................................................................................

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Experiment # 2

Title

Direct control of a double acting

cylinder by using 5/2 DCV, double
solenoid.

Objectives Solenoid coil 2

Solenoid coil 1

Students to be familiar with:

• 5/2 DCV, double solenoid.
• Electro-pneumatic components.
• Electric circuits.

Background

A direct control circuit is used to

control a pneumatic circuit by
using push button switches; that
give a direct signal to the solenoid. 4 2

Y1 Y2
Required components 5 3
1

SR. Name Qty.

Double – acting
1 1
cylinder
5/2 way valve,
2 1
double solenoid.
3 Power supply 1
4 Switches 1

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AT0000 – Pneumatic Systems

Procedure

1. Connect the pneumatic circuit

according to the pneumatic circuit a).
2. Connect the electric circuit according
to the electric circuit b).
4 2
3. Check that all parts are connected
properly with each other. Y1 Y2
5 3
4. Switch the power supply on and open 1
the service unit.
5. Press switch S1. Explain what
happens to the cylinder.
.....................................................
.....................................................
..................................................... a) Pneumatic circuit
.....................................................
1 2
6. Release switch S1 and explain what +24V
happens to the cylinder. Did the
piston retract?
..................................................... 3 3
.....................................................
S1 S2
...............................................
.................................................... 4 4
7. Press switch S2 and explain what
happen to the cylinder.
..................................................... Y1 Y2
.....................................................
.....................................................
8. Release switch S2. 0V
9. Turn the power off and close the
service unit.
b) Electric circuit
10. Dismantle and tidy up.

Conclusion
........................................................................................................
........................................................................................................
........................................................................................................
........................................................................................................
........................................................................................................

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 AT0000 – Pneumatic Systems

Assignment 1: Class work

1. What is the difference between a 5/2 directional control valve, single

solenoid and a 5/2 Directional control valve, double solenoid.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
2. Draw the I.S.O symbol of both
• a 5/2 DCV, single solenoid
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
…………………………………………………………………………………………………
• a 5/2 DCV, double solenoid.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
…………………………………………………………………………………………………
3. Draw a pneumatic and an electric circuit to control a double solenoid
valve directly, by using a normally closed detent switch.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………

Module 2: Direct and indirect control in electro-pneumatics 11

AT0000 – Pneumatic Systems

Assignment 2: Home Work

The circuit below illustrates an electro-pneumatic system. Answer the

following questions:

+24V 1

3
S1
4
4 2 3
S2
Y1
5 3 4
1

Y1

0V

Pneumatic circuit Electric circuit

1. What is the type of switch S1 and S2?

………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
2. Is the electric circuit above direct or indirect? Explain why.
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
3. What is the name of the part which labeled as Y1?
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
4. Explain what happen when switch S1 is pressed. Does the cylinder
extend?
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
5. Explain what happens when switch S2 is pressed. Does the cylinder
extend?
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
6. Suggest a way to extend the above cylinder using the same electric
circuit.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………

12 Module 2: Direct and indirect control in electro-pneumatics

 AT0000 – Pneumatic Systems

Indirect control in electro-pneumatics

Indirect control is the control of an electro-pneumatic valve using

intermediate components such as a relay, a contactor or any industrial
computer (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.

Disadvantages of direct control

• Complicated, more wiring.

• More cost involved.

Module 2: Direct and indirect control in electro-pneumatics 13

AT0000 – Pneumatic Systems

Experiment # 3

Title

Indirect control of a double acting cylinder by using 5/2 DCV, single

solenoid with spring return.

Objectives

The students will be familiar with :

1. 5/2 way valve single solenoid.
2. Relays and switches.
3. Indirect control circuit.

Background

We use a relay to indirectly control a solenoid valve.

Required components

SR. Name Qty.

1 Double acting cylinder 1
2 5/2 DCV, single solenoid 1
3 Power supply 1
4 Switches block 1
5 Relays block 1

14 Module 2: Direct and indirect control in electro-pneumatics

 AT0000 – Pneumatic Systems

Procedure

1. Connect the pneumatic circuit

according to the pneumatic circuit a).
2. Connect the electric circuit according
to the electric circuit b).
4 2
3. Check that all parts are connected
properly with each other. Y1
4. Switch the power supply on and open 5 3
1
the service unit.
5. Press switch S1 and explain what
happens to the cylinder. Did the
piston extend?
.....................................................
..................................................... a) Pneumatic circuit
.....................................................
+24V 1 2
6. Release switch S1 and explain what
happens to the cylinder. Did the
piston retract?
3 3
....................................................
.................................................... S1 K1
.................................................... 4 4
...................................................
7. Turn off the power. Connect the relay
A1
as normally closed and reconnect the
power. Explain what happen to the K1 Y1
cylinder with and without pressing A2
the switch S1. 0V
.................................................
.................................................
.................................................
2
8. Turn the power off and close the
service unit.
b) Electric circuit
Conclusion
......................................................................................................
......................................................................................................
......................................................................................................
......................................................................................................
......................................................................................................

Module 2: Direct and indirect control in electro-pneumatics 15

AT0000 – Pneumatic Systems

Experiment # 4

Title

Indirect control of a double acting cylinder by using 5/2 DCV, double

solenoid.

Objectives

The students will be familiar with :

• 5/2 DCV, double solenoid.
• Relays.
• Switches.
• Indirect control circuit.

Background

We use a relay to indirectly control a solenoid valve.

Required components

SR. Name Qty.

1 Double acting cylinder 1
2 5/2 DCV, double solenoid 1
3 Power supply 1
4 Switches block 1
5 Relays block 1

16 Module 2: Direct and indirect control in electro-pneumatics

 AT0000 – Pneumatic Systems

Procedures

1. Connect the pneumatic circuit

according to the pneumatic circuit a).
2. Connect the electric circuit according
to the electric circuit b).
3. Check that all parts are connected 4 2
properly with each other.
Y1 Y2
4. Switch the power supply on and open 5 3
the service unit. 1

5. Press switch S1 and explain what

happens to the cylinder. Did the
piston extend?
..................................................... a) Pneumatic circuit
.....................................................
..................................................... +24V 1 2 3 4
6. Release the switch S1 and explain
what happen to the cylinder. Did the
piston retract? 3 3 3 3
S1 K1 S2 K2
.....................................................
4 4 4 4
.....................................................
.....................................................
7. Press switch S2 and explain what
A1 A1
happens to the cylinder. Did the
piston retract? K1 Y1 K2 Y2
A2 A2
..................................................... 0V
.....................................................
.....................................................
8. Turn the power off and close the 2 4
service unit.
9. Dismantle and tidy up. b) Electric circuit

Conclusion
......................................................................................................
......................................................................................................
......................................................................................................
......................................................................................................
......................................................................................................
......................................................................................................

Module 2: Direct and indirect control in electro-pneumatics 17

AT0000 – Pneumatic Systems

Assignment 3: Class work

4. Draw the I.S.O symbol of both
• A 5/2 DCV, single solenoid.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
• A 5/2 DCV, double solenoid.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
5. Explain the difference between direct and indirect control.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
6. What is the function of a relay?
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
7. Draw the I.S.O symbols of a relay.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
8. Draw a pneumatic and an electric circuit to control a double solenoid
5/2 DCV indirectly through N.C. relay and pushbutton switches.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………

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 AT0000 – Pneumatic Systems

Assignment 4: Home Work

The circuit below illustrates an electro-pneumatic system. Answer the
following questions:
+24V 1 2 3 4 5 6

3 3 3 3 3
S1 S2 K1 S3 K2
4 4 4 4 4
2
Y1 Y2
5 3 A1 A1
1
K1 Y1 K2 Y2
A2 A2
0V

4 6
Pneumatic circuit Electric circuit

1. What type of switch are switches S1, S2 and S3?

………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
2. Is the electric circuit above direct or indirect? Explain why.
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
3. What is the name of the part which is labeled as Y1?
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
4. Explain what happens when the switch S1 is pressed. Does the cylinder
extend? Explain why.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
5. Explain what happens when the switch S2 is pressed. Does the cylinder
extend? Explain why.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
6. Explain how to retract the above cylinder.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………

Module 2: Direct and indirect control in electro-pneumatics 19