CHAPTER 3

ELECTRO-PNEUMATICS

3.1 Learning Outcome

At the end of this module, student will be able to:
a) Identify and use the typical electro-pneumatics components.
b) Design electro-pneumatic circuits using DCV single solenoid and DCV double
solenoids for single and multiple cylinders with various outputs.
c) Install and test-run the electro-pneumatic circuits based on the designed cicuit.

3.2 Theory

3.2.1 Definition and Advantages

Electro-pneumatic term is defined from words of electro which mean electrical and
pneumatic which mean air pressure. The electro-pneumatic equipments and system is
an integration of electrical and mechanical components with compressed air source.
The electrical controller work with 12 to 24V DC electrical source.

Electro-pneumatic controllers have the following advantages over pneumatic control

systems:
• Higher reliability (fewer moving parts subject to wear).
• Lower planning and commissioning effort, particularly for complex controls.
• Lower installation effort, particularly when modern components such as valve
terminals are used.
• Simpler exchange of information between several controllers.

Electro-pneumatic controllers have asserted themselves in modern industrial practise

and the application of purely pneumatic control systems is a limited to a few special
applications.

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3.2.2 Components
Both pneumatic and electro-pneumatic controllers have a pneumatic power section. In
an electro-pneumatic control, the signal control section is made up of electrical
components, for example with electrical input buttons, proximity switches, relays, or a
programmable logic controller. The directional control valves form the interface
between the signal control section and the pneumatic power section in the controller
(refer figure 3.1).

Power components
- Cylinder
Command - Swivel cylinder Pneumatic
execution - Pneumatic motors power section
- Optical displays

Final Control Elements

Signal - Electropneumatically
output operated directional
control valves

Processing Elements
Signal - Relays
processing - Contactors
- Programmable logic
controllers (PLCs)
Electrical signal
Input Elements control section
Signal - Pushbuttons
input - Control switches
- Limit switches
- Reed switches
- Ind. proximity sensors
- Cap. proximity switches
- Light barriers
- Pressure-actuated
switches

Signal flow Electro-pneumatic

Components

Figure 3.1: Signal flow and components of an electro-pneumatic control system

Source : Prede, G. and Scholz, D.
FESTO Electro-Pneumatic Basic Level TP201 Textbook

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3.2.2.1 Switch
There are three (3) types of electrical switches used in the design of electro-pneumatic
circuit. They are:
i) Opened contact switch
ii) Closed contact switch
iii) Multiple contact switches.

Figure 3.2(a), 3.2(b) and 3.2(c) shows the three types of contact switches at the
training box.

3 13 23 33 43

4 14 24 34 44

Switch Ordinary No.

Position of switch

Figure 3.2(a): Opened contact switches

11 21 31 41
1

2
12 22 32 42

Switch Ordinary No.

Position of switch

Figure 3.2(b): Closed contact switches

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 Single unit Multiple units

2 4 12 14 22 24 32 34 42 44

1 11 21 31 41

Switch Ordinary No.

Position of switch

Figure 3.2(c): Changeover contact switches consist of opened and

closed contact switches

3.2.2.2 Switching Method for Logic Operations

Six basic switching methods in an electrical circuit consist of single or multiple
switches as shown in the Figure 3.3(a), 3.3(b) and 3.3(c).

YES Gate (Identify) NOT Gate (Negation)

24V 24V

13 11

14 12

H1 H1

0V 0V

Figure 3.3(a): YES gate and NOT gate are the simplest electrical circuits

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 OR Gate (Disjunctive) AND Gate (Conjunctive)
24V 24V 13
13 23

14
14 24 13

H1 14
H1
0V 0V

Figure 3.3(b): OR Gate and AND Gate uses parallel and serial circuits with
opened contact switches.

NOR Gate NAND Gate

24V 24V
11
11 21

12

11 12 22

12

H1
H1

0V 0V

Figure 3.3(c): NOR Gate and NAND Gate uses serial and parallel circuits with
closed contact switches.

3.2.2.3 Relay
Relay is an electrical device which contains a coil and a contactor switch. Relay also
can consist of a coil and multiple contactors. Figure 3.4 shows a coil (K) with 4
contactor switches at a training box.

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 Coil Changeover Contact

A1 12 14 22 24 32 34 42 44

A2 11 21 31 41

Switch Ordinary No.

Position of switch

Figure 3.4: Relay with a coil and multiple contactor switches

Coil Same changeover contact

A1 12 14 12 14 12 14

A2 11 11 11
ordinary condition energized de-energized
(before energize)

Figure 3.5: The current flow in the coil will change the condition of
contactor switch

Figure 3.5 illustrates the changes of contactor switch. Once the current energizes the
coil, the contactor will switch from closed contact to be an opened contact. Inversely,
once the coil is de-energized, the contactor will return to it ordinary condition.

Relay has a few functions as a safety device:

1) The high voltage output (i.e. 240V) can be switched ON through a contactor
using relay with low voltage (i.e. 24V) supplied to a coil.
2) The high current output can be switched ON through a contactor using relay
with low current supplied to a coil.
3) Switching more than one outputs simultaneously using relay with a coil with
multiple contactors.

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Figure 3.6(a) and 3.6(b) shows the electrical circuits with a relay and single output
(H1), and multiple outputs (H1, H2, H3, H4).

WITHOUT Relay WITH Relay

24V 24V

S1 S3 S1 S3

K1
S2 S2

H1 R1 H1

0V 0V

Figure 3.6(a): The electrical circuits WITHOUT and WITH relay (R1)

24V
13
S1
14 24 34 44
14 K1 K1 K1 K1

11 21 31 41

A1
K1 H1 H2 H3 H4
A2
0V

Figure 3.6(b): Relay in an electrical circuit is used to switch

4 lamps H1, H2, H3 and H4

3.2.2.4 Solenoid Valve

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Solenoid valve is an electro-mechanical device that built-in with a coil (solenoid) and
a pneumatic/hydraulic directional control valve (DCV). There are three types of built-
in solenoid directional control valve. They are:
• 3/2 Way DCV single solenoid with spring return
• 5/2 Way DCV single solenoid with spring return
• 5/2 Way DCV double solenoid

The 3/2 way DCV single solenoid with spring return is used to control the actuation of
single acting cylinder, while the 5/2 way DCV single solenoid or double solenoid
respectively are used to control the actuation of double acting cylinder.

The 5/2 way DCV single solenoid and double solenoid can be distinguished by a built-
in spring instead of coil. DCV single solenoid or monostable valve consists of a built-
in solenoid at the left hand side and a built-in spring at the right hand side of the valve.
For the case of ‘normally closed DCV’, once the electrical current energizes the
solenoid, the valve is pushed to an ‘Opened’ position. Inversely, when the solenoid is
de-energized, the spring will push the valve back to the ‘Closed’ (original) position.
DCV double solenoid consists of two solenoids at the both sides of the valve. Both
solenoids are energized by electrical current to push the valve to an ‘Opened’ and
‘Closed’ positions. It is also called ‘bistable valve’ or ‘memory valve’.

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 Pneumatic
circuit
2 2

y1 y1
1 (P) 3 1 (P) 3

3/2 way DCV single solenoid 24V

with spring return
S1

K1
Electrical
circuit
R1 y1

0V

Figure 3.7: Electro-pneumatic circuit for actuating a single acting cylinder

Figure 3.7 shows the pneumatic and electrical circuits (electro-pneumatic circuits) for
actuating a single acting cylinder using 3/2 DCV single solenoid with spring return.
Then, Figure 3.8(a) and 3.8(b) shows the pneumatic and electrical circuits for
actuating a double cylinder using 5/2 DCV single solenoid and double solenoids
respectively.

Pneumatic
circuit
4 2 4 2

y1 y1
5 3
5 3
1 (P) 1 (P)

5/2 way DCV single solenoid

24V
with spring return
S1

K1
Electrical
circuit
R1 y1

0V

Figure 3.8(a): 5/2 DCV single solenoid is used for actuating a

double acting cylinder

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 Pneumatic
circuit

4 2 4 2

y1 y2 y1 y2

5 3 5 3
1 (P) 1 (P)
24V
5/2 way DCV double solenoid

S1 K1 S2
K2
Electrical
circuit

R2
R1 y1 y2

0V

Figure 3.8(b): 5/2 DCV double solenoid is used for actuating a

double acting cylinder

3.2.2.5 Proximity Sensor

Proximity sensors are commonly used to monitor a process condition in a machine.
For instance, sensor is used to ensure the raw part was placed on a fixture, height of
raw material within control, etc. There are three types of proximity sensors (Figure
3.9), they are:
• Inductive sensor – able to detect metal, especially mild steel.
• Capacitive sensor – able to detect most parts except low density product.
• Optical sensor – able to detect bright surface reflectively except black /
rough surface.

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 Inductive Sensor Capacitive Sensor
24V 24V

R R

0V 0V 0V 0V

24V

Optical Sensor

0V 0V

Figure 3.9: Three types of proximity sensors

PS a1
Pneumatic
circuit 4 2

y1 y2

5 3

1 (P)

24V
PS

S1 a1

Electrical K1 K2

circuit K3

R2 R3
R1 y1 y2

0V

Figure 3.10: Proximity sensor (PS) is placed at the beginning of the

actuator movement

3.2.2.6 Electrical Timer

The electrical timer can be classified to two types, they are:
• Time delay ON timer
• Time delay OFF timer

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Time delay ON timer delays the switching time upon an energizing. Let say a timer is
set to 5 seconds. When the timer coil T1 is energized, the timer will start compute the
time from zero second, thus the switches will change after 5 seconds. On the other
hand, when the timer coil T1 is de-energized, all switches will instantly return to it
original conditions.

Time delay OFF timer delays the switching time upon de-energizing. Let say a timer is
set to 10 seconds. When the timer coil T2 is energized, the timer will instantly change
the switching. Inversely, when the timer coil T2 is de-energized, the timer will start
compute the time until 10 seconds before the switches return to it original conditions.
Figure 3.11 shows the symbols for both types of delay timers.

A1 17 27 35 45

T1

A2 18 28 36 46

Switch Ordinary No.

Position of switch

A1 17 27 35 45

T2

A2 18 28 36 46

Figure 3.11: Symbols of time delay ON and time delay OFF timers at a
controller box

Figure 3.12 shows the simple electrical circuit which consist of time delay OFF timer.
Once the switch S1 is pressed, the timer T2 is energized and the contactor K2 will
instantly changed to a closed contact condition. Then, if the switch S1 is released, the
timer will start computer the time to 5 seconds before the contactor K1 return to an
opened contact condition.

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 24V

S1

K1

Setting time
5 secs T1 Lamp

0V

Figure 3.12: Electrical circuit with time delay OFF timer

3.2.2.7 Electrical Counter

An electrical counter can count 1000 numbers from ‘0’ to ‘999’. The count number
can be set when a counter is connected with a switch and a relay for reset. The counter
will start counting upon receive an electrical pulse. The switch will change upon the
counting is finished. The separated signal is needed as a reset to return the switch to it
original condition and reset the counter to ‘0’.

Counter Switch Reset

4 2
A1 R1
C1

A2 1 R2

Manual reset 0 0 2 Current counting

2 4 8 User setting

Set counter

Figure 3.13: Counter, switch and reset relay need to be connected in an electrical
circuit design

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3.3 Practice

3.3.1 Practice 1

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

86400 Parit Raja, Batu Pahat, Johor Darul Ta’zim. http://www.uthm.edu.my

Fakulti Kejuruteraan Mekanikal dan Pembuatan

AMALAN KEJURUTERAAN MEKANIKAL II (BDA 1811)

Title : Electro-Pneumatic Practice I

Objectives : Upon completing this task, student be able to :

d) Draw a basic electro-pneumatic circuit, install and test run it to
move an actuator.
e) Identify and operate a few types of electro-pneumatic components.
f) Install the serial and parallel electrical circuits for OR/ AND
functions.

Task :

Design the electro-pneumatic control circuit for the following operations :

a) Press switch A to extends a cylinder piston and press switch C to retracts it.
b) Press either switch A or B will extend a cylinder piston. Then, it will be
automatically retracted when touching a limit switch.
c) Press switch A will extends a cylinder piston. It will be retracted if a sensor
detect it end while switch B is pressed.

*Use a 5/2 way DCV double solenoids.

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Name and sketch the related electro-pneumatic symbols :

a)

b)

c)

Sketch the related Pneumatic and Electrical Circuits :

a)

b)

c)

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3.3.2 Practice 2

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

86400 Parit Raja, Batu Pahat, Johor Darul Ta’zim. http://www.uthm.edu.my

Fakulti Kejuruteraan Mekanikal dan Pembuatan

AMALAN KEJURUTERAAN MEKANIKAL II (BDA 1811)

Title : Electro-Pneumatic Practice II

Objectives : Upon completing this task, student be able to :

a) Draw, install and test run the memory circuits.
b) Identify and operate a few types of electro-pneumatic components
including relay and its contactors.

Task :

Design an electro-pneumatic control circuits for the following operations :

a) Press switch A to extend a cylinder piston, while it will retract if
switch A is released.
b) Press switch A to extend a cylinder piston, and it will be retracted
once a switch B is pressed.
c) Press switches A and B to extend a cylinder piston. The piston will
be retracted if switch C is pressed or limit switch detect the piston
end. Once a piston move to extend, a green LED will be ON. Then,
a red LED will be ON when the piston reach the maximum extend
position.

* Use 5/2 way DCV single solenoid with spring return.

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Name and sketch the related pneumatic and electrical component symbols :

a)

b)

c)

Sketch the related Pneumatic and Electrical circuits :

a)

b)

c)

17
3.3.3 Practice 3

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

86400 Parit Raja, Batu Pahat, Johor Darul Ta’zim. http://www.uthm.edu.my

Fakulti Kejuruteraan Mekanikal dan Pembuatan

AMALAN KEJURUTERAAN MEKANIKAL II (BDA 1811)

Title : Electro-Pneumatic Practice III

Objectives : Upon completion this task, student be able to :

a) Draw, install and test run an electro-pneumatic circuits for multiple
cylinders with sequence motion.

Task :
Design an electro-pneumatic control circuits using two pistons for the following
operation :

Press switch A to initiate extend of piston A and switch on a green LED. Fully extend
of piston A will initiate extend of piston B. Piston A will retract to an initial position if
piston B was fully extended. Once piston A was fully retracted, a red LED will be
switching ON while piston B start to retract.
• Use two 5/2 way DCV single solenoid with spring return
• Use two 5/2 way DCV double solenoid

Write the Sequen Motion :

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Draw the Step Displacement Diagram for this operation :

Name and sketch the related pneumatic and electrical sysmbols :

Sketch the Pneumatic & Electrical circuits :

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3.3.4 Practice Case 4

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

86400 Parit Raja, Batu Pahat, Johor Darul Ta’zim. http://www.uthm.edu.my

Fakulti Kejuruteraan Mekanikal dan Pembuatan

AMALAN KEJURUTERAAN MEKANIKAL II (BDA 1811)

Title : Electro-Pneumatic Practice IV

Objective : Upon completing this task, student be able to :

a) Draw, install and test run the electro-pneumatic operation using an
electrical timer dan counter.
Task :
Install and test the following circuits :

a) (i) 24V

13 17
S1 T1

14 18

A1
5 seconds
T1 H1
A2

0V

Electro-pneumatic circuit with a ‘Time Delay ON’ timer

(ii) 24V

15 17
S1 T1

16 18

A1
5 seconds
T1 H1
A2

0V

Electro-pneumatic circuit with a ‘Time Delay OFF’ timer

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b) 24V

17 17 S2
S1 C1

18 18

A1 R1
5 seconds
C1 H1
A2
R2

0V

Electro-pneumatic circuit with an electrical counter

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3.4 References

Shuttle., (2007). Sistem Kawalan Pneumatik. Shark.

Prede, G., and Scholz, D. (1998). Electro-Pneumatic Basic Level TP201 Textbook.
Ed 12/1998. FESTO Didactic.

Groover, M.P., (2001). Automation, Production System and Computer Integrated

Manufacturing. 2nd edition. Prentice Hall.

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