CHAPTER 7

BASIC ELECTRICAL
CONTROLS FOR
FLUID POWER

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7.1 Introduction
• Electrical devices have proven to be an important means
of improving the overall control flexibility of fluid power
systems. In recent years, the trend has been toward
electrical control of fluid power systems..

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• Electro pneumatics is now commonly used in
many areas of Industrial low cost automation.
• They are also used extensively in production,
assembly, pharmaceutical, chemical and
packaging systems.
• There is a significant change in controls
systems

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In Electro pneumatic controls, mainly three important
steps are involved:
 Signal input devices -Signal generation such as
switches and contactor, Various types of
contact and proximity sensors
 Signal Processing – Use of combination of Contactors
of Relay or using Programmable
Logic Controllers
 Signal Out puts – Out puts obtained after processing
are used for activation of solenoids,
indicators or audible alarms
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7.1.1 Basic electrical devices
• Seven basic electrical devices commonly used in
control of fluid power:
1. Manually actuated push-button switches,
2. limit switches,
3. pressure switches,
4. solenoids,
5. relays,
6. timers, and
7. temperature switches.
• Can be wired either normally open (NO) or normally
closed (NC).
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Pushbuttons and their symbols
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1. Push-button switch. Mainly used for starting and
stopping operation of machinery. By the use of
simple push-button switches, an operator can cause
sophisticated equipment to begin performing
complex operation.
2. Limit switches. These open and close circuits
when they are actuated at the end of the retraction
or extension strokes of hydraulic or pneumatic
cylinders. fig-chp7\fig7.1.pptx incorporates its
own limit switches at the end of each stroke. Each
switch can be wired normally open or closed.
Symbols are also shown in the same figure.
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 There are two types
classification of Limit
switches depending
upon method of
actuations of contacts
a) Lever actuated
contacts
b) Spring loaded contacts

Cross sectional view of a limit switch

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Fig.7.1 Cylinder with built-in limit switches
3. Pressure switches. Pressure switches open or close
their contacts based on system pressure. For high
and low pressure setting, say, for a pump, it will
start the pump when pressure is low and stop the
pump when the pressure is high.
fig-chp7\fig7.2.pptx an actual pressure switch
(adjustable) and the symbol used in hydraulic
circuits. It can be wired NO or NC. It has three
terminals C (common), NC and NO.

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Fig.7.2 Pressure switch

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4. Solenoids. These are electromagnets that
provide a push or pull force to operate fluid
power valves remotely.

Cross sectional view of a 3/2 single solenoid

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 6. Timers. These are time delay devices to
control the time duration of a working cycle.
There are two types of time relay
i) Pull in delay ( on –delay timer)
ii) Drop –out delay (off delay
timer)

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7. Temperature switches. It senses a change in
temperature and opens or closes an electrical
switch. fig-chp7\fig7.3.pptx shows a
temperature screw (adjustable) with the symbol.
Also shown is a long capillary tube that enables
remote sensing.

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Fig.7.3 Remotely located temperature switch
7.1.2 Circuit diagrams
For electro hydraulic or electro pneumatic circuits,
separate circuits are drawn for the fluid and electrical
system. Electrical circuits use ladder diagrams with
the power connected to the left leg.
7.2 Electrical Components
Five basic types of electrical switches used, namely
push-button, limit, pressure, temperature, and relay
switches.
1. Push-button switches. fig-chp7\fig7.4.pptx shows
different types of switches: (a) and (b) single pole
and single-throw type; (c) double-pole, single throw
type; (d) double-pole, double throw type. 17
Fig.7.4 Push-button switch symbols
2. Limit switches (LS). fig-chp7\fig7.5.pptx shows
the various types of limit switches. The difference
with push-buttons is that they are mechanically
actuated. Among these are cams, levers, rollers,
and plungers.

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Fig.7.5 Limit switch symbols
2. Pressure switches (PS). fig-chp7\fig7.6.pptx
shows the symbols for pressure switches.

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Fig.7.6 Pressure switch symbols
2. Temperature switches. Shown in
fig-chp7\fig7.7.pptx

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Fig.7.7 Temperature switch symbols
• Electrical relays. This is an electrically
actuated switch. In fig-chp7\fig7.8a.pptx,
when switch 1-SW is closed the electromagnet
is energized and pulls

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Fig.7.8 Electrical relay (a) Schematic drawing
 the spring loaded relay arm to open the upper one and close
the lower one. The symbols are also shown in the same
figure. fig-chp7\fig7.8b.pptx
When time delay for a certain operation is required timers
are used. fig-chp7\fig7.9a,b.pptx & fig-chp7\fig7.9c,d.pptx
show different types of timer arrangements.
(a) Normally open but when energized closes after a
predetermined time
(b) Normally closed but when energized opens after a
predetermined time
(c) Normally open but when de-energized opens after a
predetermined time
(d)Normally closed but when de-energized closes after a
predetermined time
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Fig.7.9 Electrical timer symbols (c) and (d)
 The symbol for solenoid is shown in
fig-chp7\fig7.10.pptx including that of an indicator
lamp.
Indicator lamps show the active switch in a circuit
while in operation or which solenoid operator of a
DCV is energized.

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Fig.7.10 Solenoid and indicator lamps
7.3 Applications
7.3.1 Control of a cylinder using a single limit
switch
fig-chp7\fig7.11.pptx uses a single solenoid
valve and a single limit switch to control the
double-acting cylinder. In (a) is shown the
fluid circuit while
(b) shows the electrical circuit.

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Fig.7.11 Control of hydraulic cylinder using single
limit switch
• Fig. 7-11(a) gives the hydraulic circuit in which the
limit switch is labeled 1-LS and the solenoid is
labeled SOL A.
• Fig. 7-11(b) shows the use of one relay with a coil
designated as 1-CR, two separate normally open sets
of contacts, the limit switch 1-LS (NC), normally
closed (STOP) and normally open (START) push-
button switches

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• A momentary press on the START button energizes the
relay to close contact of the two CR’s.
• This will energize solenoid A which will make the left
envelope of the DCV to be in operation.
• This will then extend the cylinder.
• At the end of extension the piston rod cam will open
the NC limit switch 1-LS and this will de-energize coil
1-CR.
• This reopens the contacts of 1-CR to de-energize
solenoid A.
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• Thus, the DCV will then be in its spring-off-set
mode which will make the right envelope to be in
action and the cylinder retracts.
• The cylinder stops at the end of the end of the
retraction stroke, but the cycle is repeated each time
the START button is momentarily pressed.
• The STOP button can be a sort of emergency
button. A momentary press opens the whole circuit,
immediately stops the extension and retracts the
cylinder.

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7.3.2 Reciprocation of a cylinder using pressure or
limit switch
• fig-chp7\fig7.12.pptx shows the arrangement
how pressure switches can replace limit switches to
control the operation of double-acting hydraulic
cylinder.
• Operation starts as the switch 1 SW is closed.
Then, the cylinder reciprocates continuously until 1-
SW is opened.

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Fig.7.12 Reciprocation of cylinder using pressure
switches
• When rod is in motion both switches are open.
Assuming SOL A was last energized (left
envelope was in operation) pressure builds up
when the cylinder has fully extended.
• This is transmitted to 1-PS which energizes SOL
B and makes the right envelope in operation
resulting in retraction.
• At the end of pressure builds up again to switch
on 2-PS and energize SOL A to repeat the cycle.

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 fig-chp7\fig7.13.pptx gives the exact operation
except LS replaces PS. Note that switches are shown
in their un actuated mode in the electrical circuit.

Fig.7.13 Reciprocating of cylinder using limit switches 39

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Fig.7.14 Dual-cylinder sequencing circuit
• . Left envelope of valve V1 will be in
operation –cylinder 1 extends-closes 1LS at
the end of extension which energizes SOL C.
Left envelope of valve V2 will be in operation-
cylinder 2 extends –closes 2LS-energizes SOL
B. This will retract cylinder1 which motion
opens switch 1 LS.

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This action de-energizes SOL C and sets V2 in spring
offset mode. This sets the cylinders to retract
simultaneously.
To summarize, the complete cycle sequence
established by the momentary pressing of the START
button is as follows:
1.Cylinder 1 extends
2.Cylinder 2 extends
3.Both cylinders retract
4.Cycle is ended.

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 A second dual-cylinder circuit with a slight change
of sequence is shown in fig-chp7\fig7.15.pptx.
Pressing the START button momentarily closes
switch 1-CR which energizes SOL A and cylinder 1
will extend. At the end of extension the rod acts on
the NO -1LS (energizes SOL B) and the other NC-
1LS which de-energizes SOL A (V1 will be spring
offset mode). These two operations will extend
cylinder2 and retract cylinder1 simultaneously. At the
end of extension of cylinder 2 the NC 2-LS will be
opened and relay 2CR is de-energized. This will de-
energize SOL B and V2 will be in spring offset mode
and cylinder 2 will retract-end of the cycle.
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Fig.7.15 Second dual-cylinder sequencing circuit.
7.3.4 Electrical Control of Regenerative Circuit
fig-chp7\fig7.16.pptx shows the arrangement.
Switch 1-SW can be positioned in three locations:
extend, retract and unload. In the extend mode SOL
A is energized , cylinder extends, oil from the rod
end flows back to the piston end to increase the
velocity of extension.
When the cylinder starts to pick load higher
pressure will be generated which will actuate 1-PS
resulting coil relay 1 CR and SOL C energized.
Valve V2 will drain the oil thus reducing the speed of
the extension.
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Fig.7.16 Electrical control of regenerative cycle
 When 1-SW is placed in to the retract position,
SOL B becomes energized while the relay coil and
SOL C becomes de-energized. Therefore, the
cylinder retracts in a normal fashion to its fully
retracted position.
In unload position all contact will be open and
the valve will be in spring centered mode. The pump
will be relieved.

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7.3.6 Counting, Timing, and Reciprocation of Hydraulic
Cylinder
This arrangement is shown in fig-chp7\fig7.17.pptx
A momentary push on the START button will, start the
timer, energize relay 1-CR, and close the NO switch 1-CR.
This will, energize SOL A, light lamp L1 and the cylinder
extends (1-LS closes). At the end of extension the NO 2-LS
is closed. This switches on the counter, energizes relay 2-CR,
the two NO contacts 2-CR close, and opening the NC contact
2-CR , resulting in SOL A de-energized, SOL B energized and
lamp L2 lit. This retracts the cylinder at the end of which the
NC 1-LS is opened which opens all the NO 2-CR switches
(de-energizes SOL B) except the one NC 2-CR ,on rung 2.
This energizes SOL A and the cycle continues in automatic
reciprocation mode. 49
Fig.7.17 Counting, timing, and reciprocation
 A momentary pressing of the STOP button puts the DCV
in spring centered mode and the cylinder is immediately
stopped and locked. The pump is also unloaded.
The COUNTER registers an integer increase in value each
time an electrical pulse is received and removed.
Since the TIMER line is always live, it registers how
long the system has been operating since the START
button was depressed.
Two lamps (L1 and L2) show when the cylinder is
extending or retracting. L1 ON-extension, L2 ON-
retraction. The cylinder speed is controlled by the pressure
and temperature compensated flow control valve.

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