Activity 6.

4: Single Direction Start/Stop Control

NOTE:
In this Classroom Activity you will work on single direction start/stop control.
Complete this activity in 45 minutes.

In this part of the experiment, you will assemble and operate an electrical control
circuit to start and stop a motor turning in one direction only. This is the circuit
illustrated in Figure 100 except you will use two positions of a double solenoid
operated valve.

1. Set up the electrical fluid power training kit in either the bench or table-top
configuration.

2. Turn off the control power switch on the Electrical Control Module.

3. Plug in the main power cord from the Electrical Control Module to a 240 VAC wall
outlet, or connect and power the portable power supply.

4. Turn off the hydraulic power unit or pneumatic supply.

5. Set up a motor control system using the control and fluid power circuits illustrated
in either Figure 108 or Figure 109

6. Turn on the hydraulic power supply and increase the pressure to 300 PSI / 2070
kPa or turn on the pneumatic supply and increase pressure to 30 PSI / 207 kPa.

7. Use the two manual overrides to make sure the motor rotates in both directions freely.
The flow control valve should only control the motor speed when override A is actuated.
If it does not, check over your circuit and correct this. Adjust the speed to a moderate
level.

8. Turn on the control power switch and observe your system. Does the motor
begin running or does it remain stationary? Record your observation.

9. Press pushbutton 1PB to start the motor and then release it. The motor
should continue to run after you release the pushbutton. Record below if this
happens.

10. Now press pushbutton 2PB momentarily to stop the motor. Then release it. Does
the motor stop and remain stationary after you release 2PB?

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11. Press 1PB again momentarily to restart the motor.

Figure 108: Electro-Hydraulic Setup Diagrams for Part 1

Figure 109: Electro- Pneumatic Setup Diagrams for Part 1

12. Adjust the speed setting to a very slow speed. Then stop the motor by pressing
2PB and restart the motor again by pressing 1PB momentarily. Does the motor start
up the same as it did at the faster speed?

13. Adjust the speed back to a moderate speed.

14. Now turn off the control power switch to simulate a power outage. Does the
motor continue running?

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15. Turn on the control power switch and observe the motor. Does it restart
automatically?

16. Try pressing 1PB and then 2PB to see if the motor circuit now works again.
Record your findings.

17. Looking directly at the shaft of the motor, what direction does it turn in, CW or
CCW, when you start the motor?

Motor rotation for solenoid A

18. Turn off the control power switch and disconnect the leads to solenoid A. Then,
reconnect them to solenoid B. Hydraulic version only. Pneumatic version skips to
Part IV.

19. Turn on the control power again.

20. Press 1PB momentarily. Record below if the motor stays running when you
release 1PB and in what direction the motor now rotates.

Motor rotation for solenoid B

21. Press 2PB momentarily to stop the motor.

22. Turn off the control power switch.

23. Turn off the hydraulic power supply.

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Activity 6.5: Describe Remote Start/Stop

NOTE:
In this Classroom Activity you will work on a remote start/stop. Complete this
activity in 30 minutes.

In this part of the experiment, you will assemble and operate a motor circuit with two
start pushbuttons and then, a circuit with two stop pushbuttons.

1. From the previous activity, disconnect your existing circuit and connect the circuit
with two pushbuttons shown below. The selector switch is used in place of a
pushbutton to stop the motor.

Figure 110: Electrical Setup Diagram No.1

2. Turn on the control power switch.

3. Rotate the selector switch to the RUN position, which is right.

4. Press 1PB momentarily to start the motor. Record below if the motor runs by
pressing 1PB.

5. Turn the selector switch to the left hand position to stop the motor and then back
to the right hand position to reset it.

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6. Now press 2PB momentarily to see if you can restart the motor using a second
pushbutton. Record below what happens.

7. Stop the motor using the selector switch.

8. Turn off the control power switch and set up the new circuit having two stop
pushbuttons shown below.

Figure 111: Setup Diagram No.2

9. Turn on the control power switch.

10. Switch the selector switch to the right hand position and then back to the left
hand position to start the motor.

11. With the motor running, press 1PB to stop the motor. Record below if it stops.

12. Restart the motor using the selector switch. Reset the switch to the left hand
position. Then try pressing 2PB momentarily to see if the motor also stops using the
second pushbutton. Record below what happens.

13. Turn off the control power switch.

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Activity 6.6: Motor Control Development Programme

NOTE:
In this Classroom Activity you will work on a motor control development program.
Complete this activity in 30 minutes.

In this part of the experiment, you will be given a set of operating conditions required
by a motor control circuit. From these directions, you will develop and test a circuit to
meet these operating conditions. Your circuit should already be drawn before you
start Part I of this lab experiment.

Requirements of Circuit:

Your company needs an electrical control circuit added to an existing machine to

start and stop a motor. It must have the following operating characteristics:

1. Forward and reverse motions controlled by a single start pushbutton.

2. Operator press the start pushbutton only momentarily to start the motor running.

3. Forward and reverse motion is selected by a selector switch.

4. A single stop pushbutton will stop the motor.

5. A green indicator light will turn on when the selector switch is in the reverse mode.

6. A red indicator light will be on when the motor is running either in forward or
reverse.

7. The hydraulic circuit to be used is as follows:

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1. Draw a ladder diagram of he control circuit that would be required to perform the
above requirements.

2. Set up your diagram on the electrical fluid power training kit and test it out. Make
any changes required to the circuit to make it work when you test it. Record those
changes on your diagram.

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QUESTIONS

Answer the following questions. Complete the questions in 15 minutes.

1. Name three advantages to using fluid motors instead of electric motors.

2. A conveyor drive system requires a hydraulic motor to drive it in one direction

only. It also requires speed adjustment and deceleration. Draw a hydraulic circuit
below that will perform these functions.

3. Draw below, a ladder diagram circuit to start and stop the conveyor drive system
in Question 2. This circuit should have one start pushbutton and two stop
pushbuttons.

4. In the experiment, Part I step 9, why does the motor continue to run after the start
pushbutton is released?

5. In the experiment, Part I step 15, did the motor start running again after the power
was restored? Explain.

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Activity 7.1: Jog Control of a Single Solenoid Valve

NOTE:
In this Classroom Activity you will work on jog control of a single solenoid valve.
Complete this activity in 45 minutes.

In this part you will assemble and operate a cylinder reciprocation circuit with both
manual and automatic modes. This circuit will use a single-solenoid directional
control valve and is the same circuit illustrated in Figure 114.

1. Set up the electrical fluid power training kit in either the bench or table-top
configuration.

2. Turn off the control power switch.

3. Turn off the hydraulic power unit or the pneumatic power supply.

4. Plug in the main power cord from the Electrical Control Module to a 240VAC
outlet, or connect and power the portable power supply.

5. Set up the manual/automatic cylinder reciprocation circuit using the setup

diagrams illustrated in either Figure 117

NOTE:
Do not mount the limit switches yet.

6. Turn on the pneumatic supply and increase the pressure to 30 PSI / 207 kPa.

7. Actuate the manual override to extend the cylinder. Adjust the cylinder speed so
that it takes about five seconds to extend and five seconds to retract.

8. Mount the limit switches with the roller arm orientation illustrated in Figure 117.
LS1 should actuate when the cylinder is fully extended. LS2 should actuate when the
cylinder is fully retracted. Actuate the manual override to extend the cylinder to
adjust and test the actuation of the limit switches.

9. Turn selector switch 1SS to the right hand position to put the circuit in the
automatic mode.

10. Turn on the control power switch and observe the operation of the circuit in the
automatic mode. Does the cylinder reciprocate continuously? Record below what
happens.

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11. Now switch to the manual mode by rotating 1SS to the left hand position. What
happens to the cylinder? Does it stop? Record your findings.

Figure 117: Single solenoid jog control diagram

12. Try jogging the cylinder by pressing 1PB.What happens when you press 1PB?
Record your findings.

13. Release 1PB and observe what happens to the cylinder. Does it stop or retract?
Record your findings.

14. Repeat steps 12 and 13 several times to become familiar with the jogging of a
single solenoid valve.

15. Switch back to the automatic mode by rotating 1SS to the right. What happens?
Record your findings.

16. While the circuit is cycling in the automatic mode, try pressing 1PB to jog the
cylinder. Record below what effect this has on the circuit.

17. Turn off the control power switch.

18. Turn off pneumatic power supply.

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Activity 7.2: Jog Control of a Double Solenoid Valve

NOTE:
In this Classroom Activity you will work on jog control of a double solenoid valve.
Complete this activity in 30 minutes.

In this part of the experiment you will assemble and operate a cylinder reciprocation
circuit similar to the one illustrated in Figure 115 using a double-solenoid directional
control valve. This circuit uses two push-buttons to jog the cylinder forward and
reverse. The only change in the circuit is a second set of contacts from 2PB have
been added to rung 6 to avoid a backtracking signal. You will note that 1CRB has
been deleted and 1CRA is used to control sol A. Also, LS2 has been moved.

The reason for these changes is to accommodate the fact that the learning kit limit
switches are SPDT and not DPDT.

1. From the previous classroom activity, disconnect your existing electrical control
and fluid power circuits and set up the new circuits illustrated in Figure 118. Use
either the hydraulic or pneumatic circuit illustrated in Figure 118.

NOTE:
Use the same cylinder and limit switch setup used in Part I. Just switch your
connections from the 2-position valve to the 3-position valve.

Figure 118: Double solenoid jog control diagram

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2. Turn on the hydraulic power unit and increase the pressure to 300 PSI / 2070 kPa
or turn on the pneumatic power supply and increase the pressure to 30 PSI / 207
kPa.

3. Extend and retract the cylinder using the manual overrides. Make sure the cylinder
extends when override A is actuated.

4. Turn on the control power switch.1SS should still be in the automatic mode (right
hand position) so the cylinder should now be cycling continuously. Record below if
you observe this.

5. Try pressing 1PB or 2PB to see if the jog pushbutton can affect the automatic
circuit. Record below what effect pressing 1PB and 2PB has on the operation of the
circuit.

6. Switch 1SS to the left hand position to place the circuit into the manual mode.
Record below what happens to the cylinder.

7. Press 1PB to jog the cylinder forward. What happens to the cylinder? Record your
observation.

8. Release 1PB and record what happens to the cylinder.

9. Press 2PB momentarily. What happens to the cylinder? Record your observation.

10. Repeat steps 7, 8, and 9 by pressing 1PB and 2PB alternating to jog the cylinder
forward and reverse.

11. Move 1SS back to the automatic mode. What happens to the cylinder? Record
your observation.

12. Turn off the control power switch.

13. Turn off the hydraulic or pneumatic system.

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Activity 7.3: Two-Speed Jog Control

NOTE:
In this Classroom Activity you will work on a two-speed jog control. Complete this
activity in 30 minutes.

In this part of the experiment you will add a two-speed control to the circuit used in
Part II. This is the same circuit illustrated in Figure 115, except the automatic portion
of the circuit has been omitted. This circuit has only the manual mode with two-
speeds.

1. Continuing from the previous classroom activity, set up the two-speed jog control
circuit illustrated in Figure 119.The fluid power unit shown below is for a hydraulic
system. If you are using a pneumatic system, connect it in a similar manner.

Figure 119: Two speed jog control diagram

2. Turn on the hydraulic power unit and increase the pressure to 300 PSI / 2070 kPa
or turn on the pneumatic system and set the pressure to 30 PSI / 207 kPa.

3. Energize the manual overrides of the 3-position valve to extend and retract the
cylinder. Actuating the manual override on solenoid A should extend the cylinder.
When you cycle the cylinder adjust flow control No.1 so that the cylinder extends or
retracts in about 3 seconds. This will be the fast speed.

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4. Now actuate the manual override on valve No.2 and hold it. Then, extend and
retract the cylinder using the manual overrides on solenoid A and solenoid B on
valve No.1 and set the cylinder speed as slow as possible using flow control No.2.
Now, energize the override on valve No.2 and hold it. Then, extend and retract the
cylinder using the overrides on valve No.1 and set the cylinder speed as slow as
possible using flow control No.2.

5. Release the manual overrides.

6. Set the selector switch 1SS to the left hand position, which is the fast jog mode.

7. Turn on the control power switch.

8. Press 1PB to jog forward. Record below what happens to the cylinder and if its
speed is fast or slow.

9. Release 1PB and press 2PB to jog reverse. Record below what happens to the
cylinder and if its speed is fast or slow.

10. Switch the selector switch 1SS to the right hand position for the slow jog mode.

11. Repeat steps 8 and 9.Record below if the cylinder moves in the same direction
when 1PB and 2PB are pressed and if the speed is fast or slow.

12. With the circuit in the slow jog mode find out the smallest distance you can move
the cylinder by pressing a jog pushbutton momentarily. Use a ruler to measure the
distance and record it below.

Slow Jog inches/cm

Fast Jog inches/cm

13. Switch the selector to the fast-jog mode and repeat step 12 to find the smallest
distance the cylinder can be moved in the fast jog mode. Record this distance in the
space provided in step 12.

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QUESTIONS

Answer the following questions. Complete the questions in 15 minutes.

1. What is a jog pushbutton circuit used for?

2. What mode should the control be in when the jog control pushbuttons are active?

3. What determines the number of jog pushbuttons required for a double-acting

cylinder?

4. What is most often used to choose the automatic or manual modes?

5. For what reason would a two-speed jog control circuit be needed?