Electrohidraulica PDF

Electrohydraulics
TP 601
Textbook
093611 EN
Order No.: 093611
Edition: 03/2006
Authors: C. Lffler, D. Merkle, G. Prede, K. Rupp, D. Scholz
Graphics: Doris Schwarzenberger
Layout: 30.05.2006, Beatrice Huber
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2006
Internet: www.festo-didactic.com
e-mail: did@de.festo.com
The copying, distribution and utilization of this document as well as the

communication of its contents to others without expressed authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Contents
Preface ______________________________________________________________ 5
1. Introduction ___________________________________________________ 7
1.1 Areas of application of electrohydraulics ____________________________ 7
1.2 Basic control engineering terms ___________________________________ 9
1.3 Hydraulic and electrohydraulic control systems _____________________ 15
1.4 Advantages of electrohydraulic control systems _____________________ 21
2. Fundamentals of electrical technology____________________________ 23

2.1 Direct current and alternating current _____________________________ 23
2.2 Ohm's Law ___________________________________________________ 24
2.3 Mode of operation of a solenoid__________________________________ 26
2.4 Mode of operation of a capacitor _________________________________ 28
2.5 Mode of operation of a diode ____________________________________ 29
2.6 Measurement in electrical circuits ________________________________ 30
3. Components and assemblies in the electrical signal control section ___ 35

3.1 Power supply unit _____________________________________________ 35
3.2 Push button and control switches ________________________________ 36
3.3 Sensors for measuring displacement and pressure___________________ 38
3.4 Relays and contactors __________________________________________ 48
3.5 Programmable logic controllers __________________________________ 53
3.6 Overall structure of the signal control section _______________________ 54
4. Solenoid actuated directional control valves _______________________ 57

4.1 Exercises ____________________________________________________ 57
4.2 Design and mode of operation ___________________________________ 59
4.3 Designs and hydraulic performance data___________________________ 77
4.4 Performance data of solenoid coils _______________________________ 90
4.5 Electrical connection of solenoid coils _____________________________ 93
5. Design of an electrohydraulic control system ______________________ 97

5.1 Procedure for the development of a control system __________________ 97
5.2 Procedure for the planning of a control system ______________________ 99
5.3 Application example: Design of a sawing machine __________________ 103
5.4 Procedure for the realisation of the control system__________________ 122
Festo Didactic GmbH & Co. KG TP 601 3

Contents
6. Documentation of an electrohydraulic control system ______________ 127

6.1 Function diagram _____________________________________________ 128
6.2 Sequence table ______________________________________________ 137
6.3 GRAFCET____________________________________________________ 139
6.4 Hydraulic circuit diagram ______________________________________ 162
6.5 Electrical circuit diagram _______________________________________ 176
6.6 Terminal connection diagram ___________________________________ 187
7. Safety measures for electrohydraulic control systems ______________ 197

7.1 Dangers and protective measures _______________________________ 197
7.2 Effect of electric current on the human body _______________________ 198
7.3 Measures to protect against accidents with electric current___________ 201
7.4 Control panel and indicating elements____________________________ 202
7.5 Protecting electrical equipment against environmental impact ________ 206
7.6 Safety recommendations for electro-hydraulic systems ______________ 208
8. Relay control systems ________________________________________ 209

8.1 Use of relay control systems in electrohydraulics ___________________ 209
8.2 Direct and indirect actuation____________________________________ 209
8.3 Logic operations _____________________________________________ 213
8.4 Signal storage _______________________________________________ 216
8.5 Delay_______________________________________________________ 222
8.6 Sequence control with signal storage via double solenoid valves ______ 224
8.7 Circuit for evaluating control elements____________________________ 235
8.8 Sequence control system for a sawing machine ____________________ 238
Index _____________________________________________________________ 265
Standards _________________________________________________________ 273
4 Festo Didactic GmbH & Co. KG TP 601

Preface
Electrohydraulics are in use in numerous areas of industrial automation. To give a

few examples, woodworking machines, machine tools, process engineering plants,
presses, plastics processing machines and conveyor systems worldwide are
operated using electrohydraulic control systems. However, electrohydraulic control
systems are also in use in a wide variety of ways such as in mobile hydraulics which
include agricultural vehicles, road construction or street cleansing.
Changing requirements and technical development have distinctly changed the

appearance of control systems. The relay in the signal control section increasingly
has been replaced by programmable logic controllers in many areas of application in
order to meet the increased need for flexibility. In the power section too, advanced
electrohydraulic control systems feature new concepts adapted to the needs of
industrial practice. To mention just a few keywords such as control block, bus
networks and proportional hydraulics. The close interaction of fluid power
engineering with microelectronics, sensors and information technology leads to
numerous innovations in the area of oil-hydraulic drives and control systems. These
in turn open up new fields of application to electrohydraulics with more challenging
tasks in process control.
As an introduction to the subject, the textbook first of all explains the design and
mode of operation of the components required for the construction of an
electrohydraulic control system. The following chapters describe the procedure for
the planning, design and realisation of electrohydraulic control systems, using fully
detailed examples.
All readers of this book are invited to contribute with tips, suggestions and
constructive criticism in order to improve the book.
March 2006 The authors

1. Introduction
1.1 Hydraulics involves the use of hydraulic fluids. Hydraulic fluids are most commonly
Areas of application of used to perform mechanical work. Mechanical work is necessary in order to carry out
electrohydraulics movements and generate forces. The function of hydraulic drives is to convert the
energy stored in hydraulic fluid into kinetic energy.
The following are used as hydraulic drives:

Cylinders (linear drives) for the generation of straight-linear movements ,
Motors and semi-rotary actuators drives (rotary drives) to generate rotary
movements.
Hydraulic linear cylinder (Storz Hydrauliksysteme GmbH) and hydraulic motor (Sauer-Danfoss GmbH & Co)
Hydraulic systems are used if high performance levels, excellent heat dissipation,
regular movement, high switching dynamics or extremely high forces are required.
Applications of electrohydraulics can be found both in stationary and mobile

hydraulics. Characteristic of electrohydraulics is the receiving, processing and
output of signals. The valves forming the interface to the power section are also
solenoid actuated.
Important branches of electrohydraulics are:

Machine building, where electrohydraulic system for example are used to feed
machine tools, for the generation of force for presses or in injection moulding
machine for plastics processing
Automotive engineering, where electrohydraulic systems are the preferred
option for the actuation of construction machinery or also for the control of
steering mechanisms on agricultural machinery
Steel and power station construction. Here, electrohydraulic systems are used
for theatre technics, lifting platforms, for the control of locks, weir gates and
movable bridges

1. Introduction
Aircraft construction, where for example the actuation of the landing flaps and
rudders is realised electrohydraulically
Ship building, where for example the rudder or the cargo cranes are controlled
electrohydraulically
Application example In the case of modern CNC controlled machine tools, tools and workpieces are
clamped hydraulically. Feed functions and spindle drives can also be hydraulically
realised.
Rotary indexing machine

1. Introduction
1.2 Hydraulic drives can only do work usefully if their motions are precise and carried
Basic control engineering out at the right time and in the right sequence. Coordinating the sequence of motion
terms is the task of the control system.
Control engineering deals with the design and structure of control systems. The
following section covers the basic terms used in control engineering.
Control DIN 19226, Part 1 defines the term control as follows:

Controlling open loop control is that process taking place in a system whereby
one or more variables in the form of input variables exert influence on other
variables in the form of output variables by reason of the laws which characterize
the system. The distinguishing feature of open loop control is the open sequence of
action via the individual transfer elements or the control chain.
The term open loop control is widely used not only for the process of controlling but
also for the plant as a whole.
Application example In an assembly device, locating holes on sub-bases for valves are sealed with
blanking plugs. The closing process is triggered via the operation of a pushbutton at
the workplace. When the pushbutton is released, the piston retracts to the retracted
end position.
In this control, the position of the pushbutton (pushed, not pushed) is the input
variable. The position of the pressing cylinder is the output variable. The loop is
open because the output variable (position of the cylinder) has no influence on the
input variable (position of the pushbutton).

1. Introduction
Assembly device for fitting caps in locating holes
Controls must evaluate and process information (for example, pushbutton pressed
or not pressed). The information is represented by signals. A signal is a physical
variable, for example
The pressure at a particular point in a hydraulic system
The voltage at a particular point in an electrical circuit

1. Introduction
Pressure
7
MPa
5
4
3
2
1
0 Time
Signal and information: Signal/physical variable
Pointer position
7
6 23 45
5 1 6
0 7
4 8
3
2
1
0 Time
Signal and information: Information, analogue
Display
Pressure
7 3 MPa
6
5
4
3
2
1
0 Time
Signal and information: Information, digital

1. Introduction
Pressure
Supply
pressure
Yes 1
No 0 Time
Signal and information: Information, binary
A signal is the representation of information The representation is by means of the

value or value pattern of the physical variable. The different signal types are
described in DIN 19226, Part 5.
Analogue signal An analogue signal is a signal in which information is assigned point by point to a
continuous value pattern of the signal parameter.
Application example In the case of a pressure gauge, each pressure value (information parameter) is
assigned a particular display value (= information). If the signal rises or falls, the
information changes continuously.
Digital signal A digital signal is a signal with a finite number of value ranges of the information
parameter. Each value range is assigned a specific item of information.
Application example A pressure measuring system with a digital display shows the pressure in
increments of 1 MPa. There are 8 possible display values (0 to 7 MPa) for a pressure
range of 7 MPa. That is, there eight possible value ranges for the information
parameter. If the signal rises or falls, the information changes in increments.
Binary signal A binary signal is a digital signal with only two value ranges for the information
parameter. These are normally designated 0 and 1.
Application example A control lamp indicates whether a hydraulic system is being correctly supplied with
hydraulic fluid. If the supply pressure (= signal) is below 5 MPa, the control lamp is
off (0 status). If the pressure is above 5 MPa, the control lamp is on (1 status).

1. Introduction
Classification of controllers Controllers can be divided into different categories according to the type of
by type of information information representation, into analogue, digital and binary controllers.
representation
Controllers
Binary Analogue Digital

controllers controllers controllers
Classification of controllers by type of information representation
Logic controller A logic controller generates output signals through logical association of input
signals.
Application example The assembly device for sub-bases is extended so that it can be operated from two
positions. The two output signals are linked. The piston rod advances if either
pushbutton 1 or 2 is pressed or if both are pressed.
Sequence controller A sequence controller is characterized by its step by step operation. The next step
can only be carried out when certain criteria are met.
Application example Drilling station. The first step is clamping of the workpiece. As soon as the piston rod
of the clamping cylinder has reached the forward end position, this step has been
completed. The second step is to advance the drill. When this motion has been
completed (piston rod of drill feed cylinder in forward end position), the third step is
carried out, etc.

1. Introduction
Signal flow in a control A control system can be divided into the functions signal input, signal control, signal
system output and command execution. The mutual influence of these functions is shown
by the signal flow diagram.
Signals from the signal input are logically associated (signal control). Signals for
signal input and signal process are low power signals. Both functions are part of
the signal control section.
At the signal output stage, signals are amplified from low power to higher power.
Signal output forms the link between the signal control section and the power
section.
Command execution takes place at a high power level that is, in order to move
heavy loads (e.g. a lock gate) or to exert a high force (such as for a press).
Command execution belongs to the power section of a control system.
Command execution
section
Power
Signal output
Signal control
section
Signal processing
Signal input
Signal flow in a control system
The components in the circuit diagram of a purely hydraulic control system are
arranged so that the signal flow is clear. Bottom up: input elements (such as
manually operated valves), logical association elements (such as shuttle valves),
signal output elements (power valves, such as 4/2-way valves) and finally command
execution (such as cylinders).

1. Introduction
1.3 Hydraulic and electrohydraulic control systems both exhibit a hydraulic power
Hydraulic and section. However, the signal control section is constructed differently.
electrohydraulic control In the case of hydraulic control systems, this section is mainly carried out
systems manually. It is rare for the signal control to be effected by means of a hydraulic
circuit, which then comprises for example shuttle valves.
In the case of an electrohydraulic control system, the signal control section is
constructed using electrical components, which include for example electrical
input keys, proximity sensors, pressure switches, relays or a programmable logic
controller.
In the case of both types of control, the directional control valves form the inteface
between the signal control section and the hydraulic power section.
Power component
Cylinder
Hydraulic power
Command execution Swivel cylinder
Hydraulic motors
section
Optical displays
Final control elements

Signal output Directional control valves
Hydraulic signal control section

Processing elements
Directional control valves
Signal processing Shuttle valves
Pressure control valves
Input elements
Signal input (mechanically operated)
(manually operated)
Signal flow Hydraulic components
Signal flow and components of a hydraulic control system

1. Introduction
Power components
Cylinder
Hydraulic power
Command execution Swivel cylinder
Hydraulic motors
section
Optical displays
Final contol elements

Electropneumatically
Signal output operated directional
control valves
Processing elements
Electrical signal control section

Relays
Signal processing Contactors
Programmable logic
controllers (PLCs)
Input elements
Pushbuttons
Control switches
Limit switches
Signal input Reed switches
Ind. proximity sensors
Cap. proximity switches
Light barriers
Pressure-actuated switches
Signal flow Electrohydraulic

components
Signal flow and components of an electrohydraulic control system

1. Introduction
In contrast with purely hydraulic control systems, electrohydraulic control systems

require a separate energy supply, both for the power section and for the signal
control section.
Hydraulic power
section:
Electrical signal control section: Signal flow Power flow
Drive section
Signal Signal Signal Energy control

input processing output section
Control energy supply Energy supply

section
Interaction of signal flow with power flow

1. Introduction
Hydraulic and electrohydraulic control systems also differ in respect of the

representation of the circuit diagram.
The purely hydraulic control system is represented by means of a single overall
circuit diagram.
Electrohydraulic control system are represented in two separate circuit diagrams.
One circuit diagram represents the electrical section and the other circuit
diagram the hydraulic section of the control system.
1A1 1B1 1B2
1Z2
B 1V5 P
1V3 1V4 1V6
T
A
1V2 A B
1M1 1M2
P T
1Z1
1V1 P
Circuit diagram of an electrohydraulic control system: Hydraulic circuit diagram

1. Introduction
24 V 1 2 3 4 5 6
11 32 34 32 34
S1 K1 K2
12 31 31
13 12 14 13 22 24
S2 K1 S3 K2
14 11 14 21
2 4 2 4
1B2 1B1
1 1
12 14 22 24
K2 K1
11 21
K1 K2 1M1 1M2
A2 A2
0V 12 12
11 14 .2 11 14 .1
22 22
21 24 .3 21 24 .4
32 32
31 34 .5 31 34 .6
42 42
41 44 41 44
Circuit diagram of an electrohydraulic control system: Electrical circuit diagram

1. Introduction
Design and mode of The illustration shows an example of the design and mode of operation of a modern
operation of an electrohydraulic control system.
electrohydraulic control The electrical signal control section switches the electrically (solenoid) actuated
system directional control valves.
The directional control valves effect the retracting and advancing of the piston
rod.
The position of the piston rod is acknowledged to the signal control section via
proximity sensors.
Structure of a modern electrohydraulic control system (Festo AG & Co. KG, Storz Hydrauliksysteme GmbH)

1. Introduction
1.4 In comparison with purely hydraulic control systems, electrohydraulic control

Advantages of systems exhibit the following advantages:
electrohydraulic control Greater reliability:
systems Fewer moving components subject to wear are required.
Reduced planning and commissioning complexity, in particular in the case of
complex control systems:
The control program is electronically formulated and therefore can be easily
corrected and adapted.
Reduced installation complexity:
Electrical signals can be easily transmited over large distances via cables.
Mechanical signal transmission by means of rod linkage and cable pulls or
hydraulic signal transmission is far more complex.
The control system can be easily modified and adapted:
The program can be easily and flexibly adapted to varying process sequences if
the control program is electronically formulated.
Simpler exchange of information between several controllers:
Several PLCs can be networked via special communication interfaces if the
control programs are stored in a PLC. Exchange of information is often effected
via standardised, easy to use bus systems.
Easy to deploy in automatic production plants:
In automation technology, the entire signal processing function is usually
effected electrically or electronically. Therefore, electrohydraulic systems can be
more easily deployed in automatic production plants.

1. Introduction

2. Fundamentals of electrical technology
2.1 A simple electrical circuit consists of a voltage source, a load, and connection lines.
Direct current and
alternating current Physically, charge carriers electrons move through the electrical circuit via the
electrical conductors from the negative pole of the voltage source to the positive
pole. This motion of charge carriers is called electrical current. Current can only flow
if the circuit is closed.
There are two types of current - direct current and alternating current:
If the electromotive force in an electrical circuit is always in the same direction,
the current also always flows in the same direction. This is called direct current
(DC) or a DC circuit.
In the case of alternating current or an AC circuit, the voltage and current change
direction and strength in a certain cycle.
Direct current Alternating current

Current I
Current I
Time t Time t
Direct current and alternating current plotted against time

The diagram shows a simple DC circuit consisting of a voltage source, electrical

lines, a control switch, and a load (here a lamp).
3
S
+
4
V = 12 V
DC circuit
Technical direction of flow When the control switch is closed, current I flows via the load. The electrons move
from the negative pole to the positive pole of the voltage source. The direction of
flow from quotes "positive" to "negative" was laid down before electrons were
discovered. This definition is still used in practice today. It is called the technical
direction of flow.
2.2
Ohm's Law
Electrical conductors Electrical current is the flow of charge carriers in one direction. A current can only
flow in a material if a sufficient number of free electrons are available. Materials that
meet this criterion are called electrical conductors. The metals copper, aluminium
and silver are particularly good conductors. Copper is normally used for conductors
in control technology.
Electrical resistance Every material offers resistance to electrical current. This results when the free-
moving electrons collide with the atoms of the conductor material, inhibiting their
motion. Resistance is low in electrical conductors. Materials with particularly high
resistance are called insulators. Rubber- and plastic-based materials are used for
insulation of electrical wires and cables.

Source emf The negative pole of a voltage source has a surplus of electrons. The positive pole
has a deficit. This difference results in source emf (electromotive force).
Ohm's law Ohm's law expresses the relationship between voltage, current and resistance. It
states that in a circuit of given resistance, the current is proportional to the voltage,
that is
If the voltage increases, the current increases.
If the voltage decreases, the current decreases.
V=RI
V = Voltage Unit: Volt (V)

R = Resistance Unit: Ohm (W)
I = Current Unit: Ampere (A)
Electrical power In mechanics, power can be defined by means of work. The faster work is done, the
greater the power needed. So power is "work divided by time".
In the case of a load in an electrical circuit, electrical energy is converted into kinetic
energy (for example electrical motor), light (electrical lamp), or heat energy (such as
electrical heater, electrical lamp). The faster the energy is converted, the higher the
electrical power. So here, too, power means converted energy divided by time.
Power increases with current and voltage.
The electrical power of a load is also called its electrical power input.
P=VI
P = Power Unit: Watt (W)

V = Voltage Unit: Volt (V)
I = Current Unit: Ampere (A)

Application example Power of a coil

The solenoid coil of a hydraulic 4/2-way valve is supplied with 24 V DC. The
resistance of the coil is 18 Ohm. What is the power?
The current is calculated by means of Ohm's law:
V 24 V
I= = = 1.3 A
R 18
The electrical power is the product of current and voltage:
P = V I = 24 V 1.3 A = 32 W
2.3 A magnetic field is induced when a current is passed through an electrical

Mode of operation of a conductor. The strength of the magnetic field is proportional to the current.
solenoid Magnetic fields attract iron, nickel and cobalt. The attraction increases with the
strength of the magnetic field.
Air-core coil Coil with iron core

and air gap
I
I
Electrical coil and magnetic lines of force

Structure of a solenoid The solenoid has the following structure:

The current-bearing conductor is wound around a coil. The overlapping of the
lines of force of all loops increases the strength of the magnetic field resulting in
a main direction of the field.
An iron core is placed in the centre. When current flows, the iron is also
magnetized. This allows a significantly higher magnetic field to be induced with
the same current (compared to an air-core coil).
These two measures ensure that a solenoid exerts a strong force on ferrous
(= containing iron) materials.
Applications of solenoids In electrohydraulic controls, solenoids are primarily used to control the switching of
valves, relays or contactors. This can be demonstrated using the example of the
spring-return directional control valve:
If current flows through the solenoid coil, the piston of the valve is actuated.
If the current is interrupted, a spring pushes the piston back into its initial
position.
Reactance in AC circuits If a AC voltage is applied to a coil, an alternating current flows. This means that the
current and magnetic field are constantly changing. The change in the magnetic field
induces a current in the coil. The induced current opposes the current that induced
the magnetic field. For this reason, a coil offers "resistance" to an alternating
current. This is called reactance. The reactance increases with the frequency of the
voltage and the inductance of the coil.
Inductance is measured in Henry (H).
Vs
1H=1 = 1 s
A
Reactance in DC circuits In the case of DC circuits, the current, voltage and magnetic field only change when
the current is switched on. For this reason reactance only applies when the circuit is
closed (switching on the current).
In addition to reactance, the coil has ohmic resistance. This resistance applies both
to AC circuits and DC circuits.

2.4 A capacitor consists of two metal plates with an insulating layer (dielectric) between
Mode of operation them. If the capacitor is connected to a DC voltage source (closing the switch S1 in
of a capacitor diagram), a charging current flows momentarily. Both plates are electrically charged
by this. If the circuit is then interrupted, the charge remains stored in the capacitor.
The larger the capacitance of a capacitor, the greater the electrical charge it can
store for a given voltage.
Capacitance is measured in Farad (F):
As
1F=1
V
If the charged capacitor is now connected to a load (closing switch S2 in diagram),

the capacitor discharges. Current flows through the load until the capacitor is fully
discharged.
Coil with iron core

Air-core coil and air gap
mA mA
S1 S2
Mode of operation of a capacitor

2.5 Diodes are electrical components that only allow current to flow in one direction:
Mode of operation In the flow direction, the resistance is so low that the current can flow
of a diode unhindered.
In the reverse direction, the resistance is so high that no current flows.
If a diode is inserted into a AC circuit, the current can only flow in one direction. The
current is rectified.
The effect of a diode on an electrical circuit is comparable to the effect of a non-

return valve on a hydraulic circuit.
Voltage
V
Time t
Current
I
Time t
Mode of operaion of a diode

2.6
Measurement in electrical
circuits
Measurement Measurement means comparing an unknown variable (such as the length of a

hydraulic cylinder) with a known variable (such as the scale of a measuring tape).
A measuring device (such as a ruler) allows such measurements to be made. The
result the measured value consists of a numeric value and a unit
(such as 30.4 cm).
Measurement in electrical Electrical currents, voltages and resistances are normally measured with
circuits multimeters. These devices can be switched between various modes:
DC current and voltage, AC current and voltage
Current, voltage and resistance
The multimeter can only measure correctly if the correct mode is set.
Devices for measuring voltage are also called voltmeters. Devices for measuring
current are also called ammeters.
TTL
400 mA 1000 V
MAX 750 V
500 V MAX
Multimeter

Danger
Before carrying out a measurement, ensure that voltage of the control system on
which you are working does not exceed 24 V!
Measurements on parts of a controller operating at higher voltages (such as
230 V) may only be carried out by persons with appropriate training or
instruction.
Incorrect measurement methods can result in danger to life.
Please observe safety instructions when working with electrical current!
Procedure for Follow the following steps when making measurements of electrical circuits.
measurements on Switch off voltage source of circuit.
electrical circuits Set multimeter to desired mode. (voltmeter or ammeter, AC or DC, resistance)
Check zeroing of pointer instruments. Adjust if necessary.
When measuring DC voltage or current, check for correct polarity. ("+" probe of
device to positive pole of voltage source).
Select largest range.
Switch on voltage source.
Observe pointer or display and step down to smaller range.
Record measurement for greatest pointer deflection (smallest measuring range).
For pointer instruments, always view from vertically above display in order to
avoid parallax error.

Voltage measurement For voltage measurement, the measuring device (voltmeter) is connected in parallel
to the load. The voltage drop across the load corresponds to the voltage drop across
the measuring device. A voltmeter has an internal resistance. In order to avoid an
inaccurate measurement, the current flowing thought the voltmeter must be as
small as possible, so the internal resistance of the voltmeter must be as high as
possible.
Voltmeter
V V P
Voltage measurement
Current measurement For current measurement, the measuring device (ammeter) is connected in series to
the load. The entire current flows through the device.
Each ammeter has an internal resistance. In order to minimize the measuring error,
the resistance of the ammeter must be as small as possible.
Ammeter
A
V P
Current measurement

Resistance measurement The resistance of a load in a DC circuit can either be measured directly or indirectly.
Indirect measurement measures the current through the load and the voltage
across the load. The two measurements can either be carried out simultaneously
or one after the other. The resistance is then measured using Ohm's law.
For direct measurement the load is separated from the rest of the circuit . The
measuring device (ohmmeter) is set to resistance measurement mode and
connected to the terminals of the load. The value of the resistance is displayed.
If the load is defective (for example, the magnetic coil of a valve is burned out), the
measurement of resistance either results in a value of zero (short-circuit) or an
infinitely high value (open circuit).
Warning The direct method must be used for measuring the resistance of a load in AC circuits.
Current I
Voltage
V V P V P
V
R=
I
indirect direct
Measuring resistance
Sources of error Measuring devices cannot measure voltage, current and resistance to any desired
degree of accuracy. The measuring device itself influences the circuit it is measuring,
and no measuring device can display a value precisely. The permissible display error
of a measuring device is given as a percentage of the upper limit of the effective
range. For example, for a measuring device with an accuracy of 0.5, the display error
must not exceed 0.5 % of the upper limit of the effective range.

Application example Display error

A Class 1.5 measuring device is used to measure the voltage of a 9 V battery. The
range is set once to 10 V and once to 100 V. How large is the maximum permissible
display error for the two effective ranges?
Range Permissible display error Percentage error
10 V 1.5 0.15 V
10 V = 0.15 V 100 = 1.66 %
100 9V
100 V 1.5 1.5 V

100 V = 1.5 V 100 = 16.6 %
100 9V
Calculating the display error
The example shows clearly that the permissible error is less for the smaller range.
Also, the device can be read more accurately. For this reason, you should always set
the smallest possible range.
Range 10 V Range 100 V
9V 9V
50 50
5 5
0 100 0 100
0 10 0 10
10 V 100 V 10 V 100 V
Measuring battery voltage (with different range settings)

3. Components and assemblies in the electrical signal control section
3.1 The signal control section of an electrohydraulic control system is supplied with
Power supply unit power via the electrical mains. The control sysem is equipped with a power supply
unit for this purpose. The individual assemblies of the power supply unit have the
following tasks:
The transformer reduces the operating voltage. The mains voltage (i. e. 230 V) is
applied to the input of the transformer. A lower voltage (i. e. 24 V) is available at
the output.
The rectifier converts the AC voltage into DC voltage. The capacitor at the rectifier
output smoothes the voltage.
The voltage regulator at the output of the power supply unit is required to ensure
that the electrical voltage remains constant regardless of the current flowing.
Transformer Rectifier Stabilization
Power supply unit
Component parts of a power supply unit for an electrohydraulic control system.
Safety precautions
Because of the high input voltage, power supply units are part of the power
installation (DIN VDE 0100).
Safety regulations for power installations must be observed.
Only authorized personnel may work on power supply units.

3.2 Switches are installed in circuits to apply a current to a load or to interrupt the
Push button and control circuit. These switches are divided into pushbuttons and control switches.
switches Control switches are mechanically detented in the selected position. The switch
position remains unchanged until a new switch position is selected. Example:
Light switches in the home.
Push button switches only maintain the selected position as long as the switch is
actuated (pressed). Example: Bell push.
Normally open contact In the case of a normally open contact, the circuit is open if the switch is in its initial
(make) position (not actuated). The circuit is closed by pressing the push button current
flows to the load. When the plunger is released, the spring returns the switch to its
initial position, interrupting the circuit.
1 3
2
3
Actuation type: Pushbutton (1) Switching element (2) Connection (3)
Normally open contact (make) section and symbol

Normally closed contact In this case, the circuit is closed when the switch is in its initial position. The circuit
(break) is interrupted by pressing the pushbutton.
1 1
2
3
Actuation type: Pushbutton (1) Connection (2) Switching element (3)
Normally open contact (break) section and symbol
Changeover contact The changeover contact combines the functions of the normally open and normally
closed contacts in one device. Changeover contacts are used to close one circuit and
open another in one switching operation. The circuits are momentarily interrupted
during changeover.
1
2 4
3
4
Actuation type: Pushbutton (1) Connection normally closed contact (2) Switching element (3)
Connection normally open contact (4)
Changeover contact section and symbol

3.3 Sensors have the task of measuring information and passing this on to the signal
Sensors for measuring control part in a form that can easily be processed. In electrohydraulic control
displacement and pressure systems, sensors are primarily used for the following purposes:
To detect the advanced and retracted end position of the piston rod in drive
cylinders
To detect the presence and position of workpieces
To measure and monitor pressure
Limit switches A limit switch is actuated when a machine part or workpiece is in a certain position.
Normally, actuation is effected by a cam. Limit switches are normally changeover
contacts. They can then be connected as required as a normally open contact,
normally closed contact or changeover contact.
2 4
4
1
3
5
6
7
1 9
Changeover contact Normally open contact Normally closed contact
2 2 2
1 1 1
4 4 4
Guide pin (1) Compression spring (4) Contact (normaly open contact (7)
Positive opening lever (2) Bent leaf spring (5) Contact blade (8)
Housing (3) Contact pressure spring (6) Contact (normaly closed contact) (9)
Mechanical limit switch: Construction and connection possibilities

Proximity switches In contrast to limit switches, proximity switches operated contactlessly (non-contact
switching) and without an external mechanical actuating force.
As a result, proximity switches have a long service life and high switching reliability.
The following types of proximity switch are differentiated:
Reed switch
Inductive proximity switch
Capacitive proximity switch
Optical proximity switch
Reed switch Reed switches are magnetically actuated proximity switches. They consist of two
contact reeds in a glass tube filled with inert gas. The magnetic field causes the two
reeds to close, allowing current to flow. In reed switches that act as normally closed
contacts, the contact reeds are closed by small magnets. This magnetic field is
overcome by the considerably stronger magnetic field of the switching magnets.
Reed switches have a long service life and a very short switching time
(approx. 0.2 ms). They are maintenance-free, but must not be used in environments
subject to strong magnetic fields (for example in the vicinity of resistance welders).
Reed switch (normally open contact)

Electronic sensors Inductive, optical and capacitive proximity switches are electronic sensors. They
normally have three electrical contacts.
Contact for supply voltage
Contact for ground
Contact for output signal
In these sensors, no movable contact is switched. Instead, the output is either

electrically connected to the supply voltage or to ground (= output voltage 0 V).
Positive and negative There are two types of electronic sensor with regard to the polarity of the output
switching sensors voltage.
In positive switching sensors, the output voltage is zero if no part is detected in
the proximity. The approach of a workpiece or machine part leads to switchover
of the output, applying the supply voltage.
In negative switching sensors, the supply voltage is applied to the output if no
part is detected in the proximity. The approach of a workpiece or machine part
leads to switchover of the output, switching the output voltage to 0 V.

Inductive proximity sensors An inductive proximity sensor consists of an electrical oscillator (1), a flip-flop (2)
and an amplifier (3). When a voltage is applied, the oscillator generates a high-
frequency alternating magnetic field that is emitted from the front of the sensor. If
an electrical circuit is introduced into this field, the oscillator is attenuated. The
downstream circuitry, consisting of a flip-flop and an amplifier, evaluates the
behavior of the oscillator and actuates the output.
Inductive proximity sensors can be used for the detection of all good electrical
conductors (materials). In addition to metals, these include, for example, graphite.
Schematic diagram Symbol

Metal
Function circuit diagram
1 2 3
Oscillator (1) Flip-flop (2) Amplifier (3)
Inductive proximity sensor

Capacitive proximity sensor A capacitive proximity sensor consists of a capacitor and an electrical resistance that
together form an RC oscillator, and a circuit for evaluation of the frequency. An
electrostatic field is generated between the anode and the cathode of the capacitor.
A stray field forms at the front of the sensor. If an object is introduced into this stray
field, the capacitance of the capacitor changes.
The oscillator is attenuated. The circuitry switches the output.
Capacitive proximity sensors not only react to highly conductive materials (such as
metals) but also to insulators of high dielectric strength (such as plastics, glass,
ceramics, fluids and wood).
Function circuit diagram
1 2 3
Oscillator (1) Flip-flop (2) Amplifier (3)
Capacitive proximity sensor

Optical proximity sensor Optical proximity sensors use optical and electronic means for object detection. Red
or infrared light is used. Semiconductor light-emitting diodes (LEDs) are particularly
reliable sources of red or infrared light. They are small and sturdy, have a long
service life and can be simply modulated. Photodiodes or phototransistors are used
as a receiver. Red light has the advantage that the light beam can be seen during
adjustment of the optical axes of the proximity switch. Polymer optical fibres can
also be used because of their low attenuation of light of this wavelength.
Three different types of optical proximity switch are differentiated:

One-way light barrier
Reflective light barrier
Diffuse reflective optical sensor
One-way light barrier The one-way light barrier has spatially separate transmitter and receiver units. The
parts are mounted in such a way that the transmitter beam is directed at the
receiver. The output is switched if the beam is interrupted.
Transmitter Receiver Transmitter Receiver
One-way light barrier

Reflective light barrier In the reflective light barrier, the transmitter and receiver are mounted together in
one housing. The reflector is mounted in such a way that the light beam transmitted
by the transmitter is practically completely reflected back to the receiver. The output
is switched if the beam is interrupted.

Receiver Receiver
Transmitter Reflector Transmitter Reflector
Reflective light barrier
Diffuse reflective optical In the diffuse reflective optical sensor, the transmitter and receiver are mounted
sensor together in one unit. If the light hits a reflective object, it is redirected to the receiver
and causes the output of the sensor to switch. Because of the functional principle,
the diffuse reflective optical sensor can only be used if the material or machine part
to be detected is highly reflective (for example polished metal surfaces, bright
paint).

Receiver Receiver
Transmitter Transmitter
Diffuse reflective optical sensor

Pressure sensors There are various types of pressure-sensitive sensors:

Pressure switch with mechanical contact (binary output signal)
Pressure switch with electronic switching ( binary output signal)
Electronic pressure sensor with analogue output signal
Mechanical pressure switch In the mechanically actuated pressure switch, the pressure acts on a cylinder
surface. If the pressure exerted exceeds the spring force of the return spring, the
piston moves and operates the contact set.
2 4
>p
1
1
4
2
Piston-actuated pressure switch
Electronic pressure switches Diaphragm pressure switches are of increasing importance. Instead of actuating a
mechanical contact, the output is switched electronically. Pressure or force sensitive
sensors are attached to the diaphragm. The sensor signal is evaluated by an
electronic circuit. As soon as the pressure exceeds a certain value, the output is
switched.
Analogue pressure sensors The design and mode of operation of an analogue pressure sensor is explained
below.
The illustration shows the piezoresistive measuring cell of the pressure sensor. The
electrical resistor changes its value as soon as a pressure acts upon the diaphragm
3. The resistor is connected to the electronic evaluation unit via the contacts 2,
which generates the output signal.
The main components of the sensor are shown in the overall structure of the
pressure sensor.

The characteristic curve of the sensor represents the linear correlation between
pressure and the electrical output signal. An increasing pressure results in an
increasing electrical voltage at the sensor output. A pressure of 1 MPa generates a
voltage of 1 V, and a pressure of 2 MPa an output voltage of 2 V, etc.
1 2
Diffused resistors (1) Contacts (2) Diaphragm (3
Construction of an analogue pressure sensor: Piezoresistive measuring cell
1 2 3 4 5 6 7
Housing (1) Cover (2) Silica gel (3)

O-ring (4) Measuring cell (5) Amplifier (6)
Connector (7)
Construction of an analogue pressure sensor: Overall structure of the sensor

Voltage
V
10
V
8
Pressure p
2 4 6 MPa 10
Characteristic of an analogue pressure sensor: Linear characteristic of sensor

3.4
Relays and contactors
Construction of a relay A relay is an electromagnetically actuated switch. When a voltage is applied to the
solenoid coil, an electromagnet field results. This causes the armature to be
attracted to the coil core. The armature actuates the relay contacts, either closing or
opening them, depending on the design. A return spring returns the armature to its
initial position when the current to the coil is interrupted.
2 3
A1 12 14 22 24
A2 11 21
A1 A2 4 2 1
Coil core (1) Relay coil (3) Insulation (5)

Return spring (2) Amature (4) Contact (6)
Construction of a relay
A relay coil can switch one or more contacts. In addition to the type of relay
described above, there are other types of electromagnetically actuated switch, such
as the retentive relay, the time relay, and the contactor.

Applications of relays In electrohydraulic control systems, relays are used for the following functions:
Signal multiplication
Delaying and conversion of signals
Association of information
Isolation of control circuit from main circuit
In purely electrical control systems, the relay is also used for isolation of DC and AC
circuits.
Retentive relay The retentive relay responds to current pulses:

The armature is energised when a positive pulse is applied.
The armature is de-energised when a negative pulse is applied.
If no input signal is applied, the previously set switch position is maintained
(retention).
The behavior of a retentive relay is analogous to that of a hydraulic double pilot

valve, which responds to pressure pulses.
Time relay There are two types of time relay pull-in delay and drop-out delay. With pull-in
delay, the armature is energised after a set delay; drop-out however, is effeced
without delay. The reverse applies in the case of the drop-out delay relay, whereby
the contacts switch accordingly. The time delay td can be set.
24 V
S1
17
D1
R1
R2 C1 K1
18
0V
Relay with pull-in delay: Internal construction

A1 17 27
1 2
24 V 18 28
A2
3 17
S1 K1
4 18
A1
K1 1M1
A2
0V
Relay with pull-in delay: Circuit diagram
Voltage at
the relay coil
24 V
0V
Time
Contact
Closed
Open
td Time
Relay with pull-in delay: Signal behaviour
Functional principle When switch S1 is actuated, current flows via the variable resistor R1 to capacitor
C1. Diode D1 connected in parallel does not allow current to flow in this
direction. Current also flows via discharge resistor R2 (which is initially not of
importance). When capacitor C1 has charged via the switching voltage of relay K1,
the relay switches.
When S1 is released, the circuit is interrupted and the capacitor discharges rapidly
via diode D1 and the resistor R2. As a result, the relay returns immediately to its
initial position.
Variable resistor R1 allows the charging current to the capacitor to be adjusted

thus also adjusting the time until the switching voltage for K1 is reached. If a large
resistance is set, a small current flows with the result that the delay is long. If the
resistance is low, a large current flows and the delay is short.

24 V
S1
17
D1
R1
R2 C1 K1
18
0V
Relay with drop-out delay: Internal construction
A1 17 27
1 2
24 V 18 28
A2
3 17
S1 K1
4 18
A1
K1 1M1
A2
0V
Relay with drop-out delay: Circuit diagram
Voltage at
the relay coil
24 V
0V
Time
Contact
Closed
Open
td Time
Relay with drop-out delay: Signal behaviour

Construction of a contactor Contactors operate in the same way as a relay.

Typical features of a contactor are:
Double switching (dual contacts)
Positive-action contacts
Closed chambers (arc quenching chambers)
These design features allow contactors to switch much higher currents than relays.
7 4 5 A1 13 23
A2 14 24
13 14
3
6
A2
A1
1 2
Coil (1) Moving switch element with contacts (4) Contact pressure spring (7)
Iron core (magnet) (2) Static switch element with contacts (5)
Amature (3) Pressure spring (6)
Construction of a contactor
A contactor has multiple switching elements, normally four to ten contacts. For
contactors as for relays there are various types with combinations of normally
open contact, normally closed contact, changeover contact, delayed normally closed
contact etc. Contactors that only switch auxiliary contacts (control contacts) are
called contactor relays. Contactors with main and auxiliary contacts are called main
or power contactors.

Applications of contactors Contactors are used for the following applications:

Currents of 4 to 30 kW are switched via the main contacts of power contactors.
Control functions and logical associations are switched by auxiliary contacts.
In electrohydraulic control systems, electrical currents and power are low. For this
reason, they can be implemented with auxiliary contactors. Main or power
contactors are not required.
3.5 Programmable logic controllers (PLCs) are used for processing of signals in binary
Programmable logic control systems. The PLC is particularly suitable for binary control systems with
controllers numerous input and output signals and requiring complex signal combinations.
PLC (Festo FEC Standard)
PLC program
Input module Central Control Unit Output module
Sensors Actuators
System components of a PLC

Structure and mode of The illustration is in the form of a box diagram illustrating the system components of
operation of a PLC a PLC. The main element (CCU)is a microprocessor system. Programming of the
microprocessors determines:
Which control inputs (I1, I24 etc.) are read in which order
How these signals are associated
Which outputs (O1, O2 etc.) receive the results of signal processing.
In this way, the behavior of the controller is not determined by the wiring
(hardware), but by the program (software).
3.6 The signal control section of an electrohydraulic control system consists of three
Overall structure of the function blocks. Its structure is shown in the following diagram.
signal control section Signal input takes place via two sensors or via push button or control switches.
The diagram shows two proximity switches for signal input.
Signal processing is normally undertaken by a relay control system or a
programmable logic controller. Other types of controller can be ignored. In the
diagram, control is undertaken by a relay control system.
Signal output is via solenoid-actuated directional control valves.

24 V
1B1
K1 K2
E1 A1
K1
1B2
K2
E2 A2
1M2 1M1
K2 K1
0V
Signal input Signal processing Signal output
Signal control section of relay control system (schematic, circuit diagram not compliant with standard)
The diagram shows a schematic representation of a signal control section of an

electrohydraulic control system, in which relays are used for signal processing.
The components for signal input (inductive proximity switches 1B1 and 1B2 are
connected via the controller inputs (I1, I2 etc.) to the relay coils (K1, K2 etc. )
Signal processing is implemented by means of suitable wiring of several relay
coils and contacts.
The components for signal output (solenoids of directional control valves 1M1
and 1M2) are connected to the controller outputs (O1, O2 etc.). They are
actuated via the relay contacts.

24 V
Programmable
microprocessor system
1B1
E1 A1
1B2
E2 A2
1M2 1M1
0V
Signal input Signal processing Signal output
Signal control section with programmable logic controller (PLC)
The diagram shows the signal control section of an electrohydraulic control system
in which a PLC is used for signal processing.
The components for signal input (inductive proximity switches 1B1 and 1B2 are
connected to the inputs of the PLC (I1, I2).
The programmable microprocessor system of the PLC undertakes all signal
processing tasks.
The components for signal output (solenoids of directional control valves 1M1
and 1M2) are connected to the PLC outputs (O1, O2 etc.). They are actuated by
electronic circuits that are part of the microprocessor system.

4. Solenoid actuated directional control valves
4.1 An electrohydraulic control system operates with two different types of energy
Exercises With electrical energy (electrical current) in the signal control section
With hydraulic energy (hydraulic fluid) in the power section.
Solenoid actuated directional control valves form the interface between the two
sections of an electrohydraulic control system. They are switched via the output
signal of the signal control section and close or open connections in the hydraulic
power section. The most important functions of solenoid actuated directional control
valves include:
The switching on and off of the hydraulic energy supply
The control of movement of operating elements by means of stopping, starting
and changing the direction of flow of the pressure media.
Actuation of a single-acting The illustration shows a solenoid actuated valve, which controls the movement of a
cylinder single-acting drive cylinder. The valve features three connections and two switching
positions. The connections are: Power port (A), pressure port (P) and tank
connection (T).
The cylinder chamber is connected to the tank via the directional control valve, if
the solenoid coil of the directional control valve is de-energised. The hydraulic
fluid is displaced into the tank via the spring force and the piston rod is retracted.
If electrical current flows through the solenoid coil, the valve switches, the fluid
flows into the cylinder chamber and the piston rod advances.
The valve reverses if the solenoid coil is de-energised. The cylinder chamber is
re-connected with the tank and the piston rod retracts.
24 V 24 V
L L
A A
P T P T
0V 0V
Actuation of a hydraulic cylinder: Single-acting

Actuation of a double-acting The diagram below shows the actuation of a double-acting cylinder.
cylinder
The double-acting drive cylinder is controlled via a directional control valve with four
connections and two switching positions. The connections are: Power ports A and B,
pressure port P and tank connection T.
If the solenoid coil is de-energised, the lefthand cylinder chamber is connected to
the tank via the directional control valve and the hydraulic fluid flows into the
righthand cylinder chamber..
The valve switches if the electrical current flows through the solenoid coil. The
hydraulic fluid flows into the lefthand cylinder chamber and the hydraulic fluid in
the righthand cylinder chamber is displaced into the tank. The piston rod
advances.
The valve reverses, if the solenoid coil is de-energised, and the piston rod
retracts.
24 V 24 V
A B A B
P T P T
0V 0V
Actuation of a hydraultic cylinder: Double-acting

4.2 Electrically actuated directional control valves are switched by means of solenoids
Design and mode of and can be divided into two groups:
operation Solenoid valves with spring return only hold the actuated switching position for
as long as the electrical current flows through the solenoid coil.
Double solenoid valves hold the last assumed switching position even if the
solenoid coils are de-energised.
Normal position In the normal position of a solenoid actuated directional control valve, all solenoid
coils are de-energised and the solenoids do not exert a force. In the case of a double
solenoid valve, the normal position cannot be unambiguously defined, since there is
no return spring.
Valve designation Additional differentiating characteristics are the number of valve ports and the
number of switching positions. The valve designation is determined by means of the
actuation, number of ports and the switching positions.
Example: 3/2-way valve with spring return

4/2-way double solenoid valve
The design and mode of operation of the most important valve types are explained
below.
Directly actuated 3/2-way In the case of directly actuated solenoid valves, the valve piston is actuated directly
solenoid valve, with spring via solenoids without any intermediate switching or amplification.
return
The illustration shows two sectional views of a directly actuated 3/2-way valve.
The valve has a power port A, a pressure port P and a tank connection T. The
assembled DC solenoid is a solenoid switching in oil, also known as a wet
solenoid. The armature operates in the hydraulic fluid and the armature chamber is
connected to the tank connection.
In the normal position, power port A is connected to the tank connection T.
Pressure port P is closed.
If an electrical current flows through the solenoid coil, the magnetic field exerts a
force upon the armature and the armature presses the piston against the
opposite spring via the armature. This causes port P to be connected to port A;
the tank connection T is closed.
If the solenoid coil is de-energised, the armature returns to the normal position
via the spring force thereby closing the connection between port P and port A,
whereas the connection between port A and connection T is open and the
hydraulic fluid is discharged via connection T.

1M1
P T
7 8 1 2 3
T A P
6 5 4
Piston (1) Housing (2) Spring (3)

Solenoid coil (4) Armature (5) Emergency manual override (6)
Stem (7) Spring disk (8)
Directly actuated 3/2-way solenoid valve with emergency manual override, normally closed: Unactuated
1M1
P T
T A P
Directly actuated 3/2-way solenoid valve with emergency manual override, normally closed: Actuated
3/2-way valves are available in both designs - normally closed and normally
open.

The illustration below shows a normally open, solenoid actuated 3/2-way valve.
Compared to the normally closed valve, the pressure and tank connections are
swapped.
1M1
P T
7 8 1 2 3
T A P
6 5 4
Directly actuated 3/2-way solenoid valve with emergency manual override, normally open: Unactuated
1M1
P T
T A P
Directly actuated 3/2-way solenoid valve with emergency manual override, normally open: Actuated
In industrual practice and for reasons of cost, the function of a 3/2-way valve is
generally realised by means of a 4/2-way valve and by closing one of the working
ports.

Emergency manual override The emergency manual override also facilitates actuation of the solenoid valve, but
without electrical energy.
It is used for example for the commissioning of a system or in the event of failure of
the normal actuating device and is triggered manually.
Directly actuated 4/2-way The illustration shows the two switching positions of a directly actuated 4/2-way
solenoid valve, with spring valve. The valve has two working ports A and B, one pressure port P and the tank
return connection T. The DC solenoid fitted is a solenoid switching in oil. The armature
operates in the hydraulic fluid and the armature chamber is connected to the tank
connection.
In the normal position, the valve piston is located at the lefthand stop. Ports P
and A and ports B and T are connected.
If an electrical current flows through the solenoid coil, the valve piston moves up
to the righthand stop. In this switching position, ports P and B and port A and T
are connected.
If the solenoid coil is de-energised, the valve piston is returned to the normal
position via the spring force.

A B
1M1
P T
1 2 3
T A P B
5 4

Solenoid coil (4) Armature (5)
Directly actuated 4/2-way solenoid valve, with spring return: Unactuated
A B
1M1
P T
T A P B
Directly actuated 4/2-way solenoid valve, with spring return: Actuated

Directly actuated 4/2-way The illustration shows the two switching positions of a directly actuated 4/2-way
double solenoid valve, with double solenoid valve. The switching positions are changed by briefly applying
detent voltage to the coil of the respective solenoid.
The valve has two working ports A and B, one pressure port P and one tank
connection T. The DC solenoid fitted is a solenoid switching in oil, with the
armature operating in the hydraulic fluid. The armature chamber is connected to the
tank connection.
If the valve piston is located at the lefthand stop, flow is released from P to A and
from B to T.
If voltage is briefly applied to the lefthand solenoid coil 1M1, the armature
pushes the valve piston into the opposite end position. Flow is released from P to
B and from A to T. This position is maintained via the detent even without
current.
If voltage is briefly applied to the righthand solenoid coil 1M2, then flow is
released from P to A and from B to T. This switching position is also maintained
via the detent.
A B
1M1 1M2
P T
1 2
1M1 1M2
T A P B
5 4 3
Piston (1) Housing (2) Solenoid coils (3)

Armature (4) Detent (5)
Directly actuated 4/2-way double solenoid valve, with detent: Solenoid coil 1M2 briefly energised

A B
1M1 1M2
P T
1M1 1M2
T A P B
Directly actuated 4/2-way double solenoid valve, with detent: Solenoid coil 1M1 briefly energised
If neither of the two solenoids is actuated, the valve piston remains in the last
assumed switching position by means of the detent. The same applies if voltage is
applied simultaneously to both solenoids since these then oppose one another with
identical force.
The switching position of the valve piston is not externally visible. A particular start
position can only be obtained by means of an electrical impulse on the respective
appropriate solenoids.

4/3-way solenoid valve, The illustration shows the three switching positions of an electrically, directly
spring centred, mid position actuated 4/3-way valve in closed position.
closed The valve has two working ports A and B, one pressure port P and a tank
connection T. The assembled DC solenoid is a solenoid switching in oil, with the
armature operating in the hydraulic fluid. The armature chamber is connected to the
tank connection.
In the normal position, no current flows through the two solenoid coils and the
valve piston is centred in its mid-position via the two springs.
If voltage is applied to the righthand solenoid coil 1M2, the valve piston is
pressed against the spring opposite and flow is released from P to A and from B
to T.
If voltage is applied to the lefthand valve coil 1M1, the valve piston is pushed in
the opposite direction and flow is released from P to B and from A to T.
Each of the two switching positions is held for as long as the respective solenoid
coil is energised. If current flow is interrupted, the valve piston switches into the
mid-position.
A B
1M1 1M2
P T
1 2 3
1M1 1M2
T A P B
5 4

Solenoid coils (4) Armature (5)
Directly actuated 4/3-way solenoid valve, mid-position closed: Neutral position

A B
1M1 1M2
P T
1M1 1M2
T A P B
Directly actuated 4/3-way solenoid valve, mid-position closed: Voltage at solenoid coil 1M2
A B
1M1 1M2
P T
1M1 1M2
T A P B
Directly actuated 4/3-way solenoid valve, mid-position closed: Voltage at solenoid coil 1M1

Effect of mid-position Directional control valves with two switching positions, for example 3/2-way or
4/2-way valves, facilitate the advancing and retracting of a cylinder. Directional
control valves with three switching positions, for example 4/3-way valves, offer
additional options for cylinder actuation owing to the additional mid-position.
Instead of a drive cylinder, you can of course also consider a motor. With these
valves you can therefore for example realise stopping, clockwise and anti-clockwise
rotation of a motor.
The additional options are explained below using the example of three 4/3-way
solenoid valves with different mid-positions. The behaviour of the drive cylinder is
examined, if the directional control valve switches into the mid-position.
4/3-way solenoid valve with closed position:

In the case of a 4/3-way solenoid valve which closes all ports, the piston rod
remains stationary. The same applies if the piston rod is not at the stop.
If the cylinder is to reliably remain in its position for an extended period of time, a
4/3-way solenoid valve in poppet design must be used. Poppet valves exhibit
zero-leakage internally.
4/3-way valve with bypass position:
With a 4/3-way solenoid valve, where the working ports are closed, the piston
rod remains stationary in the current position. The pump continues to run
pressureless and delivers the hydraulic fluid directly back into the tank. There is
no power loss.
This valve is preferred for the actuation of a consuming device that is not
continuously moved.
4/3-way solenoid valve with freely movable position:
If a 4/3-way solenoid valve is used, where the working ports are directly
connected to the tank, the piston of the drive cylinder does not exert any force
upon the piston rod. The piston rod is freely movable.
V=0
24 V 24 V
0V 0V
Effect of the mid-position with 4/3-way solenoid valve: With closed position

V=0
24 V 24 V
0V 0V
Effect of mid-position with 4/3-way solenoid valve: With bypass position
F=0
24 V 24 V
0V 0V
Effect of mid-position with 4/3-way solenoid valves: With freely movable position
The following illustration show all the possible switching variants for the mid-
position of a 4/3-way solenoid valve.
A B
P T
Switching variants for the mid-position of 4/3-way solenoid valves

Pilot control of a directional In the case of pilot actuated directional control valves, the valve piston is indirectly
control valve actuated.
Pilot actuated directional control valves consist of a hydraulically actuated main

valve and a directly actuated pilot valve.
A pilot valve is normally directly actuated via a solenoid. The control signal is
hydraulically amplified with the switching of the pilot valve and the main control
piston is displaced.
The supply of the pilot valve can be effected externally or internally.

Internal means: P and T are connected to the appropriate lines of the main control
stage.
External means: P is connected to port X and T is connected to port Y of the main
control stage.
The illustration provides a detailed explanation of the mode of operation of the pilot
stage. The function of the pilot valve is to either pilot hydraulic fluid to both or one
of the two piston front faces of the hydraulically actuated main valve. This means
that considerably higher forces are available to reverse the main control piston than
with the directly actuated version.

A B
1M1 1M2
X P T Y
Y T A P B X
Main valve (1) Pilot valve (1)
Pilot control of a directional control valve

Pilot actuated 4/3-way The following illustrations show three sectional representations of a solenoid
solenoid valve actuated, piloted 4/3-way valve in the closed position. The directional control valve
shown is of the spool valve design.
A 4/3-way valve in freely movable position acts as the pilot valve.
In the normal position, both valve coils (1M1, 1M2) are de-energised, the main
control piston is retained in the mid-position by means of the springs (4.1, 4.2). The
two spring chambers (6, 7) are connected pressureless to the tank via the pilot
valve.
The pilot valve is supplied with hydraulic fluid via the pilot line (5).
The pilot piston moves to the left if an electrical current flows through the
righthand solenoid coil (1M2).
This also causes pilot pressure to be applied in the lefthand spring chamber (6);
the righthand spring chamber (7) remains pressureless.
The pilot pressure acts upon the lefthand surface of the main control piston and
moves it against the spring (4.2) to the right until it makes contact with the cap.
With this, ports P and A are connected to ports B and T respectively in the main
valve.
This switching position is maintained for as long as electrical current flows
through the solenoid coil (1M2).
If the solenoid coil (1M2) becomes de-energised, the pilot piston moves back
into the mid-position and pressure is relieved in the spring chamber (6). The
spring (4.2) can now move the main control piston to the left until it makes
contact with the spring disk of the spring (4.1). The piston is in the mid-position.
The pilot piston moves to the right if electrical current flows through the lefthand
solenoid coil (1M1).
This means that pilot pressure is also applied in the righthand spring
chamber (7); the lefthand spring chamber (6) remains pressureless.
The pilot pressure acts on the righthand surface of the main control piston and
moves it against the spring (4.1) to the left until it comes into contact with the
cap.
This causes flow to be released in the main valve from P to B and from A to T.
This switching position is maintained for as long as electrical current flows
through the solenoid coil (1M1).
The pilot piston moves into the mid-position again if the solenoid coil (1M1)
becomes de-energised. Pressure is relieved in the spring chamber (7). The spring
(4.1) can now move the main control piston to the right until it contacts the
spring disk of the spring (4.2). The piston is in the mid-position.

A B
1M1 1M2
X P T Y
8
2
6 7
Y T A P B X
4.1 3 4.2
Main valve (1) Pilot valve (2) Main control piston (3)
Lefthand spring (4.1) Righthand spring (4.2) Control line (5)
Lefthand spring chamber (6) Righthand spring chamber (7) Pilot piston (8)
Pilot actuated 4/3-way solenoid valve in closed position: Normal position

Pilot actuated 4/3-way solenoid valve in closed position: Voltage at solenoid coil 1M2

A B
1M1 1M2
X P T Y
Y T A P B X
Pilot actuated 4/3-way solenoid valve in normally closed position: Voltage at solenoid coil 1M1
A minimum control pressure is required in order to actuate the main control piston
of the piloted valve against the spring force. This is specified in the valve
documentation and, depending on valve type, is approx. 0.5 MPa.

Comparison of pilot Directional control valves can be directly actuated or piloted. Whether a valve is to
actuated and directly be directly actuated or piloted mainly depends on the magnitude of the required
actuated valves actuating force and therefore on the size.
With a directly actuated solenoid valve, the valve piston which controls flow to the
consuming device is moved directly via the force of the solenoid. The force required
to actuate the valve piston increases in line with the size and capacity of the valve.
The greater the magnetic force, the greater the construction volume and power
consumption of the solenoid.
After a certain solenoid size, the use of directly actuated solenoid valves is no longer
viable. Directly actuated directional control valves are therefore generally only
produced up to size 10. This applies both to poppet and spool valves.
Pilot actuated valves are used to control larger hydraulic capacities this applies to
directional control valves from size 10. These valves are generally in the form of
directional control spool valves.
A piloted directional control spool valve consists of the main valve and a smaller
pilot valve.
The pilot valve is directly actuated via a solenoid. The control signal is hydraulically
amplified via the switching of the pilot valve and the main control piston is moved. A
minimum pilot pressure is required to move the main control piston. Depending on
valve type, this pressure is approximately 0.5 MPa. The solenoid of the pilot valve
therefore only needs to generate the force required to control the minimal quantity
of control oil.
Compared to directly actuated directional control valves, the solenoid of a piloted

directional control valve can be of a smaller design. The electrical power
consumption and heat emission are therefore also less. The switch-on wattage for
piloted switching valves with DC solenoid coil starts at approx. 3 W. Valves of this
type can be actuated directly via the control electronics, for example via a PLC
output signal.
Pilot actuated valves therefore exhibit a favourable electrical energy balance. If we
look at the hydraulic energy balance, this can be less favourable than that for
directly actuated valves, since the requirement for pilot valves need to be taken into
consideration when establishing the flow rate.
If you compare the cost and space required for directly actuated and piloted valves,
then directly actuated directional solenoid valves require less space and are more
cost effective than piloted directional solenoid valves.

4.3 Solenoid actuated directional control valves are produced in numerous variants and
Designs and hydraulic sizes in order to meet the different requirements of industry.
performance data
Directional control valves can be categorised
According to their mode of operation - into non-throttling and throttling
directional control valves,
According to their design - into spool valves and poppet valves
According to their mounting and connection - into surface mounted valves and
cartridge valves.
When selecting a valve, it is advisable to use a step-by-step approach.

The first step is to establish the valve type, based on the task and required
behaviour in the event of power failure. For example, a 4/2-way solenoid valve
with spring return.
The second step is to determine the valve with the help of the performance data
listed in the vendor catalogues, whereby the requirements specific to the
problem definition will be met at the lowest possible overall costs. These should
not only take into account the cost of the valve, but also the expenditure
involved in the operation, installation, maintenance and storage of replacement
parts.
The most frequently used valves types, circuit symbols and applications are listed in
the table below.

Valve type Symbol Application
Directly actuated 2/2-way solenoid valve A Shut-off function

with spring return, poppet design
Directly actuated 3/2-way solenoid valve Single-acting linear cylinder

with spring return
To switch on and off hydraulic fluid
Normally closed A
P T
Normally open A
P T
Directly actuated 4/2-way solenoid valve A B Double-acting linear cylinder

with spring return
P T
Directly actuated, 4/3-way solenoid valve Double-acting linear cylinder or motor

with spring return with intermediate stop,
with latching circuit,
With closed position A B
with rapid traverse control,
with closed-loop circuit or
P T with special requirements regarding
behaviour in the event of power failure
With bypass position A B
P T
A B
With freely movable position, tank
connection closed
P T
A B
With freely movable position, pump

connection closed P T
Applications and symbols for solenoid actuated directional control valves with spring return

Valve type Symbol Applications
Directly actuated, 4/2-way double A B Double-acting linear cylinder or motor

solenoid valve
P T
Applications and symbols for double solenoid valves
Should a valve with the desired characteristics not be available, it is for example
possible to interchange ports in order to obtain a particular switching behaviour or a
valve with a different number of ports can be used.
In order to realise the function of a 2/2-way solenoid valve, 2 ports are closed on
a 4/2-way solenoid valve.
In order to realise the function of a 3/2-way double solenoid valve, one working
port is closed on a 4/2-way double solenoid valve.
Power failure and cable An electrohydraulic control system should be configured such that the system and
break workpieces will not be damaged due to uncontrolled drive movements in the event
of power failure or a cable break. The behaviour of an hydraulic cylinder suitable for
these operating conditions can be determined by means of selecting an appropriate
directional solenoid valve.
Valve type Behaviour in the event of power failure or cable break
3/2- or 4/2-way solenoid A 3/2- way or 4/2-way solenoid valve with spring return switches
valve, with spring return into the normal position and the piston rod of the cylinder moves
into the normal position.
4/3-way solenoid valve, A spring centred 4/3-way solenoid valve also switches into the
spring centred normal position.
The cylinder is unpowered if the working ports are connected to the

tank in the normal position of the valve and if the pump connection
is closed.
If the working ports are closed and the pump and tank connections
are connected, the pump continues to operate pressureless and
returns the hydraulic fluid into the tank.
Movement of the piston is interrupted if all ports are closed.
4/2-way double solenoid A double solenoid valve maintains its position. The piston rod
valve with detent completes the started motion sequence.

Modular design of a Solenoid actuated directional control valves are of modular design. The following
solenoid actuated components are required for their functioning:
directional control valve The directional control valve,
One or two solenoids for actuation,
One or two plugs for the cable connection to the signal control section
The picture below illustrates this design using the example of a 4/2-way solenoid
valve.
Directional control valve (1) Solenoid coil (2) Plug (3)
Modular design of a solenoid actuated directional control valve
The performance data of a valve is determined mutually by all three components.

The mechanical components of a valve mainly influences the hydraulic
performance data.
The solenoid coil and cable connection primarily influence the electrical
performance data.

Performance data of a solenoid actuated directional control valve
Directional control valve Hydraulic performance data

Nominal size
Nominal flow rate
Pressure range
T A P B
Solenoid coil Electrical performance data

Operating voltage
Electric power
Duty cycle
Response time
Plug Electrical performance data

Protective circuit
Switching indication
Signal conversion
Class of protection
1 The switching time is determined by the performance data of the directional control valve and
the solenoid coil.
2 The protection class is determined by the performance data of the solenoid coil and the plug.

Solenoids Solenoids are generally used in the form of lifting solenoids available in four
designs:
DC solenoid, switching in air; also known as a dry solenoid.
DC solenoid, switching in oil; also known as a wet solenoid..
AC solenoid, switching in air.
AC solenoid, switching in oil.
The DC solenoid offers high operational reliability and facilitates soft switching. The
solenoid coil does not burn out if the armature is stopped for example as a result of
the piston sticking during the stroke. The DC solenoid is suitable for high switching
frequencies.
The AC solenoid is characterised by short switching times. The solenoid coil may
burn out if the armature cannot switch through to the end position.
In the case of a wet solenoid, the armature chamber contains hydraulic fluid. The
armature switches in the hydraulic fluid. An externally leak-proof design of the
solenoid housing is essential in this case. The armature chamber is connected to the
tank so that the solenoid is not subject to high pressures. The advantages of this
widely used design are:
Absolute leak tightness and mininal friction as the seal on the stem is not subject
to any mechanical load.
No corrosion of the internal solenoid components.
Cushioned armature stop.
Excellent heat dissipation.

1 2 3
6 5 4
Armature (1) Winding (2) Core (3)

Solenoid body (4) Armature tube (5) Emergency manual override (6)
Wet solenoid
The constructional design in the form of a dry solenoid means that the solenoid is
separate from the hydraulic fluid. The stem is sealed against the hydraulic fluid by
means of a seal. If the solenoid is to switch, it needs to overcome the friction
between stem and seal as well as the hydrostatic force of the stem in addition to the
spring force and the friction of the valve spool.
1 2 3
6 5
Armature (1) Winding (2) Core (3)

Seal (4) Solenoid body (5) Emergency manual override (6)
Dry solenoid

Connection types for Solenoid actuated directional control valves are available in two different connection
directional control valves types to meet the requirements of different installation situations.
Cartridge valves are self-retaining valves with screw-in cartridge. All the functional
elements of the valve are integrated into the screw-in cartridge and the housing is
dispensed with.
Cartridge valves are connected to a valve block mainly in the form of a separately
added plug-in valve in order to form a common housing. This offers compact
hydraulics with different levels of integration using a minimum of piping.
3/2-way solenoid valve in cartridge design (Aron S.p.A.)
Surface mounted valves are screwed onto a sub-base via a sealed surface. The sub-
base is provided with a standardised hole pattern. The hole patterns for the
individual sizes are defined by ISO 4401. Connection is indirect in that the piping is
securely screwed into the sub-base by means of pipe connectors.
The advantages of this design are:
Valves are easily removable for maintenance purposes.
Sub-bases can be equipped with valves by different manufacturers.
Ports are located at one level, the screw-on and sealing surface is flat.
Moreover ports can be led out of additional sides of the valve.
Ports sealed with flexible sealing rings are extremely reliable.

T
A B
A B
Port patterns NG 6 and NG 10, used preferably for directional control valves
The illustration below represents a 4/2-way solenoid valve in the form of a surface
mounted valve, which is screwed onto a sub-base with standard port pattern. The
valve connections to the two consuming devices and to the pump and tank are also
attached. The valve connections are fitted with quick connecting couplings.
4/2-way solenoid valve in the form of a surface mounted valve (Festo AG & Co. KG)

Application example Surface mounted valves with sub-base can be mounted flat on a specially prepared
mounting surface, which leads to a clearly configured control section. However, each
valve requires a separate line for the pressure and tank connection and, depending
on the design, also a leakage oil and pilot port. The piping complexity is
comparatively high and pressure loss may be considerable due to the extensive
piping.
Piping and space requirements are reduced if the pressure and tank connection to
the individual valve, as well as the switching connection between the valves, is not
realised in the form of a separate piping system, but as an integrated ducted system.
This type of valve linkage connects self-supporting, differently equipped valve
modules and no longer requires a mounting surface.
Self-supporting valve modules include surface mounted valves or cartridge valves.
The illustration shows a manifold block with four surface mounted valves. These
surface mounted valves are solenoid actuated directional control valves. Each valve
has two solenoids for valve actuation. The vacant valve position between the valves
is sealed with a blanking plate.
Assembly of solenoid actuated directional control valves on a manifold block (Aron S.p.A.)

Performance data of 4/3- The table below lists the hydraulic performance data and operating conditions of
way solenoid valves three 4/3-way solenoid valves.
Valve type Directly actuated Directly actuated Pilot actuated Pilot actuated
4/3-way solenoid valve 4/3-way solenoid valve 4/3-way solenoid valve 4/3-way solenoid valve
NG 4 NG 10 NG 10 NG 16
Connection type Surface mounted valve Surface mounted valve Surface mounted valve Surface mounted valve
Symbol A B A B
P T P T
Nominal size NG 04 NG 10 NG 10 NG 10
Max. operating pressure 25 MPa 32 MPa 32 MPa 32 MPa

at P/A/B
Max. operating pressure 25 MPa 16 MPa 7 MPa 16 MPa

at T
Min. pilot pressure 1 MPa 0,5 MPa
Max. pilot pressure 25 MPa 21 MPa
Max. Flow 20 l/min 100 l/min 120 l/min 300 l/min
Response time (with DC

solenoid)
20 ms 60 95 ms 20 ms 50 ms
pick-up
40 ms 25 70 ms 50 ms 60 ms
drop- out
Temperature of pressure 0 +60 C 0 +75 C 0 +75 C -20 +70 C

medium
Ambient temperature -25 +60 C -25 +60 C -20 +50 C -20 +50 C
Hydraulic performance data of solenoid actuated directional control valves (Aron S.p.A.)

Nominal size and flow Whether a directional control valve of large or small diameter is used is governed by
the consuming device to be actuated.
For example, a cylinder with a large piston surface or high speed of movement
requires the use of a valve with a high flow rate. A cylinder with a small piston
surface or low speed of movement can be actuated by a valve with a low flow rate.
Nominal size and flow rate are dimensions in respect of the flow characteristics of a
valve. The term volumetric flow rate is often used instead of flow.
The nominal size is the standardised size with the connection pattern for the
respective valve. It applies solely to surface mounted valves.
A large nominal size results in a high flow rate and a small nominal size in a low flow
rate.
The nominal flow rate of a valve is determined on the basis of defined specifications.
The specificationsa are: A differential pressure of 0.5Pa applies per control edge.
The nominal flow rate merely represents a comparative value, since a valve is rarely
used in exactly these pressure conditions. In practice, the pressure/flow
characteristic curve is therefore useful. With this, the pressure is plotted above the
flow rate.
The maximum flow rate indicates the maximum volume of hydraulic fluid that can
flow through the valve within a specified time unit.
Maximum operating The maximum operating pressure indicates the maximum pressure at which the
pressure valve can be operated. The upper pressure limit is determined by the strength of the
housing.
It should be noted that the pressure load of individual connections may vary.
Minimum and maximum The pressure range indicates the supply pressure at which the pilot actuated valve
pilot pressure can be operated. The level of pilot pressure influences the switching times of the
main stage of the valve.

Response times The response times indicate the period of time that passes between the actuation of
the contact and the valve switching.
In the case of valves with spring return, the response time for switching from the
normal position into the actuated position is generally shorter than that for reverse
switching.
A lengthy response time slows down the behaviour of an electrohydraulic control

system, since the actuation of the consuming devices is delayed by the switching
time.
Temperature of the pressure The temperature of the pressure medium influences the viscosity of the hydraulic
medium fluid and as such the flow resistance of the valves. The flow resistance decreases
with increasing temperature.
Ambient temperature The reliable functioning of a valve is only guaranteed if the ambient temperature is
within the specified limits.
If the ambient temperature deviates significantly from the operating temperature of
the pressure medium, this must be taken into consideration in the configuration of
the control system. If the ambient temperature and consequently that of the
pressure medium is low, appropriate measures must be taken when starting up the
system.

4.4 A solenoid actuated directional control valve can be equipped with different
Performance data of solenoid coils. Valve manufacturers generally offer one or several solenoid coil
solenoid coils series for each type of directional control valve, which are harmonised with the valve
with regard to connection sizes. Solenoid coils are selected on the basis of the
electrical performance data.
Technical data Example 1 Example 2
Normal voltages 12 V DC, 24 V DC 12 V DC, 24 V DC
Special voltages 48 V DC, 110 V DC 48 V DC, 110 V DC
Voltage fluctuations -10 to +10 % -10 to +10 %
Ambient temperature -30 to +60 C -54 to +60 C
Duty cycle 100 % duty cycle 100 % duty cycle
Protection class IP 65 IP 66
Power consumption for normal 27 W at 12 V DC 48 W at 12 V DC

voltages 27 W at 24 V DC 48 W at 24 V DC
Maximum winding temperature 123 C at 12 V DC 108 C at 12 V DC

(at 25 C ambient temperature) 123 C at 24 V DC 108 C at 24 V DC
Performance data of DC voltage solenoid coils (Aron S.p.A.)

Technical data Example 1 Example 2
Normal voltages 24 V/50 Hz 24 V/50 Hz

110 V/50 Hz 115 V/60 Hz 110 V/50 Hz 115 V/60 Hz
220 V/50 Hz 230 V/60 Hz 220 V/50 Hz 230 V/60 Hz
Special voltages 24 V/60 Hz 24 V/60 Hz

48 V/50 Hz 48 V/50 Hz
240 V/50 Hz 240 V/50 Hz
Voltage fluctuations -10 - % -10 - +10 %
Ambient temperature -54 +60 C -54 - +60 C
Duty cycle 100 % duty cycle 100 % duty cycle
Protection class IP 66 IP 66
Power consumption for normal 57 VA at 24 V/50 Hz 124 at 24 V/50 Hz

voltages during normal operation 55 46 VA at 110 V/50 Hz 122 103,5 at 110 V/50 Hz
55 46 VA at 220 V/50 Hz 121 99 at 220 V/50 Hz
Maximum winding temperature 100 C at 24 V/50 Hz 134 C at 24 V/50 Hz

(at 25 C ambient temperature) 123 99 C at 110 V/50 Hz 134 115 C at 110 V/50 Hz
123 99 C at 220 V/50 Hz 134 115 C at 220 V/50 Hz
Performance data of AC voltage solenoid coils (Aron S.p.A.)
Data regarding operating The voltage data listed in the tables refers to the electrical voltage at which the
voltage solenoid coils are supplied. Solenoid coils are selected such as to be suitable for the
signal control section of an electrohydraulic control system. For example, if the
signal control section operates with 24 V DC voltage, then the appropriate coil type
must be selected.
In order to ensure that the solenoid coil functions correctly, the voltage with which it
is supplied must be within certain limits. A coil type using 24 V produces the
following limit values:
Minimum voltage: Umin = 24 V (100 % - 10 %) = 24 V 0.9 = 21.6 V

Maximum voltage: Umax = 24 V (100 % + 10 %) = 24 V 1.1 = 26.4 V
If the signal control section operates with AC voltage and AC voltage solenoid coils
are therefore used, the frequency of the AC voltage must be within a predefined
range. Frequencies of up to 10% above or below 50 Hz are permissible for AC
voltage solenoid coils listed in the table. The permissible frequency range is
between 45 and 55 Hz.

Electrical performance data The power consumption of the solenoid coils must be taken into consideration when
sizing the power supply unit for the signal control section. Preferably, the power
supply unit is to be configured such as to prevent overload if all coils are actuated
simultaneously.
The heat emission of solenoid coils is to be observed during solenoid valve

operation. Data regarding the maximum possible temperature can be found in the
data sheet under the section Winding and Coil Temperature.
Duty cycle If a solenoid is actuated, current flows through the solenoid coil, which heats up due
to its ohmic resistance. The duty cycle indicates the maximum permissible
percentage of operating time during which the solenoid coil may be actuated. A
solenoid coil with a 100 % duty cycle may be current-carrying throughout the entire
period of operation.
If the duty cycle is less than 100 %, the coil will become overheated in the case of
continuous operation, causing the insulation to melt and the coil to be damaged.
The duty cycle relates to an operating period of 10 minutes. For example, if the
permissible duty cycle of a solenoid coil is 60 %, the maximum permissible current-
carrying time of this coil is only 6 minutes in respect of a period of operation of 10
minutes.
Protection class The protection class indicates to what extent a solenoid coil is protected against the
ingress of dust and water. The protection classes of the coils listed in the tables are
IP 65 and IP 66. For example, IP 65 means that the solenoid coils are protected
against the ingress of dust and are suitable for operation in an environment subject
to splash-water.
The protection class is always determined and specified in conjunction with the plug
used.
Temperature data The reliable functioning of a solenoid coil is ensured only if the ambient temperature
is within the specified limits.
Note The magnetic field of a coil and therefore the force of the solenoid build slowly when
a solenoid coil is actuated. The mean pick-up time indicates the time span between
the time when the coil is current-carrying and the time when the armature has
picked up.

The longer the pick-up time of a solenoid coil, the longer the response time of the
actuated directional control valve.
The mean pick-up time is often not separately indicated in the technical data for a
solenoid coil. However, it is always taken into account in the response times in
conjunction with the actual valve.
4.5 The solenoid coil of a directional control valve is connected to the signal control
Electrical connection of section of an electrohydraulic control system via a two-wire cable.
solenoid coils A disconnectable plug connection is located between the cable and solenoid, which
is screwed together after being plugged in to protect the plug contact against the
ingress of dust and water. The type of plug connection or cable gland connection is
specified in the technical documentation for the solenoid coil, for example cable
gland connection PG11.
Protective circuit of a
The electrical current circuit is closed and interrupted via a contact in the signal
solenoid coil
control section. If the contact opens, the current is suddenly interrupted via the
solenoid coil. This briefly induces a very high voltage in the coil due to the quick
change in current intensity. An arc may be created when the contact opens, resulting
in damage to the contact after even a short period of operation. A protective circuit
is therefore required.
The illustration shows the protective circuit of a DC voltage coil. When the contact
closes, current I1 flows through the solenoid and the diode is without current. When
the contact opens, the current flow in the main circuit is interrupted. The current
circuit is now closed via the diode, thereby enabling the current to continue flowing
through the coil until the energy stored in the magnetic field is dissipated.
The protective circuit prevents the sudden interruption of current IM; instead it is
gradually dissipated over a certain time period. The induced voltage peak is
considerably reduced so that the contact and solenoid coil are not damaged.

I1
IM = I1
ID = 0
24 V
0V
Protective circuit of a solenoid coil: Closed contact in current circuit
I1 = 0
IM
I D = IM
24 V
0V
Protective circuit of a solenoid coil: Open contact in current circuit
Additional functions Additional functions can be integrated into the cable connection apart from the
protective circuit required for the operation of a solenoid valve. These include:
An indicator light,
which is illuminated if voltage is applied to the solenoid coil.
A switching delay,
which enables delayed actuation of the solenoid coil.
Plug The protective circuit and additional functions are predominantly integrated into the
plug, but can also be built into an intermediate plug. The plug and intermediate plug
must be selected to match the voltage at which the signal control section operates.
24V DC voltage is often used for the signal control section.

4 1
Standard plug (1) Seal (2) Solenoid coil (3) Pre-assembled plug (4)
Solenoid coil and plug
Protection class To ensure that neither dust nor moisture can penetrate into the plug connection,
sockets, plugs and intermediate plugs are sealed. If the protection classes of the
intermediate plug, solenoid coil and valve differ, then the lowest of the three
protection classes applies for the valve with mounted solenoid coil and cable gland
connection.
Explosion protection If solenoid actuated directional control valves are to be used in an area subject to
explosion hazard, this requires the use of solenoid coils with moulded cable,
specially approved for this type of application.


5. Design of an electrohydraulic control system
5.1 The field of application for electrohydraulic control systems is diverse and ranges
Procedure for the from mobile machines right through to sections of production systems.
development of a control Consequently, the control system design and scope vary correspondingly.
system Electrohydraulic control systems are therefore designed to suit the project in hand.
The design of a control system includes the following:
Planning of the control system
During the planning phase, the requirements for the control system are
determined and a draft solution is drawn up for the control system.
The realisation of the control system
During this phase, the components are procured and the construction and
commissioning of the system carried out.
A systematic, step-by-step procedure helps to eliminate errors and also makes it

easier to adhere to budgets and time schedules. The flow chart below provides an
overview of the individual steps of control system design.

1. Project design
1.1 Formulation of task definition
Create positional sketch
Establish requirements
1.2 Prerequisites for implementing a control system

Define overall concept
Select operating pressure
Size and select components
Establish energy supply
1.3 Graphic and tabular representation of control

sequence
Create GRAFCET and/or
Create function diagram and/or
Create sequence table
1.4 Design of control system

Create hydraulic circuit diagram
Create electrical circuit diagram
Create terminal diagram
Create parts list
Create draft of PLC program if PLC is used
2. Implentation
2.1 Procurement of components
2.2 Installation 2.3 Programming the PLC

Mount and fasten components
Wire up signal control section components
Tubing up and piping up of power section
components
2.4 Commissioning
Download PLC program if a PLC is used
Test functioning of control system
Implementation of any necessary changes
Updating documentation
Preparation of acceptance test certificate
Procedure for the design and realisation of an electrohydraulic control system
The individual planning steps cannot be strictly divided and are to some extent
interdependent. For example, the configuration of the hydrosystem cannot be
started until the list of requirements and status diagram are available for the motion
sequences.

5.2 The planning of an electrohydraulic control system includes:

Procedure for the planning The formulation of the control task and definition of requirements for the control
of a control system system,
The design of the control system, definition of operating and system pressure
and selection of the required components,
And, as graphically as possible, representation of the control task independent of
technology,
A draft of the control system and preparation of parts lists.
The various planning steps are explained below.
Formulation of problem The planning of a control systembegins with the written formulation of the control
definition and requirements task. All requirements must be carefully, precisely and uniquely defined. The
following working aids have proved to be effective:
Lists or forms that facilitate a quick and full understanding of all the
requirements
Tables that list drives, valves and sensors,
Status diagrams for the motion sequence, stating the force or torque
requirement for each motion and the required dynamics and natural frequency,
A survey of the load pattern, including intervals during which there is no
requirement for hydraulic fluid and pressure or only one pressure is required.
A positional sketch, that illustrates the spatial arrangement of drives.
The requirements for the control system must be agreed between the designer and
the user of the control system. A diagrammatic representation of motions sequences
is ideal as it provides all those involved with a common, simple and clearly
structured language. Another advantage is if the control system designer
familiarises himself on site with the environmental and installation conditions of the
control system.

List for the compilation of requirements for an electrohydraulic control system
Operation Required control elements

Required modes of operation
Displays and warning lights
Drives Number of drives
For each drive Function

Required force and required torque
Required dynamics (speed range) and acceleration
Required stroke
Spatial arrangement
Additional function (for example displacement encoder, proximity sensor)
Initial position
Motion sequence Sequence of drive movements

Number of steps of motion sequence
Step enabling conditions
Required waiting time
Required cycle times
Communication with other controllers
Valves For each valve Function

Required flow and pressure range
Connection type
Spatial arrangement
Normal position
Power supply Mains supply (for example 230V AC voltage or 400V DC voltage)
Required system pressure
Required delivery rate (corresponds to the highest occurring consumption of all drives)
Type of pump (constant-displacement pump or variable-delivery pump)
Required tank size
Required reservoir
Required filter
Spatial arrangement
Environmental conditions (e.g. dust, acoustics,)
Sensors/signals Required proximity sensors

Required pressure switches, pressure sensors
Additional sensors and limit switches
Additional input and output signals
Parameters Installation space

Behaviour in the event of electrical power failure
Behaviour in the event of hydraulic power failure
Behaviour in the event of Emergency-Stop
Ambient conditions such as temperature, dust, moisture
Required protective measures
Maintenance requirement
Additional requirements (e.g. measures to prevent leakage of pressure fluid)

Design of the Electrohydraulic control systems can be designed in very different ways. The
electrohydraulic control following has to be decided:
system Is signal processing to be realised by means of a PLC or a relay circuit?
Can the control functions of a drive or those of an associated drive be combined
into one block?
What measures can be used to eliminate malfunction and is preventive
maintenance supported? Such measures are for example sensors, measuring
systems, whereby the operating status of the system can be followed.
Are advanced components such as bus systems to be used?
Is a modular control concept possible? This includes for example the use of
identical circuit and program modules for different control systems.
The design of the control system largely determines the subsequent design
complexity and also the amount of maintenance.
Once the overall design is defined and the required nominal forces are known, it is
possible to obtain an initial estimation of the required operating pressure.
Selection of components for The function of the control system is to combine the energy supply system with the
the control system drive section in accordance with particular specifications. The control system
comprises components for signal flow and energy flow. These include:
The hydraulic drives,
The hydraulic valves,
The control elements,
The sensors,
The PLC or the type of relays to be used.
Once the level of operating pressure has been estimated, the process of determining
the hydraulic drives can be started.
The basis for determining the final control elements is for example the displacement-
step diagram and the problem definition parameters.
Once the circuit diagram or displacement-step diagram and the required drives are
known, the performance data for the individual final control elements is also
established.

The following criteria is to be taken into account when selecting the various final
control elements:
Mode of operating,
Static and dynamic behaviour,
Efficiency ,
Space requirement,
Costs,
Reliability,
Safety considerations,
Maintenance required.
Determining the hydraulic Once the components of the control system are defined and the required drive
power pack power is thus known, the hydraulic power pack can be determined. This consists of
a pump, reservoir and accessories.
First, it is necessary to clarify whether an open or closed circuit is to be used. An

open circuit can be realised by means of throttle control or pump control. In the case
of a closed or semi-closed circuit, a following suction system is required.
Apart from determining the circuit, the type of supply system to be used is also
important. Differentiation is made between individual drive and central hydraulic
fluid supply. A central hydraulic fluid supply is used mainly in the case of large
hydraulic systems.
Graphic representation of Prior to starting with the design of circuit diagrams, it is necessary to clarify:
the control task How many sequential steps are required,
Which drives are to be actuated in the individual steps,
Via what sensor signal or after what waiting time the next sequential step is to be
effected.
The simplest way of clarifying and illustrating the functional sequence is by means of
graphic representation. Graphic methods include the displacement-step diagram,
displacement-time diagram, function diagram, sequence table and GRAFCET to DIN
EN 60848. These methods of description provide a graphic, process-oriented
representation of the function and behaviour of control systems, which is
independent of their technical realisation and thus form a part and the basis of
circuit design.

Circuit design The last step of the design process deals with the preparation and completion of all
the documentation required to construct and program the control system. These
include:
The parts list,
The hydraulic circuit diagram,
The electrical circuit diagram,
The terminal diagram
And if a PLC is used, the design of a PLC program.
5.3 A sawing machine is to cut metal tube into segments of a specific length.
Application example: The functions of the sawing machine are as follows :
Design of a sawing machine To convey material,
To clamp material,
To move the saw slide.
The illustration represents a positional sketch of the sawing machine, which is

operated by means of three hydraulic drives.:
Drive 1A1 conveys the metal tube towards the saw,
Drive 2A1 clamps the metal tube for conveying and sawing,
Drive 3A1 moves the saw slide.
3B1
3B2
3A1
Sawing
Feed
1A1
2A1
2B1
Clamping
2B2
1B1
1B2
Positional sketch of the sawing machine

Note The electrical drive and the control system of the saw are not taken into
consideration in the subsequent design of the sawing machine.
Requirements regarding the Cylinder 1A1 requires a stroke of 800 mm and a minimum force of 6000 N; cylinder
sawing machine drives 2A1 requires a stroke of 250 mm and a minimum force of 4000 N. Cylinder 3A1
requires a stroke of 500 mm and a force of 3000 N.
The speed of cylinder 1A1 and the clamping speed of cylinder 2A1 must be
adjustable. The feed speed of the saw is to be adjustable independent of load.
In the event of an electric power failure, all three drive cylinders are to remain
stationary in their current position.
Designation Hydraulic action Force/nominal torque, Additional functions Initial position

stroke, motion speed
1A1 (control chain 1) To feed material F = 6000 N Adjustable speed Cylinder retracted
s = 800 mm
vmax = 30 m/min
To retract material F = 6000 N Adjustable speed

device s = 800 mm
vmax = 30 m/min
2A1 (control chain 2) To clamp material F = 4000 N Adjustable speed Cylinder retracted
s = 250 mm
vmax = 5 m/min
To release material
3A1 (control chain 3) To advance saw slide F = 3000 N Speed adjustable Cylinder retracted
s = 500 mm independently of load
vmax = 200 mm/min
To retract saw slide
Requirements regarding the drives of the sawing machine

Motion sequence of sawing The motion sequence of the sawing machine is represented both in the form of a
machine displacement-step diagram and in tabular form.
S4 (AUT)
S6
S7
1B1
2B2
3B1
1 2 3 4 5 6 7=1
1
1B2
Cylinder 1A1
Feed
0
1B1
1
2B1
Cylinder 2A1
Clamping
2B2
0
1
3B2
Cylinder 3A1
Sawing
3B1
0
Displacement-step diagram of the working components for the sawing machine
Step Movement Movement Movement End of step, step enabling Comment

Piston rod Piston rod Piston rod condition to next step
Cylinder 1A1 Cylinder 2A1 Cylinder 3A1
Feed Clamping Sawing
1 None Advance None Pressure switch 2B1 responds Clamping material
2 Advance None None Limit switch 1B2 responds Feeding material
3 None None Advance Inductive sensor 3B2 responds Advancing slide with saw
4 None None Retract Inductive sensor 3B1 responds Retracting slide with saw
5 None Retract None Inductive sensor 2B2 responds Releasing material
6 Retract None None Limit switch 1B1 responds Retracting conveying device
Motion sequence of sawing machine

Requirements regarding The control system of the sawing machine must enable operation in a continuous
operation cycle (continuous operation). In addition, single cycle operation is also required,
whereby the sequence is carried out only once.
The control system must conform to the relevant standards. The illustration shows
the control panel for the sawing machine.
The following control functions in respect of the sawing machine are more closely
specified :
EMERGENCY-STOP:
Actuation of the EMERGENCY-STOP must not only switch off the electrical, but
also the hydraulic energy supply. The drives are to remain stationary in their
current position.
Reset:
The reset function returns the system into the initial position. In the case of the
sawing machine, initial position means: The piston rods of cylinders 1A1, 2A1
and 3A1 are retracted.
Continuous Cycle Off:
Actuation of the Continuous Cycle Off button causes the sequence in continuous
cycle to be stopped. A previously started sawing cycle is completed, after which
the system is returned into the initial position.

Main switch EMERGENCY STOP
Continuous cycle Single cycle

Automatic On Start
Continuous cycle
Off
Manual Reset
Control panel of the control system for the sawing machine
Note For reasons of simplification, additional control functions are not taken into
consideration in respect of the electrical drive of the saw.
Please note: In practice, the person responsible for safety in a company must ensure
that the behaviour of a system in the event of EMERGENCY-STOP complies with the
applicable national and local safety laws and regulations.
Requirements regarding The sawing machine is used in a production hall where temperatures fluctuate
environmental conditions between 15 and 35 degrees centigrade. The components of the hydraulic power
section and the electrical connections of the valves are to be of splash-waterproof
and dustproof design. The electrical components of the signal control section are to
be built into a control cabinet and must comply with the relevant safety regulations.

Requirements regarding An electrical supply system incorporating 400V AC voltage is available.

energy supply
The electrical motor of the hydraulic power pack is operated using mains voltage.
The electrical signal control section and the primary circuit are to be operated using
a 24V DC voltage. A power supply unit must therefore be provided for the voltage
supply.
Overall concept of the Signal processing of the sawing machine is to be realised in the form of a relay
control system control system. Due to the small number of drives and valves, the valves are
separately mounted.
All three drives are realised in the form of double-acting cylinders.
Each drive cylinder is realised in the form of a separate control chain.
Selecting the cylinders The cylinders are selected on the basis of the requirements regarding force and
stroke. The operating pressure selected is 10 MPa.

Cylinder 1A1 2A1 3A1
Required force Fsoll 6000 N 4000 N 3000 N

2 2 2
F 600 mm 400 mm 300 mm
Calculated piston surface A=
p
4A 27.6 mm 22.6 mm 19.5 mm

Calculated piston diameter D=

Piston diameter selected D 32 mm 25 mm 25 mm
2 2 2
D2 804 mm 491 mm 491 mm
Piston surface of cylinder selected A=
4
Max. force of cylinder selected F=pA 8040 N 4910 N 4910 N
Max. required speed of cylinder v 30 m/min 5 m/min 0.2 m/min
Max. consumption of cylinder selected q=Av 24.12 l/min 2.45 l/min 0.1 l/min
Calculation of performance data for the sawing machine cylinders
Based on the required driving force, cylinder 1A1 must have a minimum piston
diameter of 28 mm, cylinder 2A1 a minimum piston diameter of 23 mm and cylinder
3A1 a minimum piston diameter of 20 mm.
The following piston diameters have been selected to enable the use of standard
cylinders:
Cylinder 1A1: 32 mm,
Cylinder 2A1: 25 mm,
Cylinder 3A1: 25 mm.
Maximum consumption is determined for the cylinders selected. Since only ever one
cylinder is moving at one time during the sawing process, the maximum
consumption for the control system is obtained from the consumption of cylinder
1A1, which has the highest level of consumption of 24.12 l/min.
The data regarding consumption or flow is required for the configuration of the
hydraulic power pack and for the selection of the valves.

Designation Type Diameter of cylinder Diameter of piston Stroke (s)

(D) rod (d)
1A1 Feed Double-acting cylinder 32 mm 22 mm 800 mm
2A1 Clamping Double-acting cylinder 25 mm 18 mm 250 mm
3A1 Sawing Double-acting cylinder 25 mm 18 mm 500 mm
Cylinders for the sawing machine
Selecting the valves Spring centred 4/3-way solenoid valves are used in order to obtain the required
behaviour of drives 1A1, 2A1 and 3A1 in the event of a power failure. The 4/3-way
solenoid valves for the actuation of drives 1A1 and 3A1 for the feed and saw slide
are mid-position closed valves. A 4/3-way solenoid valve with freely movable
position is used to actuate the clamping cylinder 2A1. Based on the calculation of
the maximum flow values determined, it is possible for the nominal size of the
valves selected to be comparatively small. A standard nominal size is recommended
for all valves; in the case of this application for example,nominal size 6.
The retract and advance speeds of the conveying cylinder are regulated by means of
flow control at the discharge side.
The clamping speed of cylinder 2A1 is adjusted via a one-way flow control valve. A
piloted non-return valve ensures that the clamping position is maintained even in
the event of an electrical power failure.
A 2-way flow control valve controls the feed speed of cylinder 3A1 independent of
load. Counter pressure is effected by means of a pressure-relief valve. A non-return
valve is required to bypass the two valves.

Type Symbol Function Normal position Allocation to

control chain
4/3-way solenoid A B Controls cylinder 1A1. Mid-position 1

valve, mid-position Maintains cylinder position in closed (Cylinder 1A1 for
closed 1M1 1M2 the event of an electrical power feed)
P T failure.
One-way flow control A B Regulates the advancing speed. 1

valve
One-way flow control A B Regulates the retracting speed. 1

valve
4/3-way solenoid A B Controls cylinder 2A1. Mid-position in 2

valve , freely movable Maintains pressure in the event freely movable (Cylinder 2A1 for
position 1M1 1M2 of an electrical power failure. position clamping)
P T
One-way flow control A B Regulates the advancing speed. 2

valve
Piloted non-return B Maintain cylinder position in 2

valve the event of an electrical power
failure.
A X
Pressure gauge Adjustment and monitoring of 2

pressure switch
4/3-way solenoid A B Controls cylinder 3A1. Mid-position 3

valve, mid-position Maintains cylinder position in closed (Cylinder 3A1 for
closed 1M1 1M2 the event of an electrical power sawing)
P T failure.
2-way-flow control B Regulates the advancing speed 3

valve independent of load.
Non-return valve Bypasses the 2-way flow 3

control valve.
Pressure-relief valve P(A) Counterpressure for the 3

advancing of the cylinder.
T(B)

Type Symbol Function Normal position Allocation to

control chain
Pressure gauge Adjustment and monitoring of 3

pressure-relief valve.
Non-return valve Bypasses the pressure-relief 3

valve.
Valves for the sawing machine
Selecting the hydraulic The maximum volumetric flow rate of the drive cylinders is 24.5 l/min.
power pack
A hydraulic power pack with a constant-displacement pump is selected. The pump
delivers the maximum required flow rate of 24.5 l/min. There is no need for a
reservoir.
The formula for the delivery rate is used to calculate the pump size.
The following applies for the delivery rate q : q = qgeo n,
whereby
qgeo is the geometric delivery rate of the pump, i.e. the hydraulic fluid volume
delivered during one revolution;
n is the speed at which the pump is driven. The speed in this case is identical to
that of the speed of the electric motor and is
1390 rpm.
The geometric delivery rate qgeo of the pump is calculated using the formula for the
delivery rate q:
q 24.5 min
l
24.5 24500
qgeo = = = l= cm3 = 17.6 cm3
n 1390 rpm 1390 1390
A pump with a geometric delivery rate of 17.6 cm3/revolutions is required.

Selecting the sensors The proximity sensors are selected to correspond to the cylinders. It is advisable to
use positive switching sensors. For example, inductive sensors are suitable for
cylinders 2A1 and 3A1.
Two proximity sensors are required for the control of the saw slide in order to detect
the forward and retracted end positions. In the case of cylinder 2A1, one sensor is
sufficient to detect the retracted end position. A pressure switch is used to monitor
whether the required minimal clamping pressure is obtained.
The positions of the conveying device of cylinder 1A1 are detected via two limit
switches.
Designation Type Function Allocation to control chain
1B1 Limit switch Detects the retracted end position of 1A1 Cylinder 1A1
1B2 Limit switch Detects the forward end position of 1A1 Cylinder 1A1
2B1 Pressure switch Monitors the minimal clamping pressure Cylinder 2A1
2B2 Inductive sensor Detects the retracted end position of 2A1 Cylinder 2A1
3B1 Inductive sensor Detects the retracted end position of 3A1 Cylinder 3A1
3B2 Inductive sensor Detects the forward end position of 3A1 Cylinder 3A1
Sensors for the sawing machine

Allocation table of the The following planning steps are simplified by drawing up a list of cylinders,
sawing machine solenoid coils, sensors, display and operating components. Components which form
part of a control chain are entered on one line in the table.
Drive/ Actuated solenoid coil Sensor Control Comment

function compon
ent
Advance Retract Other Advanced Retracted Other
Cylinder 1A1 1M2 1M1 1B2 1B1 Control chain 1
S1 Main switch
S2 EMERGENCY-STOP
(Normally closed
contact!)
S3 Manual (MAN)
S4 Automatic (AUT)
S5 RESET
S6 Continuous cycle ON
S7 Single cycle START
S8 Continuous cycle OFF
Allocation table of the sawing machine

GRAFCET of the The GRAFCET indicates the steps in which the sawing sequence is executed and the
sawing machine step enablingconditions which must be fulfilled in order for the next step to be
activated.
1 "Initial start step "
S7*1B1*2B2*3B1 "Start condition"
2 2M2 "Clamp material"
2B1 "Clamping pressure reached"
3 1M2 "Transfer material"
1B2 "Feed at front"
4 3M2 "Saw slide to advance"
3B2 "Saw slide at front"
5 3M1 "Saw slide to retract"
3B1 "Saw slide at rear"
6 2M1 "Release material"
2B2 "Clamping device retracted"
7 1M1 "Conveying device to retract"
1B1 "Conveying device retracted"
GRAFCET for the sawing machine

Circuit diagrams of the The electrohydraulic circuit diagram of the sawing machine consists of a hydraulic
sawing machine and an electrical circuit diagram.
3V5
P
3M2
3V4
3Z1
3V3
T
B
B
P
3V1
3A1
3V2
3M1
3B2
3B1
2M2
2B1
T
B
X
B
B
2Z1
A
A
P
2V3
2V2
2V1
2A1
2M1
2B2
1V3
1B2
1M2
1B1
B
A
T
B
A
P
1A1
B
A
1V2
1V1
1M1
Hydraulic circuit diagram of the sawing machine

The electrical circuit diagram for the sawing machine is divided into the
representation of
Control elements (sheet 1),
Sensor evaluation (sheet 2),
Sequential step circuit (sheet 3),
Solenoid coil circuitry (sheet 4).
Please note: The circuit of the hydraulic power pack is not taken into account in the
electrical circuit diagram.

24 V 1 2
...
118
3 12 14
S1 K1
(Main 4 11 SYSTEM
switch) 3 4 ENERGIZATION
...
11 12 14
S2 K2
(EMER- 12 11 EMERGENCY STOP
GENCY RELEASED 5 6 7 8 9 10 11 12 24 V
STOP) Part 2/4
13 12 14 22 24 13 22 24 32 34
S3 K4 K4 S4 K3 K3
(MAN) 14 11 21 (AUT) 14 21 31
MANUAL 13 AUTOMATIC
...
Part 3/4
12 14 13 12 14 32 34 13 12 14
K3 S5 K12 K4 S6 K5
11 31
(RESET) 14 11 (Continuous 14 11
cycle
ON)
12 14 12 14 12 14 11
K6 K8 K10 S8
11 11 11 (Continuous 12
cycle
OFF)
Electrical circuit diagram of the sawing machine, part 1/4: control elements
K1 K2 K4 K12 K3 K5
A2 A2 A2 A2 A2 A2
Part 2/4
0V 12 12 12 12 12 12 0V
11 14 .2 11 14 .4 11 14 .6 11 14 .8 11 14 .5 11 14 .13
22 22 22 22 22 22
21 24 21 24 21 24 .7 21 24 .40 21 24 .11 21 24 .24
32 32 32 32 32 32
31 34 31 34 31 34 .10 31 34 .43 31 34 .12 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 .46 41 44 41 44
Festo Didactic GmbH & Co. KG TP 601

EMERGENCY STOP
24 V RELEASED 14 15 16 17 18 19 20 21 22 24 V
from Part 1/4 Part 4/4
2B2 BN 3B1 BN 3B2 BN

2B1
2 4 2 4 BK 2 4 BK BK
1B1 1B2 >p
1 1 1
BU BU BU

K6 K7 K8 K9 K10 K11
A2 A2 A2 A2 A2 A2
Electrical circuit diagram of the sawing machine, part 2/4: sensor evaluation
0V 12 12 12 12 12 12 0V
11 14 .7 11 14 .28 11 14 .8 11 14 .26 11 14 .9 11 14 .30
22 22 22 22 22 22
21 24 .23 21 24 21 24 .23 21 24 21 24 .23 21 24
32 32 32 32 32 32
31 34 31 34 31 34 .34 31 34 31 34 .32 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44
119
120
24 V AUTOMATIC 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
from Part 1/4
13 22 24 12 14 12 14 22 24 12 14 22 24 12 14 22 24 32 34 22 24 32 34 22 24 12 14 32 34 22 24
S7 K5 K13 K9 K14 K7 K15 K11 K16 K10 K17 K8 K18 K19 K18 K19
(Single cycle 14 21 11 11 21 11 21 11 21 31 21 31 21 11 31 21
START)
22 24
K6
21
22 24 22 24 32 34 32 34 32 34 32 34
K8 K13 K14 K15 K16 K17
21 21 31 31 31 31
22 24
K10
21
52 54
K18
51
Electrical circuit diagram of the sawing machine, part 3/4: sequential step circuit
12 14 12 14 12 14 12 14 12 14 32 34
K14 K15 K16 K17 K18 K13
11 11 11 11 11 31
K13 K14 K15 K16 K17 K18 K19

A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 0V
11 14 .25 11 14 .23 11 14 .26 11 14 .28 11 14 .30 11 14 .32 11 14 .36
22 22 22 22 22 22 22
21 24 .26 21 24 .27 21 24 .29 21 24 .31 21 24 .33 21 24 .35 21 24 .38
32 32 32 32 32 32 32
31 34 .34 31 34 .28 31 34 .30 31 34 .32 31 34 .34 31 34 .37 31 34
42 42 42 42 42 42 42
41 44 .44 41 44 .41 41 44 .47 41 44 .45 41 44 .42 41 44 .39 41 44
52
51 54 .23

EMERGENCY STOP

24 V RELEASED 39 40 41 42 43 44 45 46 47
from Part 2/4
42 44 22 24 42 44 42 44 32 34 42 44 42 44 42 44 42 44
K18 K12 K14 K17 K12 K13 K16 K12 K15
41 21 41 41 31 41 41 41 41
Electrical circuit diagram of the sawing machine, part 4/4: solenoid coil circuitry
1M1 1M2 2M1 2M2 3M1 3M2
from Part 3/4
0V
121
5.4 The realisation of an electrohydraulic control system or installation includes the

Procedure for the following steps
realisation of the control Procurement of all necessary components,
system Construction of the control system,
Programming of the control system if a PLC is used,
Commissioning of the control system.
Procedure for the construction of the control system
The following need to be available for the construction of the control system:
The completed circuit and terminal diagrams,
All electrical and hydraulic components as per parts list.
Those realising the control system must be familiar with the regulations pertaining
to industrial safety and the prevention of accidents. All safety regulations must be
observed when constructing the system. Moreover, the safety instructions in the
data sheets and manuals for components and equipment must be followed.
In order to prevent errors during assembly, pipe installation, tubing up and wiring
work is to be carried out in a specified, consistent sequence.
One possibility is
In the signal control section, to always wire from the signal input via signal
processing and the control energy supply to the valves,
In the power section, to always tube up and install piping starting from the
energy supply section via the valves through to the cylinders or the motor.
All components, tubing, piping and wiring are to be clearly identified to ensure that
connections can be easily re-established.
In addition, we recommend that any already assembled components and equipment

be correspondingly identified in the circuit diagram.
Programming of a PLC The motion sequence of the hydraulic drives is defined by the program if a
programmable logic controller (PC) is used. The starting basis for the development
of a PLC program is the formal description of the control behaviour. In other words,
the function diagram, sequence table or GRAFCET (formerly function chart). Program
development can be carried out in parallel with the configuration of the control
system.
Either a PC or a programming device and the programming environment of the PLC

can be used as a tool for developing a program.

Program development can be divided into the following steps:

Draft of the program,
Creation of the program in the programming environment either on the PC or a
programming device,
Translation of the program,
Testing of the program within the programming environment, for example by
means of simulation.
Program errors that become apparent during the program translation or testing must
be eliminated. Any subsequent program development steps must be run through
again. This process must be repeated until all identifiable errors are eliminated.
START
Design Change design
Enter
Translate
Error-free?
Yes No
Load
Test
Error-free?
Yes No
END
Development of a PLC program

The concluding function test of the program cannot be carried out until the
commissioning of the entire electrohydraulic control system or installation is carried
out. This is carried out as soon as the construction of the control system and
program development are completed.
Commissioning The purpose of commissioning is as follows:

To test the function of the control system under all the parameter conditions
occurring in practice.
To carry out the necessary adjustments on the control system; these include for
example the adjustment of proximity sensors or flow control valves.
If necessary, also to record the operating conditions of the control system.
To eliminate errors in the control system.
A visual inspection must be carried out prior to all commissioning.

Prior to starting the control system, check the following:
The electrical connections,
The correct installation and type of fittings and connectors,
The mechanical components for visible defects, such as cracks or loose
connections.
Prior to starting the system, eliminate any faults or damage detected.
When commissioning a control system, proceed according to the following steps:

Check the volume of hydraulic fluid. If necessary, top up to the correct level of
hydraulic fluid, using a filter to filter out any contamination.
Vent the pump; to do so, fill the pump with hydraulic fluid.
Check the direction of rotation of the electric drive motor.
Set all valves in the initial position.
Set the pressure valves and flow valves to the lowest possible value. The same
applies to pressure regulators of variable-displacement pumps.
If necessary, start up the control system using a flushing oil, then replace the
filter.
Pour in the new hydraulic fluid, then vent the control system again.
Check the electrical wiring and power supply.
Check the terminal allocation of the individual components.
Carry out an initial function test using reduced pressure and flow whilst checking
the adjustment and setting of sensors.
Set the performance values specified in the circuit diagrams. These include the
values for pressure, flow rate, electrical voltage.
Now carry out a complete function test.

A function test includes the recording of operating statuses, whereby hydraulic

measured variables such as pressure, flow and temperature are measured.
However, mechanical variables such as displacement, forces or speed also need to
be ascertainable.
In conclusion of the commissioning process, the documentation is to be updated.

This means:
To enter the current setting values,
To correct circuit and terminal diagrams if necessary,
To make a printout of the revised PLC program and make available a copy of the
PLC program on a data storage medium.
The implementation of the commissioning process is documented in the

commissioning protocol. This is required for the acceptance of the control system by
the ordering party.
Training of maintenance As soon as the control system operates error-free and the control system operator is
staff and acceptance satisfied with the faultless functioning of the system, the control system
certificate development process is completed.
The handover of the control system by the control system designer to the control
system operator includes the following:
The declaration of conformity,
The training of operating and maintenance personnel,
The handing over to maintenance personnel of all documentation required for
maintenance, servicing and repairs,
The preparation of an acceptance certificate, which is to be signed by the control
system designer and control system operator.

Function chart or
Function diagram Parts list
Electrical Pneumatic
circuit diagram circuit diagram
Documentation for
maintenance and repair of an
electrohydraulic control system
Terminal Program listing

diagram (if using a PLC)
Declaration of
Setting values conformity
Documentation for the maintenance, servicing and repairing of an electrohydraulic control system
Maintenance, servicing and The malfunctioning and failure of a control system causes high costs, since
repairs production or parts of production is stopped for the duration of a control system
failure. In order to eliminate downtimes, maintenance and servicing work is carried
out at defined intervals. During these, components subject to wear are replaced as a
preventive measure. If faults occur despite these measures, the failed components
must be repaired or replaced. Maintenance, servicing and repairs are facilitated if all
the control system components are clearly arranged and easily accessible.

6. Documentation of an electrohydraulic control system
Minimal downtimes are a basic prerequisite for the economical operation of an

electrohydraulic control system. Control system components are therefore designed
for high reliability and long service life. Even so, electrohydraulic control systems
still require maintenance, servicing and repairs, which need to be carried out as
quickly as possible. This is why maintenance personnel require accurate and
comprehensive control system documentation. Furthermore, detailed information is
also essential for the design and engineering stage in order to facilitate the selection
of the components to be used.
Moreover, systematic, step-by-step project documentation helps to reduce the

overall design complexity of a control system. This primarily concerns the
installation and testing of a control system.
The documentation of an electrohydraulic control system includes the following:

The function diagram, sequence table or GRAFCET (to represent the control
sequence),
The hydraulic and electrical circuit diagrams (to represent the interaction of all
components),
The terminal allocation list (to represent the terminal strip allocation in control
cabinets and terminal boxes),
The parts lists,
The positional sketch (to represent the interrelationship between working
components and machine layout),
The PLC programs on data storage medium and paper, if a PLC is used,
Commissioning and operating instructions (description of all control functions,
essential information regarding commissioning).
Circuit diagrams and terminal diagrams must be available to maintenance personnel

so that any faults or malfunction can be quickly isolated and eliminated. Fault
finding is simplified in many cases if a function diagram or GRAFCET, the positional
sketch and parts list are available. This documentation should therefore form part of
the control system documentation.
If a PLC is used for control, the PLC programs must also be available so that the
necessary modifications and optimisation can be carried out.
More complex electrohydraulic control systems also require brief commissioning

and operating instructions. These documents describe all control functions and
settings such as the valve settings.
The overall documentation must comply with the relevant directives and standards
to ensure clear and concise legibility.

6.1 The function diagram is used to graphically illustrate the motion sequence of an
Function diagram electrohydraulic control system.
Application example A container handling device is used in a production line. The container arrives at
roller conveyor 1, is lifted and transferred to roller conveyor 2.
The container handling device is equipped with two double-acting hydraulic drive
cylinders.
Cylinder 1A1 is used to lift the container and is allocated two inductive sensors
1B1 (retracted end position) and 1B2 (forward end position), as well as a 4/3-
way solenoid valve 1V1 with solenoid coils 1M1 and 1M2.
Cylinder 2A1 carries out the transfer function and is allocated limit switches 2B1
(forward end position) and 2B2 (retracted end position), as well as a
4/2-way double solenoid valve 2V1 with solenoid coils 2M1 and 2M2.
A 2-way flow control valve 1V3 is used to set the lifting speed independent of
load. A non-return valve 1V2 is used for bridging to the lowering function.
The lowering speed is set via a one-way flow control valve 1V4.
A further one-way flow control valve 2V2 is used to set the transfer speed.
A conveying cycle is triggered by means of actuating the start button, causing the
container on roller conveyor 1 to be lifted. When the conveyor has reached the
upper position, it is transferred to the second roller conveyor. The lifting and
transfer devices then simultaneously return into the initial position.
Three steps are required for one conveying cycle:

Step 1:
Piston rod of cylinder 1A1 to advance. The container is lifted.
Step 2:
Piston rod of cylinder 2A1 to advance. The container is transferred.
Step 3:
Piston rod of cylinder 2A1 to retract. The transfer device moves back.
Piston rod of cylinder 1A1 to retract. The lifting device moves back.

2B1
2A1
2B2
1B2 1A1
1B1
Positional sketch of a container handling device

Displacement-step diagram The displacement-step diagram describes the movements of working components.
The individual steps are numbered consecutively from left to right. In the case of
several working components, the individual drives are entered one below the other.
This representation illustrates the sequence of the individual movements.
1 2 3 4=5
1
Cylinder 1A1
Cylinder 2A1
Displacement Steps
Displacement-step diagram of the container handling device
Note The standard VDI 3260 function diagrams of production machines and systems has
been withdrawn. It is however still used in practice for the purpose of representing
control sequences.

Displacement-time diagram In the case of a displacement-time diagram, the movements of working components
are entered in relation to time. This form of representation explains the different
time duration of the individual steps. The displacement-time diagram of the
container handling device shows that the piston of cylinder 2A1 clearly takes longer
to advance than to retract.
1 2 3 4
1
Cylinder 1A1
Cylinder 2A1
Displacement Time t
Displacement-step diagram of the container handling device

Control chart The control chart is used to represent the operating status of the control elements in
relation to the steps or the time. The response times are considerably shorter than
the travel times of working components and are therefore not taken into account in
the diagram..
Control elements include the signal input elements and signal processing elements.
The control chart represents the statuses of the control elements 1V1 for cylinder
1A1 and of proximity sensor 1B2. Sensor 1B2 detects the forward end position of
cylinder 2A1.
0 1 2 3 4
a
Valve 1V1 0
1
Sensor 1B2
0
Status Steps
Excerpt from the control chart for the container handling device

Function diagram The function diagram is a combination of the motion and control diagrams. The lines
representing the individual statuses are referred to as function lines.
0 1 2 3 4
a
Valve 1V1 0
1
Cylinder 1A1
0
1
Sensor 1B2
0
Status Steps
Excerpt from the function diagram of the container handling device
Apart from the function lines, the signal lines can also be entered in addition in the
function diagram.
The signal line starts at the signal element and ends at the point where, depending
on this signal, a change in status is initiated. Arrows in the signal line indicate the
direction of signal flow .

Representation of signal lines and signal logic
Signal line
Signal branching
OR condition
AND condition
Signal branchings are represented by means of dot at the branching point. Status
changes of several components are initiated at a signal output.
In the case of OR conditions, a dot marks the point where the signal lines merge.
Several signal outputs cause the same status change irrespective of one another.
The AND condition is identified by means of a diagonal line at the point where the
signal lines merge. A status change occurs only if all signal outputs are available.

Representation of input elements
Input element, manually operated ON/START
OFF/STOP
ON/OFF
INCHING
Input element, mechanically operated Limit switch
Input element, hydraulically operated Pressure switch

p
The designations of the individual input elements are entered at the starting point of
the respective signal line.

Components Time
Step
1B1
1 2 3 4 5 6 7 8 9 10
2B1
Designation Identification Signal
1
Start button S1
0
Valve 1V1 b
1
Cylinder 1A1 1B2
0
a
Valve 2V1
b
1
2B2
Cylinder 2A1
0
Function diagram for container handling device
Piston rod 1A1 advances if proximity sensor 1B1 and limit switch 2B1 are
actuated and pushbutton S1 is pressed by the operator.
Proximity sensor 1B2 is actuated if cylinder 1A1 reaches its forward end position.
The piston rod of cylinder 2A1 advances.
Limit switch 2B2 is actuated if cylinder 2A1 reaches its forward end position. The
piston rod of cylinders 2A1 and 1A1 retract simultaneously.
Advantages and The mode of operation of an electrohydraulic control system can be very clearly
disadvantages of function represented by means of a function diagram. Although the standard for the function
diagram diagram has been withdrawn, function diagrams are still often used in practice. They
are used primarily for simple control systems with few control chains.
In a function diagram, the logic operations and the mutual influence of different
control chains can be represented by means of signal lines. For this application, it is
however advisable purely to represent the drive movements in a displacement-step
or displacement-time diagram. Sequence and signal logic can be better documented
by other means such as with GRAFCET or a sequence table.

6.2 The sequence table shows the interaction of control signals and the hydraulic
Sequence table control system actions.
The sequence table is not only used for the purpose of documentation, but also for
the formal representation and planning of electrohydraulic systems.
It can be created as soon as the components for the system are defined and the
hydraulic circuit diagram is available. The sequence table is then used as a model to
create the electrical circuit diagram.
Application example A container handling device is used in a production line. The container arrives at
roller conveyor 1, is lifted and transferred to roller conveyor 2.
The container handling device is equipped with two double-acting hydraulic drive
cylinders.
Cylinder 1A1 is used to lift the container and is allocated two inductive sensors
1B1 (retracted end position) and 1B2 (forward end position), as well as a 4/3-
way solenoid valve 1V1 with solenoid coils 1M1 and 1M2.
Cylinder 2A1 carries out the transfer function and is allocated the limit switches
2B1 (forward end position) and 2B2 (retracted end position), as well as a
4/2-way double solenoid valve 2V1 with solenoid coils 2M1 and 2M2.
A 2-way flow control valve 1V3 is used to set the lifting speed independent of
load. A non-return valve 1V2 is used for bridging to the lowering function.
A one-way flow control valve 1V4 is used to set the lowering speed.
A further one-way flow control valve 2V2 is used to set the transfer speed.
A conveying cycle is triggered by means of actuating the start button, causing the
container on conveyor belt 1 to be lifted. When the container reaches the upper
position, it is transferred to the second conveyor. The lifting and transfer devices
then simultaneously return into the initial position.

Three steps are required for the conveying cycle:

Step 1:
Step 2:
Step 3:
Piston rod of cylinder 1A1 to retract. The lifting cylinder moves back.
2B1
2A1
2B2
1B2 1A1
1B1

Con trol system Signal generator Solenoid Solenoid Solenoid Solenoid Comment
steps coil 1M1 coil 1M2 coil 2M1 coil 2M2
Lifting S1=1 and 1 0 0 0 The lifting speed is set via the 2-way flow control
1B1=1 and valve.
2B1=1
Transfer cylinder 1B2=1 and 1 0 1 0 The transfer speed is set via the one-way flow
advancing 2B1=1 control valve.
Transfer cylinder 1B2=1 and 0 1 0 1 The transfer device retracts and lowering starts
retracting/lower- 2B2=1 simultaneously. The flow control valve for
ing lowering is et such that the pump delivery rate for
both cylinders is roughly divided in half.
Initial position 1B1=1 and 0 0 0 0 Cylinder retracted, working energy (pressure) is

2B1=1 applied
Sequence table for the container handling device
6.3 GRAFCET is a specification language for the functional description of the sequential
GRAFCET part of control systems. GRAFCET in accordance with DIN EN 60848 enables the
graphic representation of the mode of operation of a control system irrespective of
the technology used. GRAFCET, i.e. its predecessor the function chart, is used in
numerous areas of automation for the planning and documentation of the
sequential part of control systems. GRAFCET can for instance be found in use in
power stations, process engineering applications or material flow systems.
Replacement of function In 2002, the German standard DIN 40719-6, function chart, was replaced by the
chart by GRAFCET European standard DIN EN 60848, GRAFCET. The European origin of the standard is
recognisable by the name. GRAFCET is an abbreviation and originates from the
French:
GRAphe Fonctionnel de Commande Etape Transition.
GRAFCET is also internationally standardised through the IEC 60848 standard.
The advantages of the new DIN EN 60848 standard are:

The standard is valid throughout Europe.
The description of functions has been simplified .
The standard incorporates new functions. This includes the introduction of
hierarchical levels. Hierarchical levels are necessary for precisely defined
coarse/fine structures of control system behaviour, for modes of operation and
the EMERGENCY-STOP function of complex control systems.

Structure of a GRAFCET A GRAFCET primarily describes two aspects of a control system in accordance with
defined rules:
The actions to be executed (commands),
The sequence of execution.
A GRAFCET also known as a GRAFCET chart is therefore divided into two parts.
The sequential or structural part describes the temporal sequence of the process,
whereby the process is structured into consecutive steps..
The sequential part does not describe what actions are to be executed individually.
These are contained in the action or function part. In the case of the example shown,
these are the blocks on the righthand side of the steps as well as the transition
conditions between the steps.
1B2*2B1*3B1 "Initial position"

1 P1 "Initial position display"
S1*1B2*2B1*3B1*B4 "Start condition"
2 3M1:=0 3M2:=1 "To downstream station"
3B2 "Position of downstream station"
3 1M1:=1 "Eject part"
1B1 "Part ejected"
4 3M1:=1 3M2:=0 "To magazine"
3B1 "Position of magazine"
5 2M1 "Generate vacuum"
2B1 "Vacuum generated"
6 1M1:=0 "Release part"
1B2 "Part released"
8 2M2 "Deposit part"
2B1 "Vacuum no longer generated"
Structural part Function part
GRAFCET (function chart) for a distribution process

Steps The sequences are divided into steps. Each step is shown in the form of a box,
whereby a square is preferred to a rectangle. An alphanumerical designation must
be entered in the top centre of the step field.
A step is either active i.e. it is currently being executed or inactive.
2 93 8B
Example of steps
The status of a step can be interrogated or represented via its step variable. The
step variable is a boolean variable and either has the value 1 (step active) or the
value 0 (step inactive).
2
X2
Step 2 Step variable of step 2
Example of steps and step flags
Initial step Each chain of steps has one initial step. The initial step designates the initial
position of the control system. The control system is in this initial step immediately
after it is switched on. The initial step can be recognised by its double frame. The
example shows step 1 as an initial step.
Example of an initial step

Transitions and transition A transition is the connection from one step to the next. A transition is represented
conditions by a line at a right angle to the connection between the two steps. However, if
required for reasons of clarity, it can also be shown by a horizontal line, which leads
to another step.
(4)
5
(5)
Example of a sequence structure consisting of steps and transitions
A transition can be given a transition name. This is to be entered on the left in

brackets order to prevent confusion.
Each transition must have a transition condition. The transition condition is a logic
expression that can assume the value 1 (TRUE) or 0 (FALSE). The transition to the
next step is effected if the transition condition is fulfilled. The transition condition is
entered on the righthand side of a transition.
7 7
Pushbutton pressed (S1)
(Press up) (Press up) S1*1B1
and press up (1B1)
8 8
(Press down) Press down (1B2) (Press down) 1B2
Examples of transition conditions
A transition condition can be represented in text form using a boolean expression or

by means of graphic symbols.
In the standard DIN EN 60848 , examples of transition conditions are formulated
mainly in the form of boolean expressions.
Please note: The dot or asterisk used describes an AND operation and the plus
symbol an OR operation. Negations are represented by means of a line above the
variable name.

A time-dependent transition condition is used if the initial step is to progress to the

next step after the expiry of a defined time The transition condition comprises the
time and status of the active step, both divided by an oblique slash.
5s/X9
10
Example of time-dependent execution of a step
In the example shown, X9 is the step variable of step 9, which represents the
boolean status of step 9.
The transition condition has the value TRUE for five seconds after step 9 is activated
and assumes the value FALSE immediately afterwards, thereby deactivating the
preceding step.
The period of activation of step 9 is therefore five seconds.
Important In order to create an error-free sequence structure, steps and transitions must
always alternate!
Actions Each step is allocated one or several actions, which are executed when the step is
active.
An action is represented in the form of a square of optional width-to-height ratio.

The standard recommends using the same height for the action field and step
symbol.
Actions have different behaviour. The behaviour of an action is represented by

means of corresponding additions.
If several actions are allocated to one step, these can be graphically represented in
different ways. Please note: The order of representation does not represent a
temporal sequence!

77 Action 1 Action 2 Action 3
77 Action 1 Action 2 Action 3
77 Action 1 77 Action 1
Action 2
Action 2
Action 3
Action 3
Examples for the representation of a step with several actions
Continuously active actions Continually active actions means: The value 1, i.e. TRUE, is assigned to the specified
variable for as long as the corresponding step is active. Once the step is no longer
active, the value 0, i.e. FALSE, is assigned to the variable.
Designation in the action field can be effected in different ways. Text can be in the
form of a command or indicative form. It is also possible to directly indicate the
name of a variable.
4 Switch valve coil 3M2
4 Valve coil 3M2
4 3M2
Example of continuously active action
The actions described all have the same behaviour:

As long as step 4 is active, value 1 is assigned to variable 3M2.

Continuously active action The value 1 (TRUE) is assigned to the variable described in the action only if the
with assignment condition corresponding step is active and the assignment condition is fulfilled. If the
assignment condition is not fulfilled, the value 0 (FALSE) is assigned to the variable.
In the case of the example this means:

If step 3 is active and assignment condition B12 is fulfilled, then variable 1M2 is
assigned the value 1. In all other cases, the value of the variable 1M2 is 0.
B12
3 1M2
Example of a continuously active action with assignment condition
Storing action if step is At the point when the corresponding step is activated, the value specified in the
activated action is assigned to the variable. The value of the variable remains stored until it is
overwritten by another action.
Since the assignment of the value is effected during the activation of a step, i.e.
when a rising signal edge is available, the action is identified by means of an upward
arrow.
9 4M1:=1
14 4M1:=0
15 C:=C+1
Examples of storing actions if step is activated
In the case of the example this means:

As soon as step 9 becomes active, the value 1 is assigned to valve coil 4M1. If step 9
is no longer active, variable 4M1 retains the value 1 until this value is overwritten by
another action. If step 14 becomes active, the value 0 is assigned to valve coil 4M1.
Variable 4M1 retains the value 0 until the value of the variable is overwritten by
another action. If step 15 is active, the value of the variable C will be increased
precisely once by 1.

Storing action if step is When the step is deactivated, the variable is assigned the value specified in the
deactivated action. The value for the variable remains stored until it is overwritten by another
action.
Since the value is assigned when the step is deactivated, i.e. when the falling signal
edge applies, the action is designated by means of a downward arrow.
12 4M1:=0
Example of a storing action when step is deactivated
In the case of the example shown, this means:

If step 12 becomes inactive, the value 0 is assigned to variable 4M1. The assignment
is executed until variable 4M1 is overwritten in another action.
Storing action during event The variable described in the action is assigned the specified value only if the step is
active and if a rising edge occurs for the expression which represents the events.
The flag by the action symbolises that the action is not executed with a latching
function until an event occurs.
The arrow pointing upwards indicates that the action is executed when the event has
a rising edge.
2B1
6 Part_ok:=1
Example of a storing action if an event occurs
In the case of the example shown, this means:

If step 6 is active and the value of variable 2B1 changes from 0 to 1, then the action
represented is executed. The value 1 is assigned to the variable part _ok and is
assigned until the variable part _ok is overwritten by another action.
An action can also be executed as soon as an event is no longer true. The falling
edge of the event or assignment condition is represented by a downward arrow.

Delayed, continuously active If an action is executed with time delay, then the continuously active action with
action assignment conditon can be extended by a time period.
The active step and the time are specified as assignment condition. The assignment
condition is not fulfilled until the specified time has expired, when the variable
specified in the action receives the value 1 1.
2s/X27
27 4M1
Step 27
4M1
0 2 4 6 8 10 s 12
2s
Example of a time-delayed, continuously active action with time diagram
The following applies in the case of the example:

If step 27 is active (the status variable of step X27 has the value 1), the action
represented is executed when the specified time of 2 seconds has expired: The
value 1 is assigned to variable 4M1. The assignment is executed for as long as step
27 is active.
Please note: The time diagrams shown do not form part of the GRAFCET of a control
system. They are merely intended to explain and describe a time-delayed action.

Time-limited, continuously A time-limited action is obtained via the negation of the time-delayed action
active action condition.
5s/X29
29 5M2
Step 29
5M2
0 2 4 6 8 10 s 12
5s
Example of a time-limited, continuously active action with time diagram
The following applies for the example:

If step 29 is active, the represented action is executed for the duration of 5 seconds.
If the associated step is active for less than 5 seconds, the action is also executed
for a correspondingly shorter period.
system. They are merely intended to describe and explain a time-limited action.
Equivalent representation:
An equivalent representation for a time-limited, continuously active action is
obtained via the time-dependent transition condition.
29 5M2
5s/X29
30
Example of a time-limited, continuously active action
Here again, the value TRUE is only assigned to the variable 5M2 for five seconds
after step 29 is activated.

Time-dependent assignment Instead of the active step, it is also possible to use a variable of your choice. In this
condition case, the time on the left is started via the rising edge of the specified variable. The
action is executed when the time has elapsed. A time indicated on the right is
started via the falling edge of the variable and extends the duration of the action.
The prerequisite for this is that the step remains active.
2s/B9/4s
31 2M1
Step 31
B9
2M1
0 2 4 6 8 10 s 12
4s
2s
Example of a continuously active action with time-dependent assignment condition
The following applies in the case of the example:

If step 31 is active and the value of assignment condition B9 changes from 0 to 1,
then the time delay of 2 seconds starts. When the 2 seconds have elapsed, the
value 1 is assigned to the variable 2M1. If the value of assignment condition B9
changes from 1 to 0, then the variable 2M1 continues to hold the value 1 for 4
seconds.
system. They are merely intended to describe and explain an action with time-
dependent assignment condition.
Sequence structures Three basic forms of sequence structure can be created by combining the elements
of step and transition:
Linear sequence
Sequence divergence (alternative divergence)
Sequence splitting (parallel divergence)
Regardless of the form of sequence structure, steps and transitions must always
alternate. Sequence structures always evolve from top to bottom.

Alternative divergence In the case of alternative divergence, two or several transitions follow a step. The
sub-sequence is activated and executed and its transition condition is the first to be
fulfilled. Since is it possible to select precisely one sub-sequence in the case of
alternative divergence, the transition conditions must be mutually exclusive.
S1*S4*1B1*2B1*3B1 S1*S4*1B1*2B1*3B1
2A 1M1:=1 2B 2M1:=1
1B2 2B2
3 3M1:=1
Example of an alternative divergence
Parallel divergence In the case of parallel divergence, the fulfilment of a transition condition leads to the
simultaneous activation of several sub-sequences. The evolution of these sub-
sequences takes place simultaneously, but independently of one another. The
convergence of the sub-chains is synchronised. Only when all parallel sub-
sequences are executed completely, can a transition to the step below the double
line take place in this example to step 6.
3 3M1:=1
3B2
4A 4M1 4B 5M1
4B2 5B2
5A 5B
4B1*5B1
6 3M1:=0
Example of a parallel divergence

Feedback loop and skips Sequences are generally executed cyclically, i.e. they represent a loop. In order to
represent a loop structure, a line must evolve from the bottom up. As this direction
is the opposite of the usual top-down direction of a sequence, it must be denoted by
an arrow.
Example of a feedback loop in a sequence structure
If a directed link in a GRAFCET has to be interrupted because the GRAFCET is

complex or extends over several pages, then the identifier of the target step and the
number of the page on which it appears must be specified.
Step 10
Page 2
Example of a breakpoint in a sequence structure

Example for a GRAFCET The sequence of the distribution station from the Modular Production System MPS
of Festo Didactic can be described by means of the basic elements of GRAFCET.
1B2*2B1*3B1 "Initial position"

1 P1 "Initial position display"
S1*1B2*2B1*3B1*B4 "Start condition"
3 1M1:=1 "Eject part"
1B1 "Part ejected"
5 2M1 "Generate vacuum"
2B1 "Vacuum generated"
6 1M1:=0 "Release part"
1B2 "Part released"
8 2M2 "Deposit part"
2B1 "Vacuum no longer generated"
Structural part Function part
GRAFCET (function chart) for a distribution process
Comments Explanations for the purpose of clarification can be added in the form of comments
at any point of a GRAFCET. Comments are represented in inverted commas.

Hierarchical GRAFCETs The standard takes into consideration new elements to describe control systems.
These include the introduction of hierarchical levels, which are necessary for the
precise definition of coarse/fine structures of a control system, for modes of
operation and for the EMERGENCY-STOP function in complex control systems .
If different hierarchical levels are used, then a GRAFCET is split up into several parts.
These parts are known as SUB-GRAFCETs and are given a name, prefixed by a G.
The main elements of the structure are:

Forcing commands
Inclusive steps
Macrosteps
Forcing commands A master GRAFCET controls the subordinate GRAFCETs with so-called forcing
commands. A forcing command is linked to a step and represented in the form of a
rectangle with double lines. The steps are shown in a curly bracket and are forced.
5 G9{100}
9 G1{}
12 G4{ }
7 G2{INIT}
Examples of forcing commands
There are four types of forcing commands. These are explained with the help of
examples.
Forcing a sub-GRAFCET into a specific situation:
If step 5 becomes active, step 100 is activated in sub-GRAFCET 9; all other steps
of G9 are deactivated. In a structure with parallel divergence, several steps can
be forced. The notation in this case is as follows: G9{100, 200, 300}. Sub-
GRAFCET G9 does not require an initialising step.
Forcing a sub-GRAFCET into the current situation (freeze command):
If step 9 becomes active, the sub-GRAFCET G1 is frozen in the current position for
as long as step 9 is active.

Forcing a sub-GRAFCET into a vacant situation:

If step 12 becomes active, the sub-GRAFCET G4 is set to the vacant position; no
steps are activated. This means that all steps are de-activated by G4.
Forcing a sub-GRAFCET into the initial position:
If step 7 becomes active, sub-GRAFCET G2 is initialised, whereby only those
steps identified as initialising steps are activated. All other steps of G2 are
deactivated.
Example of application using The GRAFCET describing the control behaviour of the MPS distribution station is
forcing commands divided into three sub-GRAFCETs.
G1: Sub-GRAFCET of the modes of operation (upper hierarchical level)
G10: Sub-GRAFCET of automatic operation (lower hierarchical level)
G100: Sub-GRAFCET of manual/reset operation (lower hierarchical level)
Forcing commands only apply to the upper hierarchical level.

G10 applies to the lower hierarchical level, the sub-GRAFCET for automatic
operation, and G100, the sub-GRAFCET for manual/reset operation.
1 G10{ }
G100{INIT}
EMERGENCY STOP*S_Manual
2 G10{INIT} "Manual/Reset"
EMERGENCY STOP
EMERGENCY STOP*Reset_OK*S_Automatic
3 G100{ } "Automatic"
G1: Sub-GRAFCET of modes of operation

(upper hierarchical level)
Higher-order sub-GRAFCET for the MPS distribution station

All three GRAFCETs are started simultaneously.

G1, like any other GRAFCET, starts in the initialising step 1, where it executes two
forcing commands:
G10, the automatic operation, is force-deactivated for as long as G1 is in step 1.
G100, the reset mode, is forced into its initialising step. G100 executes its
initialising step for as long as step 1 of G1 is active.
Once the EMERGENCY-STOP is released and manual operation is selected, G1

progresses to step 2, where a forcing command is output:
G10, automatic operation, is forced into its initialising step, where it remains for
as long as step 2 of G1 is active.
The forcing command in step 2 of G1 no longer applies for sub-GRAFCET G100. G100
is therefore no longer dependent on a forcing command. Normal operation of G100
is thus released. The station is reset.
G1 advances to step 3, if the successful execution of the reset sequence is signalled

via the variable Reset_OK, the EMERGENCY-STOP is not actuated simultaneously
and automatic operation is selected. G1 jumps back to initialising step 1, if
EMERGENCY/STOP is actuated in step 2.
A forcing command is output again in step 3 of G1:

G100, the reset sequence, is force-deactivated. None of the steps of G100 are
executed. G100 remains deactivated for as long as step 3 is active.
The forcing command in step 3 of G1 no longer applies for sub-GRAFCET G10. G10 is
therefore no longer dependent on a forcing command . Normal operation of G10 is
thus released.

1B2*2B1*3B1 Flashing cycle

10 P1 100 P2 Reset_OK:=0
EMERGENCY STOP*S_Automatic*S1*1B2*2B1*3B1*B4 EMERGENCY STOP*S_Manual*S4
11 3M1:=0 3M2:=1 101 1M1:=0
3B2 1B2
12 1M1:=1 102 2M1
1B1 1s/X102
13 3M1:=1 3M2:=0 103 3M1:=0 3M2:=1
3B1 3B2
14 2M1 104 2M2
2B1 2B1
15 1M1:=0 105 3M1:=1 3M2:=0
1B2 1B2*2B1*3B1
16 3M1:=0 3M2:=1 106 Reset_OK:=1
3B2 G100: Sub-GRAFCET of manual/reset mode

(lower hierarchical level)
17 2M2
2B1
18 3M1:=1 3M2:=0
3B1
G10: Sub-GRAFCET of automatic mode

(lower hierarchical level)
Subordinate sub_GRAFCETs for the MPS distribution station
Inclusive steps One option for the structuring of a GRAFCET is the use of inclusive steps. The
inclusive step is identified by a drawn-in octagon.
12
Example of an inclusive step
The diagram means that step 12 contains further steps.

An inclusive step is incorporated into a GRAFCET in the same way as a normal step.
The steps contained are represented in a separate sub-GRAFCET and framed. The
step number of the inclusive step is entered at the top edge of the sub-GRAFCET
frame and the step name at the bottom edge of the frame. The step invoked first is
marked with an *. The steps contained are only executed for as long as the higher-
order inclusive step is active.
The diagram below represents the GRAFCET for the MPS distribution station using
inclusive steps.
2 "Manual/Reset"
EMERGENCY STOP
Reset_OK*S_Automatic
3 "Automatic"
Master GRAFCET with inclusive steps for the MPS distribution station
The steps contained in step 2 are represented within frame 2 (reset).

The steps contained in step 3 are represented in frame 3 (loop). This sub-
GRAFCET again contains an inclusive step 8.
The steps contained in step 8 are represented in frame 8 (sequence).

2 3
Flashing cycle
100 1B2*2B1*3B1
* P2 Reset_OK:=0
7 P1
*
S4
S1*1B2*2B1*3B1*B4
101 1M1:=0
8 "Cycle running"
1B2
X17*3B1
102 2M1
Loop
1s/X102
103 3M1:=0 3M2:=1
3B2
104 2M2
2B1
105 3M1:=1 3M2:=0
1B2*2B1*3B1
106 Reset_OK:=1
Reset
Sub-GRAFCETs with contained steps for the MPS distribution station

10 3M1:=0 3M2:=1
*
3B2
11 1M1:=1
1B1
12 3M1:=1 3M2:=0
3B1
13 2M1
2B1
14 1M1:=0
1B2
15 3M1:=0 3M2:=1
3B2
16 2M2
2B1
17 3M1:=1 3M2:=0
Sequence
Sub-GRAFCETs with contained steps for the MPS distribution station
Macrosteps Macrosteps are particularly suitable for the coarse/fine structuring of a control. A
macrostep incorporates a substructure of a GRAFCET, thereby making the GRAFCET
more transparent. A macrostep does not create any different hierarchies.
A macrostep is identified by means of two horizontal double lines on the step

symbol. The step name starts with M as a prefix.
M4
Example of a macrostep
Macrostep M4 represents a sub-GRAFCET.

A macrostep cannot be quit until the GRAFCET structure contained therein is

completely executed.
The rules regarding the identification of macrosteps are shown by means of an

example.
The example shows a GRAFCET using two macrosteps M2 and M4. During expansion,
the name of the first step is the same as that of the macrostep, but with the prefix E.
The name of the last step is also the same as that of the macrostep, but with the
prefix S. The steps in between can be given any name.
S_Manual
M2 "Manual/Reset"
S_Automatic
1B2*2B1*3B1
3 P1
S1*1B2*2B1*3B1*B4
M4 "Automatic"
S_Automatic
Example of a GRAFCET using macrosteps
If the GRAFCET is executed with the macrosteps, step 3 can only be activated if step
S2 in the expansion is active and the variable S_Automatic has the value 1 as a
transition condition.

Flashing cycle
E2 P2 Reset_OK:=0 E4 3M1:=0 3M2:=1
S4 3B2
21 1M1:=0 41 1M1:=1
1B2 1B1
22 2M1 42 3M1:=1 3M2:=0
1s/X22 3B1
23 3M1:=0 3M2:=1 43 2M1
3B2 2B1
24 2M2 44 1M1:=0
2B1 1B2
25 3M1:=1 3M2:=0 45 3M1:=0 3M2:=1
1B2*2B1*3B1 3B2
S2 Reset_OK:=1 3M2:=1 46 2M2
Macrostep M2 2B1
"Reset"
S4 3M1:=1 3M2:=0
Macrostep M4
"Automatic"
Expansion representation of macrosteps M2 and M4

6.4 The hydraulic circuit diagram of a control system shows how the individual hydraulic
Hydraulic circuit diagram components are interconnected and how they interact. The symbols of components
are arranged such as to obtain a clearly configured circuit diagram with the
minimum possible lines crossing. Consequently, a hydraulic circuit diagram does not
enable you to ascertain the actual spatial configuration of components.
In a hydraulic circuit diagram, the components are shown by means of circuit

symbols standardised in accordance with DIN ISO 1219-1. The following
characteristics must be identifiable by a symbol:
Actuation type,
Number of connections and designations thereof,
Number of switching positions.
The table below shows a list of symbols which frequently occur in electrohydraulic
control systems.
Note regarding the On the circuit diagram, connections must be identified using the data with which
identification of connections they are marked on the sub-base or on the block (DIN ISO 1219-2).
Symbols for valves The symbols for hydraulic valves are composed of one or several squares
Components for valve symbols
Switching positions are represented by squares
The number of squares corresponds to the number of switching

positions
Lines indicate flow paths, arrows indicate direction
Closed ports are represented by two lines drawn at right angles to each
other
Connecting lines for hydraulic fluid supply are drawn on the outside of
the square

Symbol for directional The ports, switching positions and direction of flow are represented within the
control valves symbol of a directional control valve.
In the case of a solenoid actuated directional control valve, the ports are drawn at
the switching position which the valve assumes if the electrical power supply is
switched off
Symbols for directional control valves
Anzahl der Anschlsse A

Anzahl der Schaltstellungen
P
2/2 Wegeventil in Durchflussstellung
3/2 way valve in closed position A
P T
3/2 way valve in flow position A
P T
4/2 way valve, flow from P to B and from A to T A B
P T
4/3 way valve with recirculating position A B
P T
Port designations for directional control valves P Pressure port

T Tank connection
A, B Working ports
L Leakage oil

Modes of actuation of The overall representation of a directional control valve in a hydraulic circuit diagram
directional control valves includes the following:
Basic type of valve actuation,
Reset,
Pilot control, if available,
Additional actuation, e.g. Emergency-Stop
Each actuation symbol is entered at the side of the switching positions, which
corresponds to its effective direction.
Actuation types of electrohydraulic valves
Manual operation By pressing
Mechanical resetting By spring
Spring centered
Electrical actuation By one solenoid
By two solenoids
Combined actuation Solenoid with emergency manual

override
Pilot actuated valve, double-

solenoid

Symbols for pressure valves Pressure valves are used in order to maintain the pressure as constant as possible,
irrespective of volumetric flow .
Pressure-relief valves adjust and limit the pressure in a system. The sensing of
pilot pressure is effected at input P of the valve.
Pressure regulating valves reduce changes in input pressure to a specified
output pressure. The sensing of pilot pressure is effected at the output of the
valve.
Symbols for pressure valves
Pressure relief valve, adjustable P(A)
T(B)
2-way pressure regulating valve, adjustable A(B)
P(A) L
3-way pressure regulating valve, adjustable A(B)
P(A) T

Symbols for flow valves Flow valves are used in order to reduce the speed of a cylinder or the rotational
speed of a motor. Both are dependent of the volumetric flow rate. Flow valves
therefore reduce the volumetric flow in a hydraulic system.
Flow valves are categorised according to their control and regulating functions
Flow control valves
Flow control valves are load-dependent. If the load pressure increases,
volumetric flow also increases via the valve. Flow control valves are available in
throttle and orifice form.
Flow regulating valves
Flow regulating valves are load-independent. The flow rate through the valve is
virtually constant.
Symbols for flow valves
Flow control valve Orifice, fixed A B
Orifice, adjustable A B
A B
Throttle, fixed
Throttle, adjustable A B
Flow regulating valve Adjustable B
One-way flow control valve Adjustable B

Symbols for check valves Check valves shut off flow in one direction and permit free flow in the opposite
direction.
Symbols for check valves
Non-return valve Load-free
Spring-loaded
Piloted B
A X
Shuttle valve
Double non-return valve Piloted A2 B2
A1 B1
Symbols for proportional Proportional valves are used for quick and precision setting and infinite adjustment
valves of the desired pressure or flow using an electrical signal.
Symbols for proportional valves
4/3-way proportional valve A B
1M1 1M2
P T
Proportional pressure relief valve P

Symbols for hydraulic The working components used in electrohydraulic systems are hydraulic motors,
cylinders and hydraulic hydraulic cylinders and swivel cylinders. Hydraulic cylinders generate linear
motors movements and hydraulic motors and swivel cylinders are used for continuous
rotational movements.
Symbols for single-acting cylinders
Single-acting cylinders, reset via external force
Single-acting cylinder, with spring return
Single-acting telescopic cylinder
Symbols for double-acting cylinders
Double-acting cylinder, with piston rod at one end, piston

surface greater than annular surface
Double-acting cylinder, with through piston rod
Double-acting telescopic cylinder
Double-acting cylinder, with the end position cushioning at

one end
Double-acting cylinder, with end position cushioning at

both ends
Double-acting cylinder, with adjustable end position

cushioning at both ends

Symbols for motors and swivel cylinders
Hydraulic motors with constant displacement volume, with

one direction of rotation
Hydraulic motors with constant displacement volume, with

two directions of rotation
Symbols for energy In the energy supply section, the hydraulic energy is supplied and the hydraulic fluid
transmission and prepared. Generally, the following components are used for the conversion of
preparation energy electrical energy is first converted into hydraulic and then mechanical
energy:
Electric motor or combustion engine
Coupling
Pump
Pressure display
Protective equipment
Hydraulic fluid is prepared using the following components:

Tank with level indicator
Filter
Cooler
Heater
Temperature indicator
The energy supply system is represented by means of the individual component

symbols, a combined symbol or by a simplified symbol.

Symbols for energy transmission and preparation
Hydraulic energy sources
Electric motor
Non-electrical drive unit
Fixed-displacement pump, with one rotational direction
Fixed-displacement pump, with two rotational directions
Tank
Filter
Cooler
Heater
Pressure, working and return line
Pilot line
Flexible line
Line connection
Crossed lines
Venting, continuous
Quick release coupling, connected to mechanically opening

non-return valves

Symbol for energy transmission and preparation
Hydraulic power pack, consting of P T

tank, electric motor, pump, pressure
relief valve and pressure gauge
Symbols for measuring The measurement of different physical variables is essential in hydraulic systems.
devices
Symbols for measuring devices
Pressure gauge
Thermometer
Flow measuring device
Level indicator

Symbols for pressure Pressure switches generate an electrical signal which is triggered by a preselectable
switches and pressure pressure.
sensors
The function of pressure switches and pressure sensors in electrohydraulic control
systems is:
To indicate when a specific pressure is reached,
To initiate control and regulating functions.
Symbols for pressure switches and pressure sensors
Pressure switch, electromechanical
Pressure switch, adjustable with changeover contact
Pressure sensor, analogue output signal p
Configuration of symbols in The design of a hydraulic circuit diagram, configuration of symbols and component
a hydraulic circuit diagram identification and numbering are standardised to DIN ISO 1219-2. The hydraulic
components symbols are configured as follows in the circuit diagram for an
electroydraulic control system:
At the top, the working components,
Below that the valves to influence speed; these include for instance throttle
valves, non-return valves,
Below that the control elements, i.e. the directional control,
At the bottom left, the energy supply.
In the case of control systems using several working components, the symbols for
the various drives are entered side by side. The symbols for the relevant valves are
configured beneath each drive symbol.
Position of cylinders and All components in a hydraulic circuit diagram are represented for the de-energised
directional control valves state of the electrical signal control section. The hydraulic energy is connected. This
means:
The solenoid coils of the directional control valves are not actuated.
Drives such as cylinders and motors are in the normal position.

Lifting Bending Indexing
1A1 2A1 3A1
50/28 x 300
1B1 1B2 63/40 x 200
2B1 2B2 32/20 x 100
3B1 3B2

16 x 2 16 x 2 16 x 2 16 x 2 16 x 2 16 x 2
1Z1 2Z1 3V1 A B
15 MPa 15 MPa
1V4
B P A
1V3 5 MPa
1V2 1V5 2V2
T 2V3 P T
A 5 MPa
1V1 A B 2V1 A B
1M1 1M2 2M1 2M2

P T P T
P T
0Z4
15 MPa 22 x 2 22 x 2
P
Hydraulic circuit diagram of an electrohydraulic control system using three control chains
0V2 T
0Z3 8 MPa
15 MPa
22 x 2
0M1
0V1 P 0Z2
0Z1 10 MPa
T
5,5 kW 0P1
-1 3
1420 min 16 cm
173
In the sample circuit diagram, the system number is not indicated in the component
identification code.
Identification code for Each of the components, except for the connecting pipes and tubing, are identified
components in the circuit diagram. The identification code includes the following:
The installation number:
The installation number consists of digits. This can be omitted if the entire circuit
consists of one system.
The circuit number:
The circuit number consists of digits and is mandatory.
The component identification:
The component identification is one letter and is mandatory.
The component number:
The component number consists of digits and is mandatory.
The identification code should be provided with a frame.
1 1 S 2
Installation number
Circuit number
Component code
Component number
Identification code for components in hydraulic circuit diagrams
System number If numerous systems and electrohydraulic control systems are to be used in a plant,
the system number facilitates the allocation between circuit diagrams and control
systems. All the hydraulic components of a control system are identified by means of
the same system number. In the sample circuit diagram, the system number is not
indicated in the identification code.

Circuit number All components forming part of the energy supply should preferably be identified by
means of the circuit number 0. The additional circuit numbers are allocated for the
various control chains, also referred to as circuits. The following allocation applies in
the case of the control system shown:
Energy supply and main switch: Number 0
Control chain Lifting: Circuit number 1
Control chain Bending: Circuit number 2
Control chain Indexing: Circuit number 3
Component identification Each component of an electrohydraulic control system is given a component

and component number designation and a component number. Within a circuit, components with the same
component designation are numbered from the bottom up and from left to right. The
valves of the control chain Lifting are therefore identified as follows:
Directional control valve 1V1
(circuit number 1, component designation V, component number 1)
Non-return valve 1V2
(circuit number 1, component designation V, component number 2)
Identification of components Components Identification

in a hydraulic circuit
Compressors P
diagram
Working A
components
Drive motors M
Signal detector S
Valves V
Valve coils M
Other components Z (or any other letters not listed)

Technical information Certain components in a hydraulic circuit diagram are provided with additional
information in order to facilitate the assembly of a control system and the
replacement of components during maintenance work.
Component Information Sample values
Tank Volume up to maximum permissible level in l Max. 120 l
Type of hydraulic fluid ISO VG 22 Type HLP
Electric motor Rated capacity in kW 5.5 kW
Nominal speed in rpm 1420 rpm

3 3
Constant-displacement pump and Volumetric delivery rate in cm Gear pump 16 cm /revolution
variable-displacement pump
Filter Grade of filtration in m 5 m
Pressure valve Set pressure in MPa or permissible pressure range for Betriebsdruck 8 MPa
the system
Non-return valve Opening pressure in MPa 0.1 MPa
Directional control valve Nominal size NG 6
Cylinder Cylinder diameter/ piston rod diameter stroke in mm 50/28-300 mm
The function is to be entered above each cylinder Lifting

3 3
Hydraulic motorr Absorption volume in cm 12.9 cm
Speed in rpm 1162 rpm
Piping Outer diameter and wall thickness in mm 22x2 mm
Tubing Nominal size (inner diameter) in mm 20 mm
6.5 The electrical circuit diagram of a control system shows how the electrical control
Electrical circuit diagram components are interconnected and how they interact. Depending on the task
definition, the following types of circuit diagram are used in compliance with
DIN EN 61082-2:
Overview diagram
Function diagram
Circuit diagram
Overview diagram An overview diagram provides an overview of the electrical apparatus of a relatively
large system, for example an assembly unit. It shows only the most important
interdependencies. The various subsystems are shown in greater detail in other
diagrams.

Function diagram A function diagram illustrates the individual functions of a system. No account is
taken of how these functions are executed.
Circuit diagram A Circuit diagram shows the details of the design of systems, installations,
apparatus etc. It contains:
Graphic symbols for the items of equipment
Connections between these items
Equipment identifiers
Terminal identifiers
Other details necessary for tracing the paths (signal identifiers, notes on the
representation location
Consolidated and If consolidated representation is used for a circuit diagram, each device is
distributed representation in represented as a single coherent symbol, i.e. for example even a relay that has more
a circuit diagram than one normally open and normally closed contact.
If distributed representation is used for a circuit diagram, the various components of

a device may be drawn at different locations. They are arranged in such a way as to
obtain a clear representation with straight lines and few line intersections. The
normally closed and normally open contacts of a relay, for example, can be
distributed throughout the circuit diagram as appropriate.
Electrical circuit diagram of A circuit diagram with distributed representation is used to represent the signal
an electrohydraulic control control section in electrohydraulics. It is only if control systems are very large that an
system overview diagram or function diagram is prepared in addition.
In practice, the term "electrical circuit diagram of a electrohydraulic control system"

always refers to the circuit diagram within the meaning of DIN EN 61082-2.

Electrical symbols In a circuit diagram the components are represented by graphic symbols that are
standardized according to DIN EN 60617. Symbols used to represent electrical
components that are frequently found in electrohydraulic control systems are shown
below.
Electrical symbols: basic functions
Direct current, DC voltage
Alternating current, AC voltage
Rectifier (power supply unit)
Permanent magnet
Resistor, general
Coil (inductivity)
Indicator light
Capacitor
Grounding, general
Symbols for switching elements: Basic functions and delayed actuation
Basic function With automatic Without Delayed Delayed release Delayed

return automatic actuation actuation,
return delayed release
Normally
open contact
Normally
closed
contact
Changeover
contact

Symbols for manually operated switching elements
Momentary-contact switch Latching-type switch
Normally open contact, manually

operated

operated by pressing
Normally closed contact, manually

operated by pulling

operated by turning
Symbols for electromechanical drives
General Electromechanical drive
Actuation of Electromechanical drive with

relays and two parallel windings
contactors
Electromechanical drive with

two opposed windings

pickup delay

dropout delay

pickup and dropout delay

Symbols for electromechanical drives
Electromechanical drive of an
AC relay
Electromechanical drive of a
retentive relay
Valve Electromechanical drive of a

actuation directional control valve
Symbols for relays and contactors (assembled representation)
Relays with three normally open

contacts and one normally
closed contact
with two changeover contacts
with dropout delay
with pickup delay
Retentive relay * * *
Flasher relay
5/min
Contactors Contactor with one normally

closed contact and one
normally open contact
* When a voltage is applied to the winding terminations marked by *, contact labels are placed at the
positions of the contact elements marked thus

Symbols for sensors
Limit switches Normally open contact
Normally closed contact
Proximity switches, Proximity sensors, proximity-

proximity sensors sensitive device
Proximity switch (normally open

contact), actuated by magnets
(standardized)
Proximity switch, optical
Proximity switch, inductive
Proximity switch, capacitive
Pressure switches, Pressure switch,

pressure sensors electromechanical >p
Pressure switch, electronic

p
Circuit diagram of an In the circuit diagram of an electrohydraulic control system the graphic symbols of
electrohydraulic control the components required to implement logic circuits and sequences are entered
system consecutively from the top to the bottom and from left to right. Relay coils and valve
coils are always drawn beneath the contacts.
Other measures to ensure that a circuit diagram is easy to read include:

Division into individual current paths
Identification of devices and contacts by letters and numbers
Subdivision into a control circuit and main circuit
Preparation of tables of contact elements

Current paths The individual current paths of an electrohydraulic control system are drawn
alongside each other in the circuit diagram and numbered consecutively. The circuit
diagram of an electrohydraulic control system has 10 current paths. Current paths 1
to 8 belong to the control circuit, current paths 9 and 10 to the main circuit.
24 V 1
3
S1
4
2 3 4 5 6 7 8 9 10
1B3
3 13 3 3 13 3 13 33 23
S2 K1 1B1 >p K3 1B2 K4 K3 K1
4 14 4 4 14 4 14 34 24
13
K2
14
21 21 31
K3 K4 K2
22 22 32
31 1
K4 S3
32 2
K1 K2 K3 K4 P1 1M1
A2 A2 A2 A2
0V
3 7 2 2 6 2 8
10 9 5
S1 = Main switch S2 = Start switch S3 = Acknowledgement switch

1B1/1B2 = Limit switch 1B3 = Pressure switch
Electrical circuit diagram of an electrohydraulic control system

Identification of components The components in the circuit diagram of a control system are identified by a letter.
Components with identical identifying letters are assigned consecutive numbers (for
example 1B1, 1B2 etc.).
Sensors and valve coils must be represented both in the hydraulic circuit diagram
and the electrical circuit diagram. In order to ensure that there is no ambiguity and
that the diagrams are easy to read, the symbols in both types of diagram should be
identified and numbered in the same way. For example, if a certain limit switch is
designated 1B1 in the hydraulic circuit diagram, the same identification should also
be used in the electrical circuit diagram.
Designation of components Component type Identification

in an electrical circuit
Limit switch B
diagram (DIN EN 61346-2)
Manually operated pushbutton, input S
elements
Reed switch B
Electronic proximity switch B
Pressure switch B
Indicator P
Relay K
Contactor K
Solenoid coil of a valve M
Example of identification of The components shown in the circuit diagram are identified as follows:
components Manually operated switches S1, S2 and S3
Limit switches 1B1 and 1B2
Pressure switch 1B3
Relays K1, K2, K3 and K4
Solenoid coil 1M1
Lamp P1

Terminal designations of In order to ensure error-free wiring of contacts, all connections on a component and
contacts and relays in the circuit diagram are identified in the same way. Each connection of a contact is
assigned a function number. The function numbers for different types of contact are
listed below. If a switch, relay or contactor has more than one contact, they are
numbered by means of sequence numbers prefixed to the function number.
Function numbers for Type of contact Function number

contacts
Normally closed contact 1, 2
Normally open contact 3, 4
Normally closed contact, delayed 5, 6
Normally open contact, delayed 7, 8
Changeover contact 1, 2, 4
Changeover contact, delayed 5, 6, 8
1 3 2 4
Actuation direction 2 4 1
Normally closed Normally open Changeover

contact contact contact
11 21 33 43
12 22 34 44
Contact designation by means of function numbers and sequence numbers

The diagram shows a sectional view of a relay with its associated terminal
designations. The terminals of a relay coil are designated A1 and A2.
13 23 31 41
A1
A2
14 24 32 42 24 V 1 2
3
S1
4
A1 13 23 31 41
K1 13
A2 14 24 32 42 K1
A2 14
1M1
0V
Graphic symbols and terminal designations for a relay
Example of terminal In the circuit diagram above, the terminals of relay K1 are identified as follows:
designations of a relay Coil (current path 2) A1, A2
Normally open contact (current path 3) 13, 14
(as part of a changeover contact)
Normally open contact (current path 10) 23, 24
(as part of a changeover contact)

Contact element table All contacts actuated by a relay coil or contactor coil are listed in a contact element
table. The contact element table is placed beneath the current path containing the
relay coil. Contact element tables may be shown in either simplified or detailed form.
Simplified Detailed
7 3 4 6
7 3 11 23 33 43
Normally closed 4
contact in 6 Normally open 12 24 34 44
current path 7 contact in
current path 4
Switching element table of a relay with normally closed and normally open contact
Simplified Detailed
12
11 14 .7 7 3 4 6
22
21 24 .3
32
12 14 22 24 32 34 42 44
31 34 .4
11 21 31 41
42
41 44 .6
Switching element table of a relay with changeover contact
Examples of contact element There are a total of 4 contact element tables in the circuit diagram above:
tables Current path 2 contact element table for relay K1
Current path 4 contact element table for relay K2

Actuated contacts and The electrical circuit diagram is shown in the de-energized state (electric power
sensors supply switched off). If sensors such as limit switches and proximity switches are
actuated in this position, they are identified by an arrow. The associated contacts
are also shown in the actuated position.
1 3
2 4
Actuated normally closed contact Actuated normally open contact
Representation of actuated contacts in a circuit diagram
6.6 In an electrohydraulic control system, sensors, control elements, signal processing

Terminal connection units and solenoid coils have to be wired up to each other. Particular attention
diagram needs to be paid to the arrangement of the control components:
Sensors are frequently mounted in parts of an installation that are difficult to
access.
Signal processing equipment (relays, programmable logic controllers) are usually
located in a control cabinet.
Control elements are either mounted directly in the front of the control cabinet or
the system is operated via a separate control console.
Solenoid actuated directional control valves are integrated into control blocks or
individually mounted in the vicinity of the drive units.
The large number of components and the distances between them make wiring a
significant cost factor in an electrohydraulic control system.
Wiring requirements The wiring of an electrohydraulic control system must satisfy the following
requirements:
Cost-effective design
(use of components which allow speedy wiring while maintaining a good
price/performance ratio, optimization of the circuit diagram in terms of wiring
expense, use of components with reduced number of terminals)
Simple troubleshooting
(clear wiring which is accurately documented and is easy to follow)
Swift repair
(simple replacement of components by means of terminal or plug-in connections,
no soldered-on components)

Fieldbus systems In electrohydraulics, increasing use is being made of fieldbus systems for the
transmission of signals. These systems exhibit the following characteristics:
Particularly clear, easy to maintain layout of the control circuit
Effort and cost of wiring reduced to a fraction (plug-in connections)
Amount and cost of hardware increased (more complex electronics)
The decision as to whether a fieldbus system should be used or the control system
should be set up using individual wiring is dependent on the particular application.
Control cabinet
Signal processing
Power supply Terminal strip
Solenoids Sensors
Machine
Control cabinet
Signal processing
Power supply Terminal strip
Terminal strip
Solenoids Sensors
Machine
Structure of an electrohydraulic control system using terminal strips

Wiring with terminal strips In control systems where components are wired individually, terminal strips are
used in order to satisfy the requirements regarding low wiring costs, simple
troubleshooting and repair-friendly layout. All lines leading into or out of the control
cabinet are run via a terminal strip. Faulty components can easily be disconnected
from the strip and then replaced.
If additional terminal strips are mounted directly on the installation or machine, the
supply lines used to connect the components situated outside the control cabinet
can be considerably shorter. This makes installing and replacing the components
even easier. Each additional terminal strip is fitted inside a terminal box in order to
protect it from environmental impact.
Design of terminals and A terminal has two receptacles for electrical lines; these are arranged one beneath
terminal strips the other and have an electrically conductive connection. All terminals are attached
to a strip, alongside each other. Electrically conductive connections between
adjacent terminals can be established with straps or jumpers.
1 3
Line 1 (1) Terminal (2) Line 2 (3) Mounting strip (4)
Terminal

Terminal allocation The twin goals of wiring a control system as inexpensively as possible while keeping
the structure clear are impossible to achieve at the same time. For the purpose of
maintaining a control system it is preferable if the terminals of a terminal strip are
assigned in such a way that the wiring layout is easy to follow. In practice the
following types are encountered:
Control circuits with systematic terminal allocations, helpful to maintenance
Control circuits in which the number of terminals has been minimized at the
expense of clarity
Hybrids of the two other variants
Under no circumstances must several wires be assigned to one terminal connection.
Clear terminal allocation Minimum number of terminals
Advantages Fast troubleshooting Savings (space in control cabinet, terminals)

Easy to follow Less wiring effort
Easy repair Fewer sources of error when wiring
Disadvantages Material expense Lack of clarity, time-consuming especially for newcomers

Time-consuming wiring to the system
Approaches to terminal allocation
Structure of a terminal Terminal allocations are documented in a terminal connection diagram. This consists
connection diagram of two parts: a circuit diagram and a terminal allocation list.
In the circuit diagram, each terminal is represented by a circle. The terminals are
identified by the letter X, and are numbered consecutively in sequence within the
terminal strip (terminal designation X1, X2 etc. for example). If there is more than
one terminal strip, each strip is also assigned a sequence number (terminal
designation X2.6, for example, for the 6th terminal of terminal strip 2).
The terminal allocation list itemizes the allocations of all terminals of one strip in
order. If the control system has more than one terminal strip, a separate list is
produced for each strip. Terminal allocation lists are used as aids for control system
installation, troubleshooting (measuring signals at the terminals) and repair.
Preparation of a terminal The basis on which to produce the terminal connection diagram is the circuit
connection diagram diagram with no terminal allocations shown. The terminal connection diagram is
drawn up in two stages:
1. Allocation of terminal numbers and drawing the terminals in the circuit diagram.
2. Compilation of the terminal allocation list(s).

Application example In the following an explanation is given of a terminal allocation procedure with which
to obtain clear, easy-to-follow wiring. The starting point for preparing the terminal
connection diagram is given by:
The circuit diagram of a control system without the terminal markings
A printed form for a terminal allocation list
1A1
1B1
1B2
1V1 A B
1M1
P T
24 V 1 2 3 4 5
13 2 4 22 24
S1 1B2 K2
14 1 21
BN
1B1
BK
12 14 12 14
K1 K2
BU
11 11
K1 K2 1M1
A2 A2
0V
12 12
11 14 .3 11 14 .4
22 22
21 24 21 24 .5
32 32
31 34 31 34
42 42
41 44 41 44
Hydraulic circuit diagram and electrical circuit diagram of an electrohydraulic control system

nation
nation
Desti-
Desti-
Connection brigde
Terminal no. X . . .
designation
designation
designation
designation
Component
Component
Connection
Connection
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Printed form of a terminal allocation list

Allocation of terminal The terminal numbers are allocated in ascending order and marked on the circuit
numbers diagram. The allocation procedure between the circuit diagram and terminals
comprises three stages:
1. Power supply for all current paths (terminals X1.1 to X1.4 in the circuit diagram)
2. Ground connection for all current paths (terminals X1.5 to X1.8 in the circuit
diagram)
3. Connection of all components situated outside the control cabinet,
according to the following system:
In the order of the current paths
From top to bottom within each current path
In the case of contacts, in the order of the function numbers
In the case of electronic components, in the order of supply voltage
connection, signal connection (if applicable), ground connection
In the circuit diagram, the components are allocated to terminals X1.9 to X1.17.
24 V 1 2 3 4 5
X1.1 X1.2 X1.3 X1.4

X1.9 X1.12 X1.14
13 2 4 22 24
S1 1B2 K2
14 1 21
BN
1B1 X1.13 X1.15
BK
12 14 12 14
K1 K2
BU
11 11
X1.11 X1.10
X1.16
K1 K2 1M1
A2 A2
X1.17
X1.5 X1.6 X1.7 X1.8
0V
12 12
11 14 .3 11 14 .4
22 22
21 24 21 24 .5
32 32
31 34 31 34
42 42
41 44 41 44
Circuit diagram with terminals entered

Completing the terminal Entries are made in the terminal allocation list in the following steps:
allocation list 1. Enter the component and connection designations of the components outside
the control cabinet (on the left-hand side of the terminal allocation list).
2. Enter the component and connection designations of the components inside the
control cabinet (on the right-hand side of the terminal allocation list).
3. Draw any required jumpers (in the example: terminals X1.1 to X1.4 for 24 V
supply voltage, X1.5 to X1.8 for supply ground).
4. Enter the terminal-terminal connections that cannot be implemented with
jumpers.
Machine Control cabinet

nation
nation
Desti-
Desti-
Connection brigde
Terminal no. X . . .
designation
designation
designation
designation
Component
Component
Connection
Connection
24 V 1 X1 9
2 X1 12
3 X1 14
4 K2 24
0V 5 X1 11
6 K1 A2
7 K2 A2
8 X1 17
1B1 BN 9 X1 1
1B1 BK 10 K1 A1
1B1 BU 11 X1 5
S1 13 12 X1 2
S1 14 13 K1 14
1B2 2 14 X1 3
1B2 1 15 K2 14
1M1 16 K2 21
1M1 17 X1 8
18
19
20
Terminal allocation list for the example control system

Wiring an electrohydraulic The structure of a terminal allocation list is based on the design of the terminal strip.
control system Accordingly, an electrohydraulic control system can largely be wired up on the basis
of the terminal allocation list:
All lines running to components outside the control cabinet are connected in
accordance with the list on the left-hand side of the terminal strip.
All lines running to components inside the control cabinet are connected in
accordance with the list on the right-hand side of the terminal strip.
Adjacent terminals on which a bridge has been drawn in the terminal allocation
list are connected to each other.
Lines linking two components inside the control cabinet are not routed via the
terminal strip. They are therefore not included in the terminal allocation list and
have to be wired up according to the circuit diagram.


7. Safety measures for electrohydraulic control systems
7.1 Numerous protective measures are necessary in order to ensure that

Dangers and protective electrohydraulic control systems can be safely operated.
measures
One source of danger is moving parts of machinery and equipment. On a hydraulic
press, for example, care must be taken to prevent the operator's fingers or hands
from being trapped. The table below provides an overview of sources of danger and
suitable protective measures.
Dangers from moving parts of machines and equipment

(Cylinder, axes, grippers, suction cups, clamping devices,
presses, workpieces, etc.)
Protection by Protection by Protection by

enclosure/ control and signal processing
covering signalling devices measures
Cage Warning lights Protection against
Grid EMERGENCY STOP unsupervised
Two-hand safety startup
control Setup procedure
Moving parts of machines and equipment: sources of danger and protective measures
Electric current is another source of danger. The dangers and protective measures
relating to electric current are summarized in the following table.
Dangers from components through which

electric current flows
(Power supply units, sensors, signal processing
components, solenoid coils of directional control valves)
Protection against Protection during Protection of

contact with high maintenance and electrical equipment
voltage repair work against environ-
Safety extra-low Main switch with mental influences
voltage interlocking Protection against
Covering/housing dust/foreign bodies
Adequate distance Protection against
Grounding water/moisture
Electric current: sources of danger and protective measures

Safety rules
In order to provide the best possible safeguards for operating personnel, various
safety rules and standards must be observed when designing electrohydraulic
control systems. The key standards dealing with protection against the dangers of
electric current are listed below:
Protective Measures for Electrical Power Installations up to 1000 V
(DIN VDE 0100)
Specifications for Electrical Equipment and Safety of Machines (DIN EN 60204)
Degrees of Protection of Electrical Equipment (DIN EN 60 529)
The following safety regulations apply for hydraulics:

Rules for the prevention of accidents, directives, safety regulations and testing
regulations of trade associations,
The Pan-European equipment safety law GSG 89/391/EG,
The Pan-European pressure device directive DGRL 97/23/EG.
7.2 When a person touches a live part, an electric circuit is completed. An electric
Effect of electric current on current I flows through the person's body.
the human body
Effect of electric current The effect of electric current on the human body increases with the intensity of the
current and with the length of time in contact with the current. The effects are
grouped according to the following threshold values:
Below the threshold of perception, electric current has no effect on the human
body or to human health.
Above the let-go threshold, muscles become cramped and functioning of the
heart is impaired.
Above the threshold of non-fibrillation, the effects are cardiac arrest or
ventricular fibrillation
Up to the let-go threshold, electric current is perceived but there is no danger of
fibrillation, cessation of breathing and unconsciousness. There is an acute risk to
life.
The threshold of perception, let-go threshold and non-fibrillation threshold are

plotted in the diagram for alternating current with a frequency of 50 Hz. This
corresponds to the frequency of the electrical supply network. For direct current, the
threshold values for endangering human beings are slightly higher.

10000
5000 Threshold of
ms non-fibrillation
Threshold
2000 of
1000 perception
500
1 2 Let-go 3 4
200 threshold
Time t
100
50
20
10
0
0,2 0,5 1 2 5 10 20 50 100 200 500 mA 2000
Current I
Danger zones with AC voltage (frequency 50 Hz/60 Hz)
Electrical resistance of the The human body offers resistance to the flow of current. Electric current may enter
human body the body through the hand, for example; it then flows through the body to re-emerge
at another point (such as the feet). Accordingly, the electrical resistance RM of the
human body is formed by a series circuit comprising the entry resistance R1, the
internal resistance RI and the exit resistance R2. It is calculated using the following
formula:
RM = R1 + RI + R2
The contact resistances R1 and R2 vary greatly depending on the contact surface
and the moistness and thickness of the skin. This affects the total resistance RM. It
may range between the following extremes:
Less than 1000 ohms (large contact surfaces, wet, sweaty skin)
Several million ohms (point contact, very dry, thick skin)

a) b)
I
G R1
~
I
G RI
~
R2
c) d)
I I
G RL
~
RM U RM
~
RE
a) The human body as electrical resistance

b) Electrical resistance of the human body in the form of series connection
c) Electrical resistance of the human body
d) Electrical current flowing through the human body
Touching live parts
Variables influencing the The current I through the human body is dependent on the source voltage V, the
risk of accident resistance RL of the electric line, the resistance RM of the person and the resistance
RE of the ground. It is calculated as follows:
V
I=
RL + R M + RE
According to this formula, a high current, i.e. a high level of danger, is obtained in
the following circumstances:
When touching an electrical conductor carrying a high voltage V (such as a
conductor in the electrical supply network, 230 V AC)
When touching a conductor at a low contact resistance R and consequently low
resistance RM (such as with large contact surfaces, sweaty skin, wet clothing)

7.3 There are a wide variety of protective measures which prevent the operator of an
Measures to protect against electrohydraulic control system from being put at risk from electric current.
accidents with electric
current
Protection against direct Protection against touching live parts is prescribed for both high and low voltages.
contact Such protection can be ensured in the following ways:
Insulation
Covering
Sufficient clearance
Grounding Components that are liable to be touched by anyone must be grounded. If a

grounded housing becomes live, the result is a short circuit and the overcurrent
protective devices are tripped, interrupting the voltage supply. Various devices are
used for overcurrent protection:
Fuses
Power circuit-breakers
Fault-current-operated circuit-breakers
Fault-voltage-operated circuit-breakers
Safety extra-low voltage There is no risk to life when touching an electric conductor carrying a voltage of less
than approximately 30 V because only a small current flows through the body.
For this reason, electrohydraulic control systems are not normally operated at the
voltage of the electrical supply network (such as 230 V AC) but at 24 V DC. The
supply voltage is reduced by a power supply unit with an isolating transformer.
Despite this precaution, the electrical wiring at the inputs to the power supply unit
carry high voltage.

7.4 Control elements and indicating elements must be designed in such a way as to
Control panel and ensure safe and fast operation of the control system. The functions, arrangement
indicating elements and colour coding of control elements and indicator lamps are standardized. This
allows the use of uniform operating procedures for different control systems, and
operating errors are prevented as far as possible.
Main switch Every machine and installation must have a main switch. This switch is used to
switch off the supply of electric power for the duration of cleaning, maintenance or
repair work and for lengthy shut down periods. The main switch must be manually
operated and must have only two switch positions: "0" (Off) and "1" (On). The Off
position must be lockable in order to prevent manual starting or remote starting. If
there is more than one incoming supply, the main switches must be interlocked such
that no danger can arise for the maintenance personnel.
EMERGENCY STOP The EMERGENCY STOP control switch is actuated by the operator in dangerous
situations.
The EMERGENCY STOP operating device must have a mushroom button if it is

operated directly by hand. Indirect operation by pull-cord or foot pedal is
permissible. If there is more than one workstation or operating panel, each one must
have its own EMERGENCY STOP operating device. The colour of the EMERGENCY
STOP actuation element is a conspicuous red. The area beneath the control switch
must be marked in contrasting yellow.
Once the EMERGENCY STOP device has been actuated the drives must be shut down
as quickly as possible and the control system should be isolated from the electrical
and hydraulic power supplies where feasible. The following limitations have to be
observed, however:
If illumination is necessary, this must not be switched off.
Auxiliary units and brake devices provided to aid rapid shutdown must not be
rendered ineffective.
Clamped workpieces must not be released.
Retraction movements must be initiated by actuation of the EMERGENCY STOP
device where necessary. Such movements may however only be initiated if this
can be done without danger.

Control elements of an An electrohydraulic control system has other control elements in addition to the
electrohydraulic control main and EMERGENCY STOP switch. An example of a control panel is shown in the
system diagram below.
Main switch EMERGENCY STOP
Continuous cycle Single cycle

Automatic On Start
Continuous
Off
Manual Reset Release
Inching Clamp
Control panel of an electrohydraulic control system (example)
A distinction is drawn between two different types of operation for electrohydraulic

control systems:
Manual operation
Automatic, i.e. program-controlled operation

Manual operation The following control elements have an effect in manual operation:
"Reset": The system is moved to the output position.
"Inching": Each time that this pushbutton is pressed, the sequence is extended
by one step.
Individual movements: A drive is actuated when the corresponding pushbutton
or control switch is pressed (example: "Release" or "Clamp").
Automatic operation The following operating modes are possible only in automatic operation:
Single cycle: The sequence is executed once.
Continuous cycle: The sequence is executed continuously.
Pressing the "Continuous cycle OFF" pushbutton (or a "Stop" button) interrupts the
sequence. The interruption occurs either after the next step or after completion of
the entire sequence.
The main switch and EMERGENCY STOP switch are effective in all operating modes.
They must be available on every electrohydraulic control system together with
control elements for "Manual" and "Automatic", "Start", "Stop" and "Reset".
Which control elements are necessary in addition to these is dependent on each
individual application.
Colour coding of control The table below provides an overview of the colours of control elements and what
elements these colours mean, in line with EN 60204.
Colour Command Required operating status
Red Stop, Off Shut down one or more motors.Shut down units of a machine.
Stop the cycle (if the operator presses the pushbutton during a cycle, the
machine stops once the current cycle has been completed).
EMERGENCY STOP Stop in the event of danger (e. g. shutdown because of dangerous overheating).
Green or Start, On, Inching Energize control circuits (ready for operation).
black Start one or more motors for auxiliary functions.
Start units of the machine. Inching operation (inching when switched on).
Yellow Start a return movement outside the Return machine units to the starting point of the cycle, if the cycle is not yet
normal work sequence, or start a completed.
movement to counteract dangerous Actuation of the yellow pushbutton may deactivate other, previously selected
conditions functions.
White or Any function for which none of the Control auxiliary functions which are not directly linked to the operation cycle.
black above colours is used.
Colour coding of control elements of machine control systems

Colour coding of indicator To enable operating staff to immediately identify the operating status of a system,
lamps especially malfunctions and dangerous situations, indicator lamps are colour-coded
in accordance with EN 60204. The meanings of the various colours are shown in the
table.
Colour Operating status Examples of application
Red Abnormal status Indication that the machine has been stopped by a protective device (e. g. due to
overload, over travel or some other fault).
Prompt to shut down the machine (e. g. because of overload).
Yellow Attention or caution A value (current, temperature) is approaching its permissible limit or, signal for
automatic cycle.
Green Machine ready to start Machine ready to start: Auxiliaries operational. The (various) units are at their
initial positions and the hydraulic pressure or the voltage of a transformer have
reached the prescribed values.
The operation cycle is completed and the machine is ready for restarting.
White Electric circuits energized. Normal Main switch in ON position.

(colour-less) status in operation Selection of speed or direction of rotation.
Individual drives and auxiliary devices in operation.
Machine running.
Blue Any function for which none of the

above colours is used
Colour coding of indicator lamps on machine control systems

7.5 Electrical equipment such as sensors or programmable logic controllers may be

Protecting electrical exposed to a variety of environmental impacts. The factors that may impair
equipment against operation of such equipment include dust, moisture and foreign matter.
environmental impact
Depending on the circumstances of installation and the environmental conditions,
electrical equipment may be protected by housings and seals. Such measures also
prevent danger to personnel handling the equipment.
Identification of the degree The identifier for the degree of protection in accordance with DIN EN 60529 consists
of protection of the two letters IP (standing for "International Protection") and two digits. The first
digit indicates the scope of protection against the ingress of dust and foreign
bodies, and the second digit the scope of protection against the ingress of moisture
and water. Tables show the assignment between the class of protection and the
scope of protection.
First Scope of protection Explanation

Code no. Designation
0 No protection No particular protection of persons against accidental touching of energized or

moving parts. No protection of the equipment against the ingress of solid foreign
bodies.
1 Protection against large foreign Protection against accidental large-area touching of energized or moving internal
particles parts, such as touching with the hand, but no protection against intentional
access to these parts. Protection against the ingress of solid foreign bodies with
a diameter of greater than 50 mm.
2 Protection against medium foreign Protection against touching with fingers of energized or moving internal parts.
particles Protection against the ingress of solid foreign bodies with a diameter of greater
than 12 mm.
3 Protection against small foreign Protection against small foreign particles Protection against touching of
particles energized or moving internal parts with tools, wires or similar objects with a
thickness greater than 2.5 mm. Protection against the ingress of solid foreign
bodies with a diameter of greater than 2.5 mm.
4 Protection against granular foreign Protection against the ingress of granular particles with a diameter of greater
particles than 1 mm.
5 Protection against dust accumulation Complete protection against touching of energized or moving internal parts.
Protection against detrimental accumulation of dust. The ingress of dust is not
entirely prevented, but dust must not be allowed to ingress in sufficient
quantities to impair operation.
6 Protection against dust ingress Complete protection against touching of energized or moving internal parts.
Protection against the ingress of dust.
Protection against contact, dust and foreign bodies

Second Scope of protection Explanation

Code no. Designation
0 No protection No specific protection.
1 Dripping water Drops falling vertically must not have any harmful effects.
2 Water drops at 15 angle Vertically falling drops of water must not have any harmful effects if the housing
is tilted by angle of up to 15 on either side of the vertical.
3 Spraying water Water sprayed at an angle of up to 60 on either side of the vertical must not
have any harmful effects.
5 Splashing water Water that is directed towards the housing from any direction must not have any
harmful effects.
5 Jets of water Jets of water from a nozzle directed at the housing from any direction must not
have any harmful effects.
6 Strong jets of water Strong jets of water from a nozzle directed at the housing from any direction
must not have any harmful effects.
7 Periodic immersion Water must not penetrate in harmful amounts if the housing is immersed in
water periodically under specified conditions of pressure and time.
8 Prolonged submersion Water must not penetrate in harmful amounts if the housing is continually
submersed under water in conditions which must be agreed between the
manufacturer and the user. However, the conditions must be more extreme than
those for code no. 7.
Protection against moisture and water
Example 1: PLC A programmable logic controller is accommodated in a metal housing which has slits
for cooling. IP 20 is specified as the degree of protection. This means:
First digit 2:
protection against the ingress of foreign bodies with a diameter greater than 12
mm, live parts protected against touching with fingers
Second digit 0:
no protection against the ingress of water or moisture
Example 2: Inductive The electronics for an inductive proximity switch are accommodated in an enclosed
proximity switch housing and the cable connection is sealed. The degree of protection of the sensor is
IP 65. This means:
First digit 6: Dust-proof
Second digit 5: Deckwater-tight

7.6 Design of an electro-hydraulic system

Safety recommendations Install the EMERGENCY STOP push-button in a place where it can be easily
for electro-hydraulic reached.
systems Use standardised parts only.
Enter all alterations in the circuit diagram immediately.
The rated pressure must be clearly visible.
Check whether the installed equipment can be used at the maximum operating
pressure.
The design of suction lines should ensure that no air can be drawn in.
Check the oil temperature in the suction line to the pump. It must not exceed
60 C.
The piston rods of the cylinders must not be subjected to bending loads or
lateral forces. Protect piston rods from dirt and damage.
Start-up of an electro-hydraulic system

Do not operate systems or actuate switches if you are not totally sure what
function they perform.
All setting values must be known.
Do not switch on the power supply until all lines are connected. Important: check
that all return lines (leakage lines) lead to the tank.
When starting up the system for the first time, open the system pressure relief
valve almost completely and gradually set the system to the operating pressure.
Pressure relief valves must be installed in such a way that they cannot become
ineffective.
Carefully clean the system prior to start-up, then change the filter cartridge.
Vent system and cylinders.
In particular, the hydraulic lines to the reservoir are to be carefully vented. It is
generally possible to effect venting at the safety and shut-off block of the
reservoir.
Special care is needed when handling hydraulic reservoirs. Before the reservoirs
are started up, the regulations stipulated by the manufacturer are to be studied
carefully.
Repair and maintenance of an electro-hydraulic system

Repair work may not be effected on hydraulic systems until the fluid pressure of
the reservoir has been vented. If possible, separate the reservoir from the
system (using a valve). Never drain the reservoir unthrottled! Installation and
operation are governed by the Technical Rules for Pressure Vessels.
When repairs are completed effect a new start-up in line with the safety
regulations listed above.
All hydraulic reservoirs are subject to the provisions of the pressure vessel
regulations and must be inspected at regular intervals.

8. Relay control systems
8.1 The entire signal processing operation of an electrohydraulic control system can be
Use of relay control realised by means of relays. In the past, relay control systems were produced large
systems in scale. Many of these control systems are still in use today.
electrohydraulics
Nowadays, programmable logic controllers are mostly used for signal processing
instead of relay control systems. However, relays are also used in modern control
systems, for example in EMERGENCY-STOP switchgear.
The main advantages of a relay control system are clear configuration and easy to
understand mode of operation.
8.2 The piston rod of a single-acting cylinder is to advance if pushbutton S1 is pressed

Direct and indirect and to retract again once the pushbutton is released.
actuation
Direct control of a single- The electrical circuit diagram for the direct control of a single-acting cylinder is
acting cylinder shown in the diagram below. If pushbutton S1 is pressed, current flows through the
solenoid coil 1M1 of the 3/2-way solenoid valve. The solenoid picks up, the valve
switches into the actuated position and the piston rod advances.
Current flow is interrupted if the pushbutton is released. The solenoid drops out, the
solenoid valve switches into the normal position and the piston rod retracts.
Indirect control of a single- If pushbutton S1 is actuated in the case of indirect control, current flows through the
acting cylinder relay coil K1. Contact K1 of relay K1 closes and the 3/2-way solenoid valve switches.
The piston rod advances.
Current flow through the relay coil K1 is interrupted if the pushbutton is released.
Relay K1 drops out and the solenoid valve switches into the normal position. The
piston rod retracts.

1A1
1V1 A
1M1
P T
Control of a single-acting cylinder: Hydraulic circuit diagram
24 V 1
S1
1M1
0V
Control of a single-acting cylinder: Electrical circuit diagram for direct control
24 V 1 2
S1 K1
K1 1M1
0V
Control of a single-acting cylinder: Electrical circuit diagram for indirect control

In electrohydraulic control systems, indirect control is generally used. The reason for
this is that the current flowing through the solenoid coil usually exceeds the current
permissible for the pushbutton and consequently would damage it.
Example:
The current through a coil is 0.5 A. The permissible current through the pushbutton
is 0.1 A.
Additional advantages of indirect control are:

It enables you to separate the control circuit (generally 24 V) and the primary
circuit (generally 230 V).
Several solenoid valves can be switched with one pushbutton or control switch.
Complex logic operations are possible between the signals of different
pusbuttons.
Control of a double-acting The piston rod of a double-acting cylinder is to advance if pushbutton S1 is pressed
cylinder and to retract if the pushbutton is released.
1A1
1V1 A B
1M1
P T
Control of a double-acting cylinder: Hydraulic circuit diagram

24 V 1
S1
1M1
0V
Control of a double-acting cylinder: Electrical circuit diagram for direct control
24 V 1 2
S1 K1
K1 1M1
0V
Control of a double-acting cylinder: Electrical circuit diagram for indirect control
The electrical signal control section remains with regard to the control of the single-
acting cylinder. A 4/2-way solenoid valve is used since two cylinder chambers are
connected to the energy supply.

8.3 In order to realise the desired movements of hydraulic cylinders, it is often

Logic operations necessary to interlink the signals of several control elements.
Parallel connection The advancing of the piston rod of a cylinder is to be triggered by means of two
(OR operation) different input elements, pushbuttons S1 and S2.
The contacts of the two pushbuttons S1 and S2 are configured in parallel in the
circuit diagram.
The solenoid valve remains in the normal position for as long as neither of the
pushbuttons are pressed. The piston rod is retracted.
If at least one of the two pushbuttons is pressed, the solenoid valve switches
into the actuated position and the piston rod advances.
If both pushbuttons are released, the solenoid valve switches into the normal
position and the piston rod retracts.
1A1
1V1 A
1M1
P T
Parallel connection of two contacts (OR operation): Hydraulic circuit diagram with single-acting cylinder
1A1
1V1 A B
1M1
P T
Parallel connection of two contacts (OR operation): Hydraulic circuit diagram with double-acting cylinder

24 V 1 2 3
S1 S2 K1
K1 1M1
0V
Parallel connection of two contacts (OR operation): Electrical circuit diagram with indirect control
Series connection (AND The piston rod of a cylinder is to advance only if both pushbuttons S1 and S2 are
operation) actuated.
The contacts of the two pushbuttons are configured in series in the circuit diagram.
The solenoid valve remains in the normal position for as long as neither or only
one of the two pushbuttons is actuated. The piston rod is retracted.
The solenoid valve switches if both pushbuttons are pressed simultaneously; the
piston rod advances.
If at least one of the two pushbuttons is released, the solenoid valve switches
into the normal position and the piston rod retracts.
1A1
1V1 A
1M1
P T
Series connection of two contacts (AND operation): Hydraulic circuit diagram with single-acting cylinder

1A1
1V1 A B
1M1
P T
Series connection of two contacts (AND operation): Hydraulic circuit diagram with double-acting cylinder
24 V 1 2
S1 K1
S2
K1 1M1
0V
Series connection of two contacts (AND operation): Electrical circuit diagram with indirect control

Tabular representation of The OR and AND operations are represented in the two tables below. The following
logic operations values are assigned to the signals in the three columns on the right:
0: Pusbbutton not actuated, i.e,.piston rod does not advance,
1: Pushbutton actuated, i.e. piston rod advances.
Pushbutton S1 Pushbutton S2 Piston rod S1 S2 1M1

actuated actuated advancing
Non No No 0 0 0
Yes No Yes 1 0 1
No Yes Yes 0 1 1
Yes Yes Yes 1 1 1
OR operation
Pushbutton S1 Pushbutton S2 Piston rod S1 S2 1M1

actuated actuated advancing
No No No 0 0 0
Yes No No 1 0 0
No Yes No 0 1 0
Yes Yes Yes 1 1 1
AND operation
8.4 In the previously described circuits using 3/2- or 4/2-way solenoid valves, the piston
Signal storage rod advances only for as long as the input button is being pressed. If the pushbutton
is released whilst the piston is advancing, the piston rod retracts without having
reached the forward end position.
In practice it is usually necessary for the piston rod to advance fully even if the
pushbutton is only pressed briefly. To do so, the directional control valve must
remain in the actuated position after the pushbutton is released. The pushbutton
actuation must be stored.

Signal storage via double A double solenoid valve maintains its switching position even if the corresponding
solenoid valve solenoid coil is no longer current-carrying. The valve is used as memory.
Manual advance and return The piston rod of a double-acting cylinder is to be controlled by means of briefly
stroke control via double- actuating two pushbuttons. Pushbutton S1 causes the piston rod to advance and
solenoid valve pushbutton S2 causes the cylinder to retract.
1A1
1V1 A B
1M1 1M2
P T
Manual advance and return stroke control using signal storage via double solenoid valve: Hydraulic circuit diagram
24 V 1 2 3 4
S1 S2 K1 K2
K1 K2 1M1 1M2
0V
Manual advance and return stroke control using signal storage via double solenoid valve: Electrical circuit diagram
with indirect control
The two pushbuttons act indirectly on the coils of a double solenoid valve.

Solenoid coil 1M1 is energised if pushbutton S1 is pressed. The double solenoid

valve switches and the piston rod advances. If the pushbutton is released during the
advancing movement, the piston rod nevertheless moves into the forward end
position, since the current switching position is maintained via a detent.
Solenoid coil 1M2 is energised if pushbutton S2 is actuated. The double solenoid

valve switches again and the piston rod retracts. The switching position is
maintained by means of the detent even without current.
Automatic return stroke The piston rod of a double-acting cylinder is to advance if pushbutton S1 is pressed.
control via double solenoid The piston rod is to automatically retract once the forward end position is reached.
valve
1A1 1B1
1V1 A B
1M1 1M2
P T
Automatic return stroke control using signal storage via double solenoid valve: Hydraulic circuit diagram
24 V 1 2 3 4
S1 1B1 K1 K2
K1 K2 1M1 1M2
0V
Automatic return stroke control using signal storage via double solenoid valve: Electrical circuit diagram with
indirect control

The circuit diagrams show the following: If pushbutton S1 is briefly pressed,

solenoid coil 1M1 is energised and the piston rod advances. The valve position is
maintained by means of the detent even without current. Limit switch 1B1 switches
if the piston rod reaches the forward end position. Current flows through the
solenoid valve 1M2 and the piston rod retracts.
The precondition for retracting is that pushbutton S1 must be released beforehand.
Oscillating movement with The piston rod of a double-acting cylinder is to automatically advance and retract as
double solenoid valve soon as limit switch S1 is actuated. The piston rod is to assume its retracted end
position if the control switch is reset.
1A1 1B1 1B2
1V1 A B
1M1 1M2
P T
Automatic advance and return stroke control using signal storage via double solenoid valve: Hydraulic circuit
diagram
24 V 1 2 3 4
S1 1B2 K1 K2
1B1
K1 K2 1M1 1M2
0V
Automatic advance and return stroke control using signal storage via double solenoid valve: Electrical circuit
diagram using indirect control

At the start the control system is the initial position. The piston rod is retracted and
limit switch 1B1 is actuated. The piston rod advances if the contact of S1 is closed.
When the forward end position is reached, limit switch 1B2 is actuated and the
piston rod retracts. If the contact of S1 is still closed, a new movement cycle is
started when the retracted end position is reached. If the contact of S1 has been
opened in the meantime, the piston rod remains in the retracted end position.
Relay circuit with self- Current flows through the relay coil if the ON pushbutton of the circuit shown is
latching loop pressed. The relay picks up and contact K1 closes. Once the ON pushbutton is
released, current continues to flow through contact K1 via the coil and the relay
remains in the actuated position. The ON signal is stored. This is known as a relay
circuit with self-latching loop.
24 V 1 2 24 V 1 2
EIN K1 EIN K1
AUS AUS
K1 K1
0V Dominierend 0V Dominierend
EIN AUS
Dominant setting Dominant resetting
Self-latching loop
If the OFF pushbutton is pressed, the current flow is interrupted and the relay drops
out.
If the ON and OFF pushbuttons are pressed simultaneously, then the two circuits
exhibit different behaviour:
In the dominant setting self-latching circuit current flow through the relay K1,
whereas in the dominant resetting self-latching circuit no current flows through the
relay K1.

Manual advance and return The piston rod of a double-acting cylinder is to advance if pushbutton S1 is pressed
stroke control via relay with and to retract if pushbutton S2 is pressed. A relay with self-latching loop is to be
self-latching loop used for signal storage.
1A1
1V1 A B
1M1
P T
Manual advance and return stroke control with signal storage via self-latching relay: Hydraulic circuit diagram
24 V 1 2 3
S1 K1 K1
(EIN)
S2
(AUS)
K1 1M1
0V
Manual advance and return stroke control with signal storage via self-latching relay: Electrical circuit diagram
Relay K1 moves into the self-latching loop if pushbutton S1 is pressed. The

directional control valve is actuated via a further relay contact of K1 and the piston
rod advances. The piston rod retracts if the self-latching loop is interrupted via the
actuation of pushbutton S2.
Since the self-latching loop in question is dominant resetting, actuation of both

pushbuttons causes the piston rod to retract or remain in the retracted end position.

Comparison of signal Signal storage can be effected via a double solenoid valve in the power section or
storage via double solenoid via a relay with self-latching loop in the signal control section. The two different
valve and self-latching relay circuits exhibit different behaviour in the case of simultaneously available setting
and resetting signals as well as in the event of a power failure or cable fracture.
Comparison of signal storage via self-latching loop and double solenoid valve
Signal storage via Signal storage via electrical latching circuit,

double solenoid combined with spring-return valve
valve
Dominant setting Dominant resetting
Setting and resetting Valve position Valve is actuated Valve switches to

signal simultaneous unchanged normal position
Electrical power Valve position Valves switches to Valve switches to

failure unchanged normal position normal position
8.5 With many applications it is necessary for the piston rod of a hydraulic cylinder to
Delay remain in a position for a defined time period, such as in the case of the drive of a
pressing device. The pressing device presses two workpieces against one another
until the adhesive has bonded.
Pick-up delay relays or drop-out delay relays are used for tasks of this type.

Control of a cylinder with The piston rod of a cylinder is to advance if pushbutton S1 is pressed, to remain in
timing the forward end position for ten seconds and to retract again automatically.
1A1 1B1
1V1 A B
1M1 1M2
P T
Delayed retraction (pick-up delay relay, storage via double-solenoid valve): Hydraulic circuit diagram
24 V 1 2 3 4
S1 1B1 K1 K2
K1 K2 1M1 1M2
0V
Delayed retraction (pick-up delay relay, storage via double solenoid valve): Electrical circuit diagram
The diagram shows the electrical circuit diagram for delayed retracting. The piston
rod advances if pushbutton S1 is pressed. When the forward end position is
reached, limit switch 1B2 closes and current flows through coil K2. Contact K2 still
remains open for the duration of the time delay.Only when the time delay has
elapsed, does contact K2 close and the piston rod retract.

8.6 Sequence control systems require signals to be stored. This can be effected either
Sequence control with via self-latching relays or via double solenoid valves. The design of a circuit with
signal storage via double signal storage via double solenoid valves is explained below.
solenoid valves
Application example: A container handling device is used in a production line. The containers arrive at
Container-handling device roller conveyor 1, are lifted and transferred to roller conveyor 2.
The container handling device features two double-acting hydraulic drive
cylinders.
Cylinder 1A1 is used to lift a containers. Two inductive sensors 1B1 (retracted
end position) and 1B2 (forward end position) and a 4/2-way double solenoid
valve 1V1 with solenoid coils 1M1 and 1M2 are allocated to the cylinder.
Cylinder 2A1 executes the transfer function. This cylinder is allocated limit
switches 2B1 (retracted end position) and 2B2 (forward end position), as well as
a 4/2-way double solenoid valve 2V1 with solenoid coils 2M1 and 2M2.
The lifting speed is set independent of load by means of a
2-way flow control valve 1V3. A non-return valve 1V2 is used for the transition to
lowering.
The lowering speed is set by means of a one-way flow control valve 1V4.
A further flow control valve 2V2 is used to set the transfer speed
A conveying cycle is triggered by pressing pushbutton S1: The conveyor on roller
conveyor 1 is lifted. When the container has reached its upper position, it is
transferred to a second roller conveyor. The lifting and transfer devices then
simultaneously return into the initial position.
Three steps are required for a conveying cycle:

Step 1:
Step 2:
Step 3:
Piston rod of cylinders 1A1 to retract. The lifting device moves back.

2B1
2A1
2B2
1B2 1A1
1B1

Displacement-step diagram The program controlled motion sequence of the container handling process can be
of container handling device clearly represented in a displacement-step diagram. If the control system is too
complex, then only the motion sequence of the working components is shown. A
GRAFCET chart can be used to clearly represent the signal control section.
S1
1B1
2B1
1 2 3 4=1
1
1B2
Cylinder 1A1
0
1B1
1
2B2
Cylinder 2A1
0
2B1
Displacement-step diagram of container handling device

GRAFCET of container Another form of representing sequence control systems is GRAFCET. This clearly
handling illustrates the sequence of the individual steps and step enabling conditions. The
step enabling conditions indicate the signal states which must exist in order for the
respective subsequent step to be executed.
The GRAFCET representation is recommended for complex sequence control
systems.
1 "Initial step"
S1*1B1*2B1 "Start condition"
2 1M1:=1 1M2:=0 "Lifting"
1B2 "Lifting up"
3 2M1:=1 2M2:=0 "Transferring"
2B2 "Transferring at front"
4 1M2:=1 1M1:=0 "Lifting device to retract"
2M2:=1 2M1:=0 "Transfer device to retract"
1B2*1B2 "Lifting down and transferring retracted"
GRAFCET for container handling device
In the GRAFCET for the container handling device, step 1 is the initial step. Step 1 is
vacant in this application and therefore does not include any actions. The actions of
step 2 are executed as soon as the start condition is fulfilled: The lifting device
moves up. The actions are realised as latching actions and are executed when the
step is activated. Being latching actions, they will still be executed if step 2 is no
longer active. This is necessary, since the lifting platform is to remain in the upper
position until the container has been transferred to the second roller conveyor. For
this reason, the lifting platform is only moved down again in step 4. The valves for
the actuation of the drives are double solenoid valves. To ensure that the valve
switches into the desired switching position, both valve coils are assigned the
required values.

Hydraulic circuit diagram of The control system is realised with the use of double-acting cylinders and 4/2-way
container handling process double solenoid valves. Additional valves such as flow control valves or one-way
flow control valves are required to adjust the speed of the working components.
1A1 2A1 2B1 2B2
1B2
1B1
A B
1V4 2V2
B A
B
1V3
1V2
1V1 A B 2V1 A B
1M1 1M2 2M1 2M2

P T P T
Lifting Transferrring
Hydraulic circuit diagram of the container handling device

Design of the relay circuit A systematic approach should be adopted when designing the relay circuit diagram.
diagram It is advisable to first of all plan the circuit diagram for the sensor evaluation and the
start button S1. This circuit diagram is then expanded with the addition of the
individual sequential steps. The planned steps are shown below.
Sensors
Control circuit: proximity switches, limit switch and pushbutton
Sequence and valve actuation
Control circuit and main circuit: first sequence step
Control circuit and main circuit: second sequence step
Control circuit and main circuit: third sequence step
Procedure for the design of the relay circuit diagram for the container handling device

Sensor evaluation In a relay circuit, the input signals of the control system are interlinked via contacts.
The electronic proximity sensors used in this case do not have any contacts, but
instead generate the output signal via an electronic circuit. Each sensor signal, this
also includes the signals of pushbuttons and control switches, are therefore routed
to the coil of a relay, which in turn switches the necessary contacts. For example, if
proximity sensor 1B1 responds, current flows through the coil of relay K1. The
corresponding contacts switch into the actuated position.
24 V
1B1 1B2
2B1 2B2 S1
K1 K2 K3 K4 K5
0V
Electrical circuit diagram with sensor evaluation

First sequential step In order to start the sequence, the following preconditons must be fulfilled:
The piston rod of cylinder 1A1 is in the retracted end position (proximity sensor
1B1 and relay K1 are actuated),
The piston rod of cylinder 2A1 is in the retracted end position (limit switch 2B1
and relay K3 are actuated),
Start button S1 and therefore also relay K5 are actuated.
If all the conditions are fulfilled, relay coil K6 picks up. Valve coil 1M1 is actuated
and the piston rod of cylinder 1A1 advances.
24 V
1B1 1B2
2B1 2B2 S1 K5 K6
K1
K3
K1 K2 K3 K4 K5 K6 1M1
0V
Electrical circuit diagram with sensor evaluation and 1 sequential step

Second sequential step As soon as the piston rod of cylinder 1A1 reaches the forward end position, sensor
1B2 responds. Relay K2 switches and the second sequential step is activated. Valve
coil 2M1 is actuated and the piston rod of drive 2A1 advances.
24 V
1B1 1B2
2B1 2B2 S1 K5 K6 K2
K1
K3
1M1 2M1
K1 K2 K3 K4 K5 K6
0V
Electrical circuit diagram with sensor evaluation and first and second sequential steps

Third sequential step Sensor 2B2 responds if the piston rod of cylinder 2A1 reaches the forward end
position and the third sequential step is actuated. Valve coils 1M2 and 2M2 are
actuated and the piston rods of drives 1A1 and 2A1 retract simultaneously.
24 V
1B1 1B2
2B1 2B2 S1 K5 K6 K4 K2 K4
K1
K3
1M1 1M2 2M1 2M2

K1 K2 K3 K4 K5 K6
0V
Electrical circuit diagram with sensor evaluation and all sequential steps

The illustration shows the entire electrical circuit diagram of the container handling
device, complete with connection designations, switching element table and current
path designations.
24 V 1 2 3 4 5 6 7 8 9 10 11 12
BN BN
1B1 1B2
BK BK 2 4 2 4 13 12 14 12 14 12 14 12 14 22 24
2B1 2B2 S1 K5 K6 K4 K2 K4
1 1 14 11 11 11 11 21
BU BU
12 14
K1
11
12 14
K3
11
1M1 1M2 2M1 2M2

K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12
11 14 .8 11 14 .11 11 14 .8 11 14 .10 11 14 .8 11 14 .9
22 22 22 22 22 22
21 24 21 24 21 24 21 24 .12 21 24 21 24
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44
Electrical circuit diagram of container handling device
Note All relay contacts are in the form of changeover contacts.

The contact of the limit switch is in the form of a changeover contact.
The contacts of the pushbutton and switch are in the form of normally closed and
normally open contacts.

8.7 Relay control systems for electrohydraulic systems incorporate:

Circuit for evaluating The sequence of the system
control elements The operation of the system
Procedure for designing A standard circuit for the evaluation of the control elements usually provides the
basis for the design of a relay circuit. The standard circuit is then extended with
control-specific functions, such as sequence control and logic operations.
Relay circuit for evaluating It is stipulated that control switches (latching-type switches) must be used for
control elements switching on electrical power and for the EMERGENCY STOP function. All other
control elements may take the form of either pushbuttons (momentary-contact
switches) or control switches. In the circuit shown, the control elements for
"Manual", "Reset", "Automatic", "Continuous cycle ON", "Continuous cycle OFF"
and "Single cycle Start" are implemented as pushbuttons, as are the elements for
individual movements

24 V 1 2 FROM POWER SUPPLY UNIT
236
MAIN
SWITCH K1
ON/OFF
3 4 5 SYSTEM ENERGIZATION
EMER-
GENCY K2 K2
STOP
EMERGENCY STOP
6 7 8 7 10 11 EMERGENCY STOP RELEASED
AUT K3 MAN K4 K3 K4
12 13 MANUAL
RESET
K4 K3
RESET
SETTING UP/
INDIVIDUAL 14 15
MOVEMENTS
1A1+ 2A1+ 3A1+
16 17 18 AUTOMATIc
COUNTINOUS SINGLE
CYCLE CYCLE
ON K5 START K5
Design of a relay control system with selection of operating modes by pushbutton

COUNTINOUS
CYCLE START-
OFF CONDITION
S8
K1 K2 K3 K4 (Continuous K5 K6 K6 = First stage
cycle Control unit
OFF)
0V

Main switch When the main switch is closed, relay K1 is energised. Voltage is supplied to the
signal control section and the entire system via contact K1.
EMERGENCY STOP If the EMERGENCY STOP switch is actuated, relay K2 is de-energised and the
associated contacts switch to the normal position.
The EMERGENCY STOP line is connected to the supply voltage via the normally
closed contact of K2. Warning lamps can be actuated via this line, for example.
The "EMERGENCY STOP released" line is de-energized, causing the voltage
supply to the signal control section to be interrupted. As long as EMERGENCY
STOP applies, all control elements except the main switch are rendered
inoperative.
Manual operation When the "Manual" pushbutton is actuated, relay K4 picks up and latches. The line
marked "Manual" in the circuit diagram is connected to the supply voltage. If relay
K3 is latched, the latching is released. The line marked "Automatic" is disconnected
from the supply voltage.
Reset, setup, individual These functions can only be executed in manual mode. Power is therefore supplied
movements to the associated contacts and relays via the line marked "Manual".
Automatic operation When the "Automatic" pushbutton is actuated, relay K3 is energised and latches.
The line marked "Automatic" in the circuit diagram is connected to the supply
voltage. If relay K4 is latched, the latching is released, and the line marked
"Manual" is disconnected from the supply voltage
Continuous cycle ON, These functions are only possible in automatic operation. Electrical power is
Continuous cycle OFF, therefore supplied to the associated contacts and relays via the line marked
Single cycle Start "Automatic".
If "Automatic" operation is selected (relay K3 latched) and "Continuous cycle ON" is
active (relay K5 latched), the control system runs in continuous operation. This
means that when one movement cycle is completed, the next one follows
automatically.
Actuating the "Continuous cycle OFF" pushbutton releases the latching of relay K5.
The program-controlled sequence stops as soon as the last step in the sequence is
completed.
When the "Single cycle Start" pushbutton is actuated, the sequence (movement
cycle) is executed once only.

8.8 The design of a relay control system is explained stating clearly defined
Sequence control system requirements with regard to operation, performance and behaviour in the event of a
for a sawing machine fault.
Description of sawing A sawing machine cuts metal tubing into segments of a specific size.
machine The sawing machine incorporates the follwing functions: Conveying of material,
clamping of material, moving the saw slide.
The sawing machine is equipped with three double-acting hydraulic drive
cylinders.
Cylinder 1A1 conveys the material to the saw. The following are allocated to this
cylinder: Two limit switches 1B1 (retracted end position) and 1B2 (forward end
position), as well as a 4/3-way solenoid valve, mid position closed, with solenoid
coils 1M1 and 1M2.
Cylinder 2A1 clamps the material for the conveying function and during the
sawing process. An inductive sensor 1B2 detects the retracted end position of
the cylinder. The clamping pressure whilst the cylinder is advancing is monitored
by means of a pressure switch 1B1. A 4/3-way valve, with freely movable
position and coils 2M1 and 2M2, is used to control the drive.
Cylinder 3A1 moves the saw slide. The following are allocated to this
cylinder:Two inductive sensors 3B1 (retracted end position) and 3B2 (forward
end position), as well as a 4/3-way solenoid valve, mid-position closed, with
solenoid coils 3M1 and 3M2.
The retract and advance speed of the conveying cylinder is adjusted each with a
one-way flow control valve.
The clamping speed is adjusted by means of a one-way flow control valve. A
piloted non-return valve ensures that the clamping position is maintained even in
the event of a power failure.
A 2-way flow control valve is used to adjust the feed speed of the saw slide
independent of load. The counter pressure is effected by means of a pressure
relief valve.
In the event of a power failure, all three drive cylinders remain in their current
position.
The sawing machine has standard operating functions:
Main switch (S1)
EMERGENCY-STOP (S2)
Manual (S3)
Reset (S5)
Automatic (S4)
Continuous cycle ON (S6)
Continuous cycle OFF (S8)
Individual cycle Start (S7)

Six steps are required for a sawing cycle:

Step 1:
Piston rod of cylinder 2A1 advances. The material is clamped.
Step 2:
Piston rod of cylinder 1A1 advances. The material is conveyed to the sawing
device.
Step 3:
Piston rod of cylinder 3A1 advances. The saw slide advances. The material is
sawed.
Step 4:
Piston rod of cylinder 3A1 retracts. The saw slide moves back.
Step 5:
Piston rod of cylinder 2A1 retracts. The material is no longer clamped.
Step 6:
Piston rod of cylinder 1A1 retracts. The conveying device moves back.
The control system of the sawing machine is to be realised in the form of a relay
control system with reset sequencer.

3B1
3B2
3A1
Sawing
Feed
1A1
2A1
2B1
Clamping
2B2
1B1
1B2
Positional sketch of sawing machine

The displacement-step diagram illustrates the motion sequence of the working

components of the sawing machine.
S4 (AUT)
S6
S7
1B1
2B2
3B1
1 2 3 4 5 6 7=1
1
1B2
Cylinder 1A1
Feed
0
1B1
1
2B1
Cylinder 2A1
Clamping
2B2
0
1
3B2
Cylinder 3A1
Sawing
3B1
0
Displacement-step diagram of the working components of the sawing machine

The complex control sequence of the sawing machine is clearly illustrated and
specified using GRAFCET.
1 "Initial start step "
S7*1B1*2B2*3B1 "Start condition"
2 2M2 "Clamp material"
2B1 "Clamping pressure reached"
3 1M2 "Transfer material"
1B2 "Feed at front"
4 3M2 "Saw slide to advance"
3B2 "Saw slide at front"
5 3M1 "Saw slide to retract"
3B1 "Saw slide at rear"
6 2M1 "Release material"
2B2 "Clamping device retracted"
7 1M1 "Conveying device to retract"
1B1 "Conveying device retracted"
GRAFCET for sawing machine
Hydraulic circuit diagram of The hydraulic circuit diagram for the sawing machine is drawn up as soon as the
the sawing machine operating sequence and the components of the sawing machine are defined.
Please note: For reasons of clarity, the circuit of the hydraulic power pack is
represented in a simplified form.

3V5
P
3M2
3V4
3Z1
3V3
T
B
B
P
3V1
3A1
3V2
3M1
3B2
3B1
2M2
2B1
T
B
X
B
B
2Z1
A
A
P
2V3
2V2
2V1
2A1
2M1
2B2
1V3
1B2
1M2
1B1
B
A
T
B
A
P
1A1
B
A
1V2
1V1
1M1
Hydraulic circuit diagram of sawing machine

Design of relay control The control system of the sawing machine is to be realised in the form of a relay
system control system with reset sequencer.
The relay control system is designed in the following order:

Voltage supply
Sensor evaluation
Operation
Program actuated sequence
Circuitry of solenoid coils
The flow chart shows the various steps of the proposed circuit diagram.

Power supply
Power supply: main switch, EMERGENCY STOP
Sensors
Control circuit: sensors
Operation
Control circuit: Manual, Reset control elements
Control circuit: Control elements - Automatic, Continuous

cycle ON, Continuous Cycle OFF, Single cycle Start
Sequence
Control circuit: step 1
Valve actuation
Main circuit: solenoids 1 to 6
Procedure for the design of the relay circuit diagram for the sawing machine

Due to the complexity of the circuit diagram, the circuit is represented in six part-
steps.
Control elements: Main A standard circuit is used to evaluate the control elements. The evaluation of the
switch (S1) and control elements main switch and EMERGENCY-STOP are simplified in contrast to the
EMERGENCY-STOP (S2) standard circuit, since the EMERGENCY-STOP signal is only required in inverted
form. The illustration shows the corresponding circuit diagram.
24 V
S1 K1
(Main
switch) SYSTEM ENERGIZATION
S2 K2
(EMERGENCY
STOP) EMERGENCY STOP RELEASED
K1 K2
0V
Relay circuit for the control elements main switch and EMERGENCY-STOP

Please note: For reasons of simplification, the voltage supply and evaluation of the
status of the hydraulic power pack have not been taken into consideration in the
relay circuit diagram.
Sensor evaluation Power is supplied to the sensors for as long as EMERGENCY-STOP is not actuated.
Relays K6 to K11 are allocated to the sensors 1B1 to 3B2.
EMERGENCY STOP
24 V RELEASED 24 V
2B2 3B1 3B2

2B1
1B1 1B2 >p
K6 K7 K8 K9 K10 K11
0V 0V
Relay circuit diagram for sensor evaluation
Control elements: Manual The circuit diagram shows the evaluation of the control elements "manual" and
(S3) and reset (S5) "reset". Evaluation of the manual pushbutton is effected according to the
standard circuit for the control elements. If pushbutton S3 for "manual" is actuated,
relay K4 switches to the self-latching loop triggered via relay K3. Relay K3 switches
as soon as the automatic mode selector switch is actuated.

The piston rods of cylinders 1A1, 2A1 and 3A1 stop in the current position if the
EMERGENCY-STOP pusbutton is pressed. The drives must be returned to the initial
position in order to render the control system ready for operation. The reset
sequence is used for this.
If manual mode is selected and pushbutton S5 "reset" is actuated, relay K12

switches to the self-latching loop. The reset sequence is completed if the piston rods
of the cylinders assume the following positions:
Cylinder 1A1:
Retracted end position (sensor 1B1 responds, relay K6 is actuated)
Cylinder 2A1:
Retracted end position (sensor 2B2 responds, relay K8 is actuated.)
Cylinder 3A1:
Retracted end position (sensor 3B1 responds, relay K10 is actuated)
The self-latching loop of relay K12 is released via the normally closed contacts K6,
K8 and K10, if all three conditions are fulfilled.
EMERGENCY STOP
24 V RELEASED 24 V
S3 K4 K4
(MAN)
MANUAL
K3 S5 K12
(RESET)
K6 K8 K10
K4 K12
0V 0V
Relay circuit diagram for the control elements "manual" and "reset"

Control elements:- The pushbuttons "automatic", "continuous cycle ON" and "continuous cycle OFF
Automatic, (S4), continuous are evaluated according to the standard circuit. "Continuous cycle ON" is stored via
cycle ON (S6), continuous the self-latching loop of relay K5. The self-latching loop of relay K5 is released by
cycle OFF (S8) actuating the "continuous cycle OFF" pushbutton.
The self-latching loop of relay K3 for the "automatic" mode is released by actuating
pushbutton S3 for manual".
EMERGENCY STOP
24 V RELEASED 24 V
S4 K3 K3
(AUT)
AUTOMATIC
K4 S6 K5
(Continuous
cycle ON)
S8
(Continuous
cycle OFF)
K3 K5
0V 0V
Relay circuit diagram for the control elements "automatic", "continuous cycle ON", "continuous cycle OFF"
The pushbutton individual cycle Start is evaluated in the executive part of the
relay circuit diagram.

Reset sequencer with self- Various options are available to realise a step-by-step execution using a relay
latching relay en Relais control system. Here, a reset sequencer is used.
The motion sequence consists of six steps. Relays K13 (for step 1) to K18 (for step 6)
are allocated to these six steps.
Step Movement Movement Movemenet End of step, step enabling Comment

piston rod piston rod Piston rod condition to the next step
cylinder 1A1 cylinder 2A1 cylinder 3A1
feeding clamping sawing
1 None Advance None Pressure switch 2B1 responds Clamping of material
2 Advance None None Limit switch 1B2 responds Feeding of material
3 None None Advance Inductive sensor 3B2 responds Advancing of saw slide
4 None None Retract Inductive sensor 3B1 responds Retracting of saw slide
5 None Retract None Inductive sensor 2B2 responds Releasing of material
6 Retract None None Limit switch 1B1 responds Retracting of conveying device
Motion sequence of the sawing machine
The diagram shows the basic design of the resetting sequencer using signal storage
via self-latching relays.

24 V AUTOMATIC

Setting condition Setting condition Setting condition Setting condition Setting condition Setting condition
for step 1 for step 2 for step 3 for step 4 for step 5 for step 6
K18 K13 K13 K14 K14 K15 K15 K16 K16 K17 K17 K18 K19 K18 K19
Basic design of the resetting sequencer for the sawing machine

K14 K15 K16 K17 K18 K13
K13 K14 K15 K16 K17 K18 K19
0V 0V
251
Latching of steps The mode of operation of the resetting sequencer is explained using the example of
the 2nd sequential step.
If the preceding step is set here step 1, the normally open contact of relay K13 is
closed and the other setting conditions for step 2 are fulfilled, relay K14 moves to
the self-latching loop. The self-latching loop of relay K13 is interrupted via the
normally closed contact of relay K14, thereby setting the second sequential step and
deactivating the first sequential step.
Since, in continuous operation, step 1 follows step 6 again, the normally closed
contact K13 of step 1 is used to interrupt the self-latching loop for relay K18 of the
last step.
Start condition of the To enabIe the sequence to start, the sixth sequential step (relay K18) must be
resetting sequencer activated. When switching into automatic operation, relay coil K18 is therefore
activated via the automatic string and the normally closed contact K19. Relay K18
switches to the self-latching loop. Current flows through the coil of relay K19 via a
normally open contact of K18, and the relay K19 also switches to the self-latching
loop. Current no longer flows via the normally closed contact of K19.
Relay K19 remains in the self-latching loop for as long as the "automatic" string is
actviated. Relay K19 thereby indicates that the start condition is no longer fulfilled.
Note The relays K1 to K12 are already in use for the control elements and sensor
evaluation.

Step enabling conditions The step enabling conditions for all six sequential steps are set out in one table. To
ensure the desired sequence, all of the steps can only be set if the relay of each of
the preceding steps is activated.
Step enabling condition Mode of operation, control Actuated sensor(s) with associated Active step with associated
element relay relay
Start of 1st step S7 or K5 1B1 (K6) and 2B2 (K8) and 3B1 (K10) 6 (K18)
Step 1 after step 2 Without condition 2B1 (K9) 1 (K13)
Stept 3 after step 4 Without condition 3B2 (K11) 3 (K15)
Step enabling conditions for the six sequential steps
Relay circuit diagram for the The relay circuit to realise the six sequential steps is obtained by transferring the
program controlled step enabling conditions to the resetting sequencer.
sequence

254
24 V AUTOMATIC
(Single
cycle
START)
Relay circuit diagram for the six sequential steps

K6
K8 K13 K14 K15 K16 K17
K10
K18
K14 K15 K16 K17 K18 K13
K13 K14 K15 K16 K17 K18 K19
0V 0V

Start of 1st sequential step In order for the first sequential step to be activated, the following conditions must
be fulfilled:
Piston rod of cylinder 1A1 in the retracted end position
(Relay K6 activated)
Piston rod of cylinder 2A1 in retracted end position
(Relay K8 activated),
Piston rod of cylinder 3A1 in retracted end position
Step 6 active
Either continuous cycle active (relay K5 in the self-latching loop) or individual
cycle Start (pushbutton S7) activated.
If all of the conditions are fulfilled, relay K13 switches to the self-latching loop and
the first step is active.
Advancing from the 1st to 2 nd The setting condition for the second step is fulfilled if pressure switch 1B2 responds
sequential step whilst the second sequential step is active. The step is activated via the activation of
relay K14. Relay K14 switches to the self-latching loop. The self-latching loop of
relay K13 is interrupted via the normally closed contact K14, as a result of which the
first sequential step is de-activated.
Advancing from the 2nd to Relay K15 switches to the self-latching loop if limit switch 1B2 responds whilst the
the 3rd sequential step second sequential step is active. The self-latching loop of relay K14 is interrupted.
Advancing from the 3rd to Relay K16 switches to the self-latching loop if the inductive sensor 3B2 responds
the 4th sequential step whilst the third sequential step is active. The self-latching loop of relay K15 is
interrupted.
Advancing from the 4th to Relay K17 switches to the self-latching loop if the inductive sensor 3B1 responds
the 5th sequential step whilst the fourth step is active. The self-latching loop of relay K16 is interrupted.
Advancing from the 5th to Relay K18 switches to the self-latching loop if the inductive sensor 2B2 responds
the 6th sequential step whilst the fifth sequential step is active. The self-latching loop of relay K17 is
interrupted.

Advancing from the 6th to The same conditions as those for starting the first sequential step apply for
the 1st sequential step advancing from the sixth to the first sequential step.
Primary circuits All of the six solenoid coils of the directional control valves are actuated via the
primary circuits. In order for the coils to be supplied with energy, the main switch
must be in the ON position and the EMERGENCY STOP unactivated. The additional
conditions for the activation of solenoid coils are listed in the table.
Solenoid coil Effect Condition (with actuated relay) Comment
1M1 Cylinder 1A1 retracts Step 6 (K18) or reset (K12) Retracting of conveying device
1M2 Cylinder 1A1 advances Step 2 (K14) Advancing of material
2M1 Cylinder 2A1 retracts Step 5 (K17) or reset (K12) Releasing of material
2M2 Cylinder 2A1 advances Step 1 (K13) Clamping of material
3M1 Cylinder 3A1 retracts Step 4 (K16) or reset (K12) Retracting of saw slide
3M2 Cylinder 3A1 advances Step 3 (K15) Advancing of saw slide
Conditions for the actuation of solenoid coils

The diagram shows the circuitry of the solenoid coils.
EMERGENCY STOP
24 V RELEASED
K18 K12 K14 K17 K12 K13 K16 K12 K15
1M1 1M2 2M1 2M2 3M1 3M2
0V
Circuitry of the solenoid coils of directional control valves

List of relays The table below includes all the relais with the associated functions used for the
control of the sawing machine.
Relay number in Relay type/ Function

the circuit circuit type
diagram
K1 Standard Switching of electrical energy, main switch S1
K2 Standard EMERGENCY-STOP, S2
K3 Self-latching Automatic operation, S4
K4 Self-latching Manual operation, S3
K5 Self-latching Continuous cycle, S6
K6 Standard Limit switch 1B1
K7 Standard Limit switch 1B2
K8 Standard Inductive sensor 2B2
K9 Standard Pressure switch 2B1
K12 Self-latching Reset, S5
K13 Self-latching Step 1
K19 Self-latching Start condition of sequencer
Relay functions

List of control elements The table includes all the switches and pushbuttons used for the control of the
sawing machine.
Switch number Type Comment
S1 Switch Main switch
S2 Switch EMERGENCY-STOP (normally closed contact!)
S3 Pushbutton Manual (MAN)
S4 Pushbutton Automatic (AUT)
S5 Pusbutton RESET
S6 Pushbutton Continuous cycle ON
S7 Pushbutton Single cycle START
S8 Pushbutton Continuous cycle OFF
Control element functions
Complete electrical circuit Please note:

diagram of the sawing For reasons of simplification, the hydraulic power pack is not taken into account
machine in the electrical circuit diagram.
All relay contacts are in the form of changeover contacts.
The contact of the limit switch is in the form of a changeover contact.
The contacts of pushbuttons and switches are in the form of normally closed and
normally open contacts.

24 V 1 2
...
260
3 12 14
S1 K1
(Main 4 11 SYSTEM
switch) 3 4 ENERGIZATION
...
11 12 14
S2 K2
(EMER- 12 11 EMERGENCY STOP
GENCY RELEASED 5 6 7 8 9 10 11 12 24 V
STOP) Part 2/4
13 12 14 22 24 13 22 24 32 34
S3 K4 K4 S4 K3 K3
(MAN) 14 11 21 (AUT) 14 21 31
MANUAL 13 AUTOMATIC
...
Part 3/4
12 14 13 12 14 32 34 13 12 14
K3 S5 K12 K4 S6 K5
11 (RESET) 14 11 31 (Continuous 14 11
cycle
ON)
12 14 12 14 12 14 11
K6 K8 K10 S8
11 11 11 (Continuous 12
cycle
OFF)
Electrical circuit diagram of the sawing machine Part 1/4: Control elements
K1 K2 K4 K12 K3 K5
A2 A2 A2 A2 A2 A2
Part 2/4
0V 12 12 12 12 12 12 0V
11 14 .2 11 14 .4 11 14 .6 11 14 .8 11 14 .5 11 14 .13
22 22 22 22 22 22
21 24 21 24 21 24 .7 21 24 .40 21 24 .11 21 24 .24
32 32 32 32 32 32
31 34 31 34 31 34 .10 31 34 .43 31 34 .12 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 .46 41 44 41 44

EMERGENCY STOP
24 V RELEASED 14 15 16 17 18 19 20 21 22 24 V

2B2 BN 3B1 BN 3B2 BN
2B1
2 4 2 4 BK 2 4 BK BK
1B1 1B2 >p
1 1 1
BU BU BU
Electrical circuit diagram of the sawing machine Part 2/4: Sensor evaluation
K6 K7 K8 K9 K10 K11
A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 0V
11 14 .7 11 14 .28 11 14 .8 11 14 .26 11 14 .9 11 14 .30
22 22 22 22 22 22
21 24 .23 21 24 21 24 .23 21 24 21 24 .23 21 24
32 32 32 32 32 32
31 34 31 34 31 34 .34 31 34 31 34 .32 31 34
42 42 42 42 42 42
261
41 44 41 44 41 44 41 44 41 44 41 44
262
24 V AUTOMATIC 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
from Part 1/4
13 22 24 12 14 12 14 22 24 12 14 22 24 12 14 22 24 32 34 22 24 32 34 22 24 12 14 32 34 22 24
(Single cycle 14 21 11 11 21 11 21 11 21 31 21 31 21 11 31 21
START)
22 24
K6
21
22 24 22 24 32 34 32 34 32 34 32 34
K8 K13 K14 K15 K16 K17
21 21 31 31 31 31
22 24
K10
21
52 54
K18
51
12 14 12 14 12 14 12 14 12 14 32 34
Electrical circuit diagram of the sawing machine Part 3/4: Sequential step circuit
K14 K15 K16 K17 K18 K13
11 11 11 11 11 31
K13 K14 K15 K16 K17 K18 K19

A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 0V
11 14 .25 11 14 .23 11 14 .26 11 14 .28 11 14 .30 11 14 .32 11 14 .36
22 22 22 22 22 22 22
21 24 .26 21 24 .27 21 24 .29 21 24 .31 21 24 .33 21 24 .35 21 24 .38
32 32 32 32 32 32 32
31 34 .34 31 34 .28 31 34 .30 31 34 .32 31 34 .34 31 34 .37 31 34
42 42 42 42 42 42 42
41 44 .44 41 44 .41 41 44 .47 41 44 .45 41 44 .42 41 44 .39 41 44
52
51 54 .23

EMERGENCY STOP

24 V RELEASED 39 40 41 42 43 44 45 46 47
von Part 2/4
42 44 22 24 42 44 42 44 32 34 42 44 42 44 42 44 42 44
K18 K12 K14 K17 K12 K13 K16 K12 K15
41 21 41 41 31 41 41 41 41
Electrical circuit diagram of the sawing machine Part 4/4: Circuitry of solenoid coils
1M1 1M2 2M1 2M2 3M1 3M2
von Part 3/4
0V
263
Measures to reduce There are various measures whereby the number of relays and contacts can be
equipment and installation reduced compared to the sawing machine example mentioned above. This reduces
costs investment and installation costs, but can also lead to unwanted consequences,
particularly with regard to behaviour in the event of a fault. Whether and, if required,
what measures are useful to reduce the number of relays, greatly depends on the
application.
Measures Advantages Disadvantages
Signal storage via double Fewer relays Frequently unwanted

solenoid valves behaviour in the event of a
fault
Can only be used to a limited

extent in the case of many
control systems
Fault finding made more

difficult
Simplication of reset conditions Fewer contacts and conditions Unfavourable behaviour in the
event of fault
Possibilities for saving components in relay control systems

Index
3/2-way solenoid valve, directly actuated_________________________________ 59

4/2-way double solenoid valve, directly actuated __________________________ 64
4/3-way solenoid valve, mid-position ____________________________________ 68
4/3-way solenoid valve, piloted _________________________________________ 72
A Actuated contacts and sensors ________________________________________ 187

Actuation types _____________________________________________________ 164
Alternating current ___________________________________________________ 23
Alternative branching ________________________________________________ 150
Analogue signal______________________________________________________ 12
AND operation __________________________________________________ 214, 216
Application example
Sequence control for a sawing machine___________________________ 238
Planning of a sawing machine___________________________________ 103
Container handling device__________________________________ 128, 137
Areas of application of electrohydraulics___________________________________ 7
Automatic operation _____________________________________________ 204, 237
B Binary signal ________________________________________________________ 12
C Cable fracture _______________________________________________________ 79

Capacity __________________________________________________________ 28
Changeover contact __________________________________________________ 37
Circuit diagram
Electrical____________________________________________________ 176
Hydraulic ___________________________________________________ 162
Circuit for the evaluation of control elements _____________________________ 235
Circuit number______________________________________________________ 174
Colour coding
of control elements ___________________________________________ 204
of warning lights _____________________________________________ 205
Command execution __________________________________________________ 14
Commissioning _____________________________________________________ 124
Component number _________________________________________________ 175
Components, identification code _______________________________________ 174
Condensator ________________________________________________________ 28

Index
Conductors, electrical _________________________________________________ 24

Connection designations
of valves ________________________________________________ 162, 163
of contacts and relays _________________________________________ 184
Connection types
Surface-mounted valves ________________________________________ 84
Cartridge valves _______________________________________________ 84
Contactor __________________________________________________________ 48
Container handling device
Sequential steps _________________________________________ 224, 231
Application example __________________________________________ 224
Design of a relay circuit diagram_________________________________ 229
GRAFCET____________________________________________________ 227
Hydraulic circuit diagram ______________________________________ 228
Sensor evaluation ____________________________________________ 230
Displacement-step diagram ____________________________________ 226
Continuous cycle, ON/OFF ____________________________________________ 237
Control elements, Circuit for the evaluation of ____________________________ 235
Control panel _______________________________________________________ 202
Control switch _______________________________________________________ 36
Control
Definition _____________________________________________________ 9
of a double-acting cylinder _____________________________________ 211
of a single-acting cylinder ______________________________________ 209
Electrohydraulic _______________________________________________ 15
Relay________________________________________________________ 49
Circuit diagram of an electrohydraulic _________________________ 18, 115
Signal flow in a_____________________________________________ 14, 15
Advantages of an electrohydraulic ________________________________ 21
Current measurement _________________________________________________ 32
Current paths_______________________________________________________ 182
D Danger zones in the case of AC voltage __________________________________ 199

DC current __________________________________________________________ 23
Delay _________________________________________________________ 222
Designation of
protection class ______________________________________________ 206
electrical components _________________________________________ 183
hydraulic components _________________________________________ 175

Index
Development of a control system _______________________________________ 97

Diffuse sensor _______________________________________________________ 44
Digital signal ________________________________________________________ 12
Diode __________________________________________________________ 29
Direction of flow, technical _____________________________________________ 29
Actuation types ______________________________________________ 164
Flow rate_____________________________________________________ 88
Designation of connections_________________________________ 162, 163
Performance data _____________________________________________ 87
Mid-position_______________________________________________ 66, 68
Modular design _______________________________________________ 80
Nominal size_______________________________________________ 87, 88
Response times ____________________________________________ 87, 88
Pilot control _______________________________________________ 70, 72
Displacement-step diagram ___________________________________________ 130
Displacement-time diagram ___________________________________________ 131
Documentation _________________________________________________ 126, 127
Double-acting cylinder
Actuation of a_____________________________________________ 58, 211
Duty cycle __________________________________________________________ 92
E Earthing _________________________________________________________ 201

Effect of electrical current_____________________________________________ 198
Electrical circuit diagram__________________________________________ 176, 181
Electrical circuit ______________________________________________________ 23
Electromotive force ___________________________________________________ 25
Emergency manual override ____________________________________________ 62
EMERGENCY-STOP switch_________________________________________ 202, 237
Environmental impact ________________________________________________ 206
F Fieldbus systems____________________________________________________ 188

Function diagrams___________________________________________________ 128

Index
G GRAFCET
Sequence structure _______________________________________ 140, 149
Actions _____________________________________________________ 143
Alternative divergence_________________________________________ 150
Hierarchical levels ____________________________________________ 153
Parallel divergence ___________________________________________ 150
Steps ______________________________________________________ 141
Transitions __________________________________________________ 142
H Hydraulic power pack _________________________________________________ 35
I Identification code for components _____________________________________ 174

Individual movements____________________________________________ 204, 237
Inductivity __________________________________________________________ 27
Installation number__________________________________________________ 174
Insulators __________________________________________________________ 24
L Latching circuit
Dominant resetting ___________________________________________ 220
Dominant setting _____________________________________________ 220
Limit switches _______________________________________________________ 38
Logic control system __________________________________________________ 13
Logic operations
Parallel connection ___________________________________________ 213
Series connection ____________________________________________ 214
M Main switch ____________________________________________________ 202, 237

Maintenance _______________________________________________________ 126
Manual operation _______________________________________________ 203, 237
Measuring
Display errors_________________________________________________ 34
Error sources _________________________________________________ 33
in the electrical circuit __________________________________________ 30
Mid-position ________________________________________________________ 66

Index
N Nominal flow rate _________________________________________________ 87, 88

Nominal size _____________________________________________________ 87, 88
Normal position______________________________________________________ 59
Normally closed contacts ______________________________________________ 37
Normally open contact ________________________________________________ 36
O Ohms law __________________________________________________________ 24

OR operation ___________________________________________________ 213, 216
P Parallel divergence __________________________________________________ 150

Performance data
of a valve ____________________________________________________ 81
of 4/3-way solenoid valves _____________________________________ 87
of solenoid coils ______________________________________________ 90
Pilot control _________________________________________________________ 70
Planning of a control system ___________________________________________ 99
Planning of a sawing machine
Application example __________________________________________ 103
Selection of sensors __________________________________________ 113
Selection of valves____________________________________________ 110
Selection of cylinders _________________________________________ 108
Operation ___________________________________________________ 106
Electrical circuit diagram _______________________________________ 118
Power supply ____________________________________________ 108, 112
GRAFCET____________________________________________________ 115
Ambient conditions ___________________________________________ 108
Displacement-step diagram ____________________________________ 105
Power failure ________________________________________________________ 79
Power section _______________________________________________________ 15
Power, electrical _____________________________________________________ 25
Pressure range ______________________________________________________ 88
Pressure sensor
General ______________________________________________________ 45
Analogue ____________________________________________________ 45
Pressure switch ______________________________________________________ 45
Programmable logic controller __________________________________________ 53
Protection against direct contact _______________________________________ 201
Protection class, designation of ________________________________________ 206
Protective circuit _________________________________________________ 93, 201
Protective extra-low voltage ___________________________________________ 201
Protective measures _____________________________________________ 201, 208

Index
Proximity sensors
General ______________________________________________________ 40
Inductive_____________________________________________________ 41
Capacitive____________________________________________________ 42
Magnetic (reed switch) _________________________________________ 39
Optical ______________________________________________________ 43
Pushbutton _________________________________________________________ 36
R Realisation of a control system ________________________________________ 122

Rectifier __________________________________________________________ 35
Reed switch _________________________________________________________ 39
Relay control systems
Applications _________________________________________________ 209
Direct actuation ______________________________________________ 209
Indirect actuation_____________________________________________ 209
Relays __________________________________________________________ 48
Remanence relay_____________________________________________________ 49
Reset sequencer ________________________________________________ 244, 250
Reset _____________________________________________________ 204, 237
Resistance measurement ______________________________________________ 33
Resistor
Electrical_____________________________________________________ 24
Inductive_____________________________________________________ 27
Response times ___________________________________________________ 87, 89
Retro-reflective sensor ________________________________________________ 44
S Safety principles ____________________________________________________ 208

Safety regulations ___________________________________________________ 197
Sensors
Function _____________________________________________________ 38
Electronic ____________________________________________________ 40
Negative switching ____________________________________________ 40
Positive switching _____________________________________________ 40
Sequence control for a sawing machine
Description__________________________________________________ 238
List of relays_________________________________________________ 258
Control elements _________________________________246, 247, 249, 259
Electrical circuit diagram _______________________________________ 260
Primary circuits ______________________________________________ 256
Reset sequener ______________________________________________ 250

Index
Sensor evaluation ____________________________________________ 247

Step enabling conditions_______________________________________ 253
Sequence control ________________________________________________ 13, 224
Sequence table _____________________________________________________ 137
Servicing _________________________________________________________ 126
Setting up _________________________________________________________ 203
Signal control section ___________________________________________ 14, 15, 54
Signal flow __________________________________________________________ 14
Signal input __________________________________________________________ 4
Signal output________________________________________________________ 14
Signal processing ____________________________________________________ 14
Signal storage
via double solenoid valve __________________________________ 217, 224
via relay circuit with self-latching loop ________________________ 220, 238
Signal
General ______________________________________________________ 10
Analogue ____________________________________________________ 12
Binary _______________________________________________________ 12
Digital _______________________________________________________ 12
Signalling devices ___________________________________________________ 202
Single cycle ____________________________________________________ 204, 237
Single-acting cylinder
Actuation of a_____________________________________________ 57, 209
Solenoid coils
Operating voltage _____________________________________________ 91
Duty cycle____________________________________________________ 92
Explosion protection ___________________________________________ 95
Performance data _____________________________________________ 91
Mean pick-up time _____________________________________________ 92
Protective circuit ______________________________________________ 93
Protection class _______________________________________________ 92
Temperature data _____________________________________________ 92
Additional functions ___________________________________________ 94
Solenoid
Applications _______________________________________________ 27, 80
Mode of operation and design ___________________________________ 26
Wet solenoid _________________________________________________ 82
Dry solenoid __________________________________________________ 82
Switches __________________________________________________________ 36
Switching element table ______________________________________________ 186
Symbols
Connection designations_______________________________ 162, 163, 184
Actuation types ______________________________________________ 164
Pressure switches and pressure sensors __________________________ 172

Index
Pressure valves ______________________________________________ 165

Electrical____________________________________________________ 178
Electromechanical drives ______________________________________ 179
Energy transmission __________________________________________ 169
Hydraulic ___________________________________________________ 162
Hydraulic cylinders and hydraulic motors _________________________ 168
Measuring devices____________________________________________ 171
Proportional valves ___________________________________________ 167
Relays ______________________________________________________ 180
Switching elements ___________________________________________ 178
Contactors __________________________________________________ 180
Sensors ____________________________________________________ 181
Shut-off valves _______________________________________________ 167
Flow valves__________________________________________________ 166
Valves ______________________________________________________ 162
Directional control valves ______________________________________ 163
T Technical information ________________________________________________ 176

Terminal allocation list ___________________________________________ 192, 194
Terminal allocation __________________________________________________ 190
Terminal connection diagram __________________________________________ 187
Terminal numbers ___________________________________________________ 193
Through-beam sensor_________________________________________________ 43
Time relay __________________________________________________________ 49
Transformer _________________________________________________________ 35
V Valve connections ____________________________________________________ 84

Valve designation ____________________________________________________ 59
Valve types _________________________________________________________ 77
Voltage measurement_________________________________________________ 32
Voltage regulation____________________________________________________ 35
Volumetric flow rate __________________________________________________ 88
W Wiring
Using terminal strips __________________________________________ 189
An electrohydraulic control system ______________________________ 195

Standards
Norm
DGRL 97/23/EG Druckgerterichtlinie

05/1997 Directive concerning pressure equipment
DIN VDE 0100 Bestimmungen fr das Errichten von Starkstromanlagen mit Nennspannungen bis 1000 V
05/1973
DIN EN 418 Sicherheit von Maschinen;NOT-AUS-Einrichtung, funktionelle Aspekte; Gestaltungsleitstze

01/1993 Safety of machinery;emergency stop equipment, functional aspects; principles of design
DIN EN 982 Sicherheit von Maschinen; Sicherheitstechnische Anforderungen an fluidtechnische Anlagen und deren
09/1996 Bauteile; Hydraulik
Safety of machinery;safety requirements for fluid power systems and their components; hydraulics
DIN ISO 1219-1 Fluidtechnik;Grafische Symbole und Schaltplne;Teil 1: Grafische Symbole

03/1996 Fluid power systems and components;grafic symbols and circuit diagrams;part 1: grafic symbols
DIN ISO 1219-211/1996 Fluidtechnik;Grafische Symbole und Schaltplne;Teil 2: Schaltplne

Fluid power systems and components;grafic symbols and circuit diagrams;part 2: circuit diagrams
DIN ISO 3320

08/2001
Fluidtechnik;Durchmesser von Zylinderbohrungen und Kolbenstangen; Metrische Reihe
Fluid power systems and components;cylinder bores and piston rod diameter; metric series
DIN ISO 3322 Fluidtechnik;Zylinder; Nenndrcke

08/2001 Fluid power systems and components;cylinders; nominal pressures
ISO 4401 Fluidtechnik;4-Wege-Hydroventile; Befestigungsflchen

07/2005 Hydraulic fluid power;four-port directional control valves; works contract
DIN EN ISO 12100-1 Sicherheit von Maschinen;Grundbegriffe, allgemeine Gestaltungsleitstze;Teil 1: Grundstzliche

04/2004 Terminologie, Methodologie
Safety of machinery;basic concepts, general principles for design;part 1: basic terminology, methodology
DIN EN ISO 12100-2 Sicherheit von Maschinen;Grundbegriffe, allgemeine Gestaltungsleitstze;Teil 2: Technische Leitstze
04/2004 Safety of machinery;basic concepts, general principles for design;part 2: technical principles
DIN EN 50005 Industrielle Niederspannungs-Schaltgerte; Anschlussbezeichnungen und Kennzahlen , Allgemeine Regeln

07/1977 Low voltage Switchgear and controlgear for industrial use;terminal marking and distinctive number;
general rules
DIN EN 50011 Industrielle Niederspannungs-Schaltgerte; Anschlussbezeichnungen und Kennbuchstaben fr bestimmte

05/1978 Hilfsschtze
Low voltage Switchgear and controlgear for industrial use;terminal marking, distinctive number and
distinctive letter for particular contactor relays
DIN EN 50012 Industrielle Niederspannungs-Schaltgerte; Anschlussbezeichnungen und Kennbuchstaben fr

05/1978 Hilfsschaltglieder von bestimmten Schtzen
Low voltage switchgear and controlgear for industrial use;terminal marking and distinctive number for
auxiliary contacts of particular contactors

Standards
Norm
DIN EN 50013 Industrielle Niederspannungs-Schaltgerte; Anschlussbezeichnungen und Kennzahlen fr bestimmte

05/1978 Befehlsgerte
Low voltage switchgear and controlgear for industrial use; terminal marking and distinctive number for
particular control switches
DIN EN 60073(VDE 0199) Grund- und Sicherheitsregeln fr die Mensch-Maschine-Schnittstelle, Kennzeichnung;

05/2003 Codierungsgrundstze fr Anzeigegerte und Bedienteile
Basic and safety principles for man-machine interface, marking and identification;coding principles for
indicators and actuators
DIN EN 60204-1 Sicherheit von Maschinen; Elektrische Ausrstung von Maschinen; Teil 1: Allgemeine Anforderungen
11/1998 Safety of machinery; electrical equipment of machines; part 1: general requirements
DIN EN 60529 Schutzarten durch Gehuse (IP-Code)

09/2000 Degrees of protection provided by enclosures (IP code)
DIN EN 60617-2 Grafische Symbole fr Schaltplne; Teil 2: Symbolelemente, Kennzeichen und andere Schaltzeichen fr
08/1997 allgemeine Anwendungen
Graphical symbols for diagrams; part 2: symbol elements, qualifying symbols and other symbols having
general application
DIN EN 60617-3 Grafische Symbole fr Schaltplne; Teil 3: Schaltzeichen fr Leiter und Verbinder
08/1997 Graphical symbols for diagrams; part 3: conductors and connecting devices
DIN EN 60617-4 Grafische Symbole fr Schaltplne; Teil 4: Schaltzeichen fr passive Bauelemente

08/1997 Graphical symbols for diagrams; part 4: basic passive components
DIN EN 60617-5 Grafische Symbole fr Schaltplne; Teil 5: Schaltzeichen fr Halbleiter und Elektronenrhren
08/1997 Graphical symbols for diagrams; part 5: semiconductors and electron tubes
DIN EN 60617-6 Grafische Symbole fr Schaltplne; Teil 6: Schaltzeichen fr Erzeugung und Umwandlung elektrischer
08/1997 Energie
Graphical symbols for diagrams; part 6: production and conversion of electrical energy
DIN EN 60617-7 Grafische Symbole fr Schaltplne; Teil 7: Schaltzeichen fr Schalt- und Schutzeinrichtungen
08/1997 Graphical symbols for diagrams; part 7: switchgear, controlgear and protective devices
DIN EN 60617-8 Grafische Symbole fr Schaltplne; Teil 8: Schaltzeichen fr Mess-, Melde- und Signaleinrichtungen
08/1997 Graphical symbols for diagrams; part 8: measuring instruments, lamps and signalling devices
DIN EN 60617-12 Grafische Symbole fr Schaltplne; Teil 12: Binre Elemente

04/1999 Graphical symbols for diagrams; part 12: binary logic elements
DIN EN 60848 GRAFCET Spezifikationssprache fr Funktionsplne der Ablaufsteuerung

12/2002 GRAFCET Specification language for sequential function charts
DIN EN 60947 Niederspannungsschaltgerte; Teil 1-8

Low voltage switchgear and controlgear; part: 1-8
DIN EN 61082-1 Dokumente der Elektrotechnik; Teil 1: Allgemeine Regeln

05/1995 Preparation of documents used in electrotechnology; part 1: general requirements

Standards
Norm
DIN EN 61082-2 Dokumente der Elektrotechnik; Teil 2: Funktionsbezogene Schaltplne

05/1995 Preparation of documents used in electrotechnology; part 2: function-oriented diagrams
DIN EN 61082-3 Dokumente der Elektrotechnik; Teil 3: Verbindungsplne, Verbindungstabellen und Verbindungslisten
05/1995 Preparation of documents used in electrotechnology; part 3: connection diagrams, tables and lists
DIN EN 61346-1 Industrielle Systeme, Anlagen und Ausrstungen und Industrieprodukte; Strukturierungsprinzipien und
01/1997 Referenzkennzeichnung; Teil 1: Allgemeine Regeln
Industrial systems, installations and equipment and industrial products; structuring principles and
reference designations; part 1: discussion of concepts
DIN EN 61346-2 Industrielle Systeme, Anlagen und Ausrstungen und Industrieprodukte; Strukturierungsprinzipien und
12/2000 Referenzkennzeichnung; Teil 2: Klassifizierung von Objekten und Kodierung von Klassen
Industrial systems, installations and equipment and industrial products; structuring principles and
reference designations; part 2: classification of objects and codes for classes
DIN EN 175301-803 Bauartspezifikation: Rechteckige Steckverbinder; Flachkontakte mit 0,8 mm Dicke; Unverlierbare
10/2000 Verriegelungsschraube
Detail specification: rectangular connectors; flat contacts 0,8 mm thickness; locking screw not detachable

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Electrohydraulics

The copying, distribution and utilization of this document as well as the

2. Fundamentals of electrical technology____________________________ 23

3. Components and assemblies in the electrical signal control section ___ 35

4. Solenoid actuated directional control valves _______________________ 57

5. Design of an electrohydraulic control system ______________________ 97

Festo Didactic GmbH & Co. KG TP 601 3

6. Documentation of an electrohydraulic control system ______________ 127

7. Safety measures for electrohydraulic control systems ______________ 197

8. Relay control systems ________________________________________ 209

Index _____________________________________________________________ 265

Standards _________________________________________________________ 273

4 Festo Didactic GmbH & Co. KG TP 601

Electrohydraulics are in use in numerous areas of industrial automation. To give a

Changing requirements and technical development have distinctly changed the

March 2006 The authors

Festo Didactic GmbH & Co. KG TP 601 5

The following are used as hydraulic drives:

Applications of electrohydraulics can be found both in stationary and mobile

Important branches of electrohydraulics are:

Festo Didactic GmbH & Co. KG TP 601 7

Rotary indexing machine

8 Festo Didactic GmbH & Co. KG TP 601

Control DIN 19226, Part 1 defines the term control as follows:

Festo Didactic GmbH & Co. KG TP 601 9

Assembly device for fitting caps in locating holes

10 Festo Didactic GmbH & Co. KG TP 601

Signal and information: Signal/physical variable

Signal and information: Information, analogue

Signal and information: Information, digital

Festo Didactic GmbH & Co. KG TP 601 11

Signal and information: Information, binary

A signal is the representation of information The representation is by means of the

12 Festo Didactic GmbH & Co. KG TP 601

Binary Analogue Digital

Classification of controllers by type of information representation

Festo Didactic GmbH & Co. KG TP 601 13

Signal flow in a control system

14 Festo Didactic GmbH & Co. KG TP 601

Final control elements

Hydraulic signal control section

Signal flow Hydraulic components

Signal flow and components of a hydraulic control system

Festo Didactic GmbH & Co. KG TP 601 15

Final contol elements

Electrical signal control section

Signal flow Electrohydraulic

Signal flow and components of an electrohydraulic control system

16 Festo Didactic GmbH & Co. KG TP 601

In contrast with purely hydraulic control systems, electrohydraulic control systems

Signal Signal Signal Energy control

Control energy supply Energy supply

Interaction of signal flow with power flow

Festo Didactic GmbH & Co. KG TP 601 17

Hydraulic and electrohydraulic control systems also differ in respect of the

1A1 1B1 1B2

Circuit diagram of an electrohydraulic control system: Hydraulic circuit diagram

18 Festo Didactic GmbH & Co. KG TP 601

Circuit diagram of an electrohydraulic control system: Electrical circuit diagram

Festo Didactic GmbH & Co. KG TP 601 19

20 Festo Didactic GmbH & Co. KG TP 601

1.4 In comparison with purely hydraulic control systems, electrohydraulic control

Festo Didactic GmbH & Co. KG TP 601 21