ELECTRICAL CONTROL

SYSTEMS
HANDS-ON SKILLS FOR MODULE 3:

TIMERS AND ADVANCED SYSTEMS

ITEMS NEEDED FOR HANDS-ON SKILLS

Amatrol Supplied
1 990-EC1 Portable Electric Relay Control Workstation

School Supplied
1 Compressed Air Supply

FIRST EDITION, MODULE 3, REV. D

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol,
Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 2012 by AMATROL, INC.
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Amatrol, Inc., 2400 Centennial Blvd., Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com

L11132-AA03UEN-E1 REV. D TIMERS AND ADVANCED SYSTEMS

Copyright © 2012 Amatrol, Inc.
 SKILL 1 CONNECT AND OPERATE A CONTROL CIRCUIT
WITH A TIMER RELAY

Procedure Overview
In this procedure, you will use a time-delay relay to control a logic circuit.
You will use the normally closed contacts of the time-delay relay to turn off an
indicator lamp after a given time that you will set has elapsed.

 1. Perform the following substeps to set up the system.

A. Make sure the main power switch is off.
B. Remove any test leads on the front panel.
 2. Connect the circuit shown in figure 1-1.

PICTORIAL DIAGRAM LADDER DIAGRAM

1PB
L1 1TR L2
1 3 2
1

1TRB
1 5 2
2 R

Figure 1-1. Pictorial and Ladder Diagram Using a Time-Delay Relay

NOTE
The time-delay relay on the 990-EC1 is an on-delay type relay that uses
solid state electronic components.

L11132-AA03UEN-E1-S01, REV. D TIMERS AND ADVANCED SYSTEMS S01-1

Copyright © 2012 Amatrol, Inc.
SKILL 1 CONNECT AND OPERATE A CONTROL CIRCUIT WITH A TIMER RELAY

 Solid-state, time-delay relays use resistor-capacitor networks to perform the

time delay function. The delay is accomplished due to a characteristic of
resistor-capacitor networks called the RC time constant. The delay time is
adjusted by changing the capacitance or resistance of the circuit. This change
is accomplished by turning the timer knob to a desired time setting.
 The cost of a solid-state timer relay is very low compared to other types of
timer relays and they can easily be replaced. An example of a solid-state time
delay relay is shown in figure 1-2.

TIME DELAY
ADJUSTMENT
KNOB

TIMER
MODULE

SUBBASE

Figure 1-2. Solid-State Timer Relay

 3. Set the control knob to 5 seconds.
 4. Turn on the main power switch.
 5. Observe the red indicator lamp.
Red Lamp Status ______________________________________ (On/Off)
 The lamp should be on at this time.
 The red indicator lamp will come on when the power supply is turned on
because the power source, L1, is wired to the normally-closed contacts of the
time-delay relay.
 6. Perform the following substeps to operate the control circuit.
A. Press and hold 1PB and observe the red lamp.
Red Lamp Status ____________________________________ (On/Off)
You should observe that the lamp goes off 5 seconds after the coil is
energized.
B. Release 1PB and observe the red lamp.
Red Lamp Status ____________________________________ (On/Off)
You should observe the red lamp come on. This indicates the timer’s
contacts have reset to their normal states.

L11132-AA03UEN-E1-S01, REV. D TIMERS AND ADVANCED SYSTEMS S01-2

Copyright © 2012 Amatrol, Inc.
SKILL 1 CONNECT AND OPERATE A CONTROL CIRCUIT WITH A TIMER RELAY

 7. Set the timer control knob to zero.

 8. Perform the following substeps to operate the circuit.
A. Press and hold 1PB and observe the red lamp.
Red Lamp Status ____________________________________ (On/Off)
The red indicator lamp will immediately go off because there is no delay
time specified. Therefore, the time-delay relay functions as a standard
relay and the contacts shift without any delay when the coil is energized.
B. Release 1PB and observe the red lamp.
Red Lamp Status ____________________________________ (On/Off)
The indicator lamp will come on because the coil is deenergized and the
contacts return to their normally-closed position. This allows current to
flow to the lamp.
 9. Repeat step 7 using various settings on the timer control knob to test the
operation of a time-delay relay.
 10. Perform the following substeps to shut down the system.
A. Turn off the main power supply.
B. Remove the test leads.

L11132-AA03UEN-E1-S01, REV. D TIMERS AND ADVANCED SYSTEMS S01-3

Copyright © 2012 Amatrol, Inc.
 SKILL 2 DESIGN A TIME-DRIVEN TRAFFIC LIGHT CIRCUIT

Procedure Overview
In this procedure, you will design, connect and operate a time-delay relay
in a control circuit that will simulate a timed traffic signal.

 1. Solve the following design problem.

 Design a control circuit that will simulate a traffic signal with a pedestrian
crosswalk. The circuit should be designed so that a pushbutton switch can be
pressed to cause the traffic light to immediately turn red and stay red for 20
seconds. This will allow the pedestrians time to safely cross the intersection.
After 20 seconds, the light should change back to green.
 Draw your circuit on a separate piece of paper.
 2. Perform the following substeps to set up the system.
A. Make sure the main power switch is off.
B. Remove any test leads on the front panel.
 3. Connect the circuit that you designed in step 1.
 4. Set the control knob to the 20 second time delay.
 5. Turn on the main power switch and observe the indicator lamps.
Red Lamp Status ______________________________________ (On/Off)

Green Lamp Status _____________________________________ (On/Off)

 The green lamp should be on and the red lamp should be off indicating that
the traffic can flow through the intersection. A pedestrian cannot cross safely
at this time.
 6. Operate the circuit that you designed and connected.
 When the pushbutton is pressed, the green lamp should go off and the red
lamp should come on. This will last for 20 seconds. The lamps should then
return to their previous status.

NOTE
In reality, when the pushbutton switch is activated, the traffic light will not
immediately change to red but will first change to yellow for a few seconds to
allow the traffic time to stop.

 7. Demonstrate the circuit to your instructor.

 This is part of your skills assessment.

L11132-AA03UEN-E1-S02, REV. D TIMERS AND ADVANCED SYSTEMS S02-1

Copyright © 2012 Amatrol, Inc.
SKILL 2 DESIGN A TIME-DRIVEN TRAFFIC LIGHT CIRCUIT

 8. Perform the following substeps to shut down the system.

A. Turn off the main power switch.
B. Remove the test leads.
 9. Place a copy of your circuit design in your portfolio.

L11132-AA03UEN-E1-S02, REV. D TIMERS AND ADVANCED SYSTEMS S02-2

Copyright © 2012 Amatrol, Inc.
 SKILL 3 CONNECT AND OPERATE A CONTROL CIRCUIT TO PERFORM AN
UNLOADED START OF A MOTOR

Procedure Overview
In this procedure, you will connect and operate a control circuit that uses
a timer relay to simulate the unloaded start of a motor, such as is required on a
centrifugal air compressor.

 1. Set up the 990-EC1.

 2. Connect the circuit shown in figure 3-1.
 In this circuit the red lamp represents the motor running in the unloaded
condition.
 The green lamp will represent the motor running in the loaded condition.

L1 L2
2PB
1PB 1CR

1CRA 1TR

1CRB 1TRB
G MOTOR RUNNING
LOADED

1TRA
R MOTOR RUNNING
UNLOADED

Figure 3-1. Ladder Diagram of a Control Circuit to Simulate an Unloaded Start a

Compressor Motor

L11132-AA03UEN-E1-S03, REV. D TIMERS AND ADVANCED SYSTEMS S03-1

Copyright © 2012 Amatrol, Inc.
SKILL 3 CONNECT AND OPERATE A CONTROL CIRCUIT TO PERFORM AN UNLOADED START OF A MOTOR

 3. Set the control knob to 5 seconds.

 4. Turn on the main power switch.
 5. Press the 2PB momentarily and observe the red indicator lamp.
Red Lamp Status ______________________________________ (On/Off)
 The red lamp should come on. This represents the motor starting up in the
unloaded condition.
 6. Observe the status of the two indicator lamps after the 5 second delay.
Red Lamp Status ______________________________________ (On/Off)

Green Lamp Status _____________________________________ (On/Off)

 The red lamp should go off and the green light should come on. This indicates
that the motor is at full speed and the compressor has started compressing air.
 7. Press the stop pushbutton 1PB momentarily and observe the indicator lamps.
Red Lamp Status ______________________________________ (On/Off)

Green Lamp Status _____________________________________ (On/Off)

 Both indicator lamps should now be off. This simulates turning off the motor.
 8. Operate the circuit a few more times to get familiar with its operation.
 9. Shut down the system.

L11132-AA03UEN-E1-S03, REV. D TIMERS AND ADVANCED SYSTEMS S03-2

Copyright © 2012 Amatrol, Inc.
 SKILL 4 DESIGN A CONTROL CIRCUIT TO PERFORM A CYLINDER DWELL

Procedure Overview
In this procedure, you will design a control circuit to perform a cylinder
dwell using a time-delay relay.

 1. Solve the following design problem.

 Design a circuit to perform the following functions:
• When the start pushbutton 1PB is pressed, the cylinder will extend and dwell
for five seconds.
• After the five seconds have elapsed, the cylinder will retract.
 Draw your circuit design on a separate piece of paper.
 2. Set up the 990-EC1.
 3. Connect the air supply to the system.

CAUTION
DO NOT EXCEED 100 psig/690 kPa WHEN USING THIS PANEL.

 4. Connect the circuit that you designed in step 1.

 5. Turn on the main power switch.
 6. Perform the following substeps to operate the control circuit.
A. Set the timer control knob to 5 seconds.
B. Press 1PB and observe the cylinder.
Cylinder Status _____________________________ (Extends/Retracts)
The cylinder will extend fully. After 5 seconds it will retract.
 7. Repeat step 6 with different timer settings, observing the dwell time of the
cylinder each time.
 8. Demonstrate the circuit to your instructor.
 This is part of your skills assessment.
 9. Place a copy of your circuit design in your portfolio.
 10. Shut down the system.

L11132-AA03UEN-E1-S04, REV. D TIMERS AND ADVANCED SYSTEMS S04-1

Copyright © 2012 Amatrol, Inc.
 SKILL 5 DESIGN A CONTROL CIRCUIT TO PERFORM TIME-DRIVEN
SEQUENCING

Procedure Overview
In this procedure, you will design, connect and operate a circuit to perform
time-driven sequencing on a cylinder.

 1. Solve the following design problem.

 Draw a ladder diagram for a time-driven sequence circuit that uses a timer
relay instead of a limit switch to determine the desired full stroke of a cylinder.
• When the circuit is not operating, the red indicator light should be on.
• A pushbutton should be used to start the sequence.
• When the circuit is activated, the green light should come on and the cylinder
should extend until the timer times out. Once this occurs, the cylinder should
retract.
 Draw your circuit design on a separate piece of paper.
 2. Set up the 990-EC1.
 3. Connect the air supply to the system.
 4. Connect the circuit that you designed.
 5. Turn on the main power switch.
 6. Perform the following substeps to operate the control circuit.
A. Set the timer for about 1 second.
B. Press 1PB and observe the indicator lamps and the cylinder.
Red Lamp Status ____________________________________ (On/Off)

Green Lamp Status __________________________________ (On/Off)

Cylinder Status _____________________________ (Extends/Retracts)

Before 1PB is pressed, the red lamp should be on to indicate that the
machine is not operating. When 1PB is pressed, the red lamp should go
out and the green lamp should come on. This indicates that the cylinder
has started to extend and the timer relay has started counting down.

L11132-AA03UEN-E1-S05, REV. D TIMERS AND ADVANCED SYSTEMS S05-1

Copyright © 2012 Amatrol, Inc.
SKILL 5 DESIGN A CONTROL CIRCUIT TO PERFORM TIME-DRIVEN SEQUENCING

C. Observe the status of the cylinder when the timer times out.
Cylinder Status _____________________________ (Extends/Retracts)
It should start to retract because it has reached its full stroke as determined
by the timer relay. The timer relay is serving the same purpose as a limit
switch.
 7. Adjust the timer up and down and repeat step 6.
 Observe how the different times effect the full stroke of the cylinder.
 8. Demonstrate the circuit to your instructor. This is part of your skills
assessment.
 9. Place a copy of your circuit design in your portfolio.
 10. Shut down the system.

L11132-AA03UEN-E1-S05, REV. D TIMERS AND ADVANCED SYSTEMS S05-2

Copyright © 2012 Amatrol, Inc.
 SKILL 6 DESIGN A DUAL CYLINDER SEQUENCE CIRCUIT USING
ONE LIMIT SWITCH

Procedure Overview
In this procedure, you will design, connect, and operate a control switch to
synchronize two cylinders using one limit switch.

 1. Solve the following design problem.

 Design a control circuit to perform the following functions:
• Use only one limit switch to sense when both cylinders are extended and will
cause them to retract at the same time.
• Use a different solenoid for each cylinder.
• Assume that the cylinders are mechanically synchronized.
 Draw your circuit on a separate piece of paper.
 2. Set up the 990-EC1.
 3. Connect the air supply to the system.
 4. Connect the circuit that you designed in step 1.
 5. Turn on the main power switch and the air supply.
 6. Perform the following substeps to operate the control circuit.
A. Press 1PB momentarily and observe the cylinders.
Cylinder 1 status ____________________________________________

Cylinder 2 status ____________________________________________

Both cylinders should extend at the same time until 2LS is actuated. Then,
both cylinders should retract at the same time.
B. Press 1PB momentarily again. Before the cylinders are fully extended,
press 2PB and observe the cylinders.
Cylinder 1 status ____________________________________________

Cylinder 2 status ____________________________________________

The cylinders should both extend until 2PB is pressed. At that point, the
cylinders should retract.
 7. Demonstrate your circuit to the instructor. This is part of your skill assessment.
 8. Place a copy of your circuit design in your portfolio.
 9. Repeat step 6 to get more familiar with the circuit’s operation.
 10. Perform the following substeps to shut down the system.
A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

L11132-AA03UEN-E1-S06, REV. D TIMERS AND ADVANCED SYSTEMS S06-1

Copyright © 2012 Amatrol, Inc.
 SKILL 7 CONNECT AND OPERATE A DUAL-CYLINDER CONTROL CIRCUIT
USING TWO LIMIT SWITCHES

Procedure Overview
In this procedure, you will connect and operate a control circuit that uses
two limit switches connected in NAND logic to control two cylinders.

 1. Set up the 990-EC1.

 2. Make sure the air supply is connected to the system.
 3. Connect the circuit shown in figure 7-1.

START
L1 STOP 2PB L2
1CR
1 1PB 3 4 2LS 5 2
1

1CRA 4LS
2

1CRB 1-SOL
1 6 2
3 CYLINDER 1
EXTEND
2-SOL
2
CYLINDER 2
EXTEND

Figure 7-1. Circuit Setup

 4. Turn on the main power switch and the air supply.
 5. Press 2PB momentarily and observe the operation of the cylinders.
Cylinder 1 status ______________________________ (Extends/Retracts)

Cylinder 2 status ______________________________ (Extends/Retracts)

 Both cylinders should extend until both are fully extended, at which point,
they should then retract.

L11132-AA03UEN-E1-S07, REV. D TIMERS AND ADVANCED SYSTEMS S07-1

Copyright © 2012 Amatrol, Inc.
SKILL 7 CONNECT AND OPERATE A DUAL-CYLINDER CONTROL CIRCUIT USING TWO LIMIT SWITCHES

 7. Modify the circuit, as shown in figure 7-2, and set the time delay control to 1
second.
 This will cause cylinder 2 to start to extend about 1 second after cylinder 1
starts to extend.
 This will show how the two-limit-switch method causes the cylinders to
retract at the same time, even if one is much slower.

START
L1 STOP 2PB L2
1CR
1 1PB 3 4 2LS 5 2
1

1CRA 4LS
2

1CRB 1-SOL
1 6 2
3 CYLINDER 1
EXTEND
1TR
2

1TRA 2-SOL
1 7 2 CYLINDER 2
EXTEND

Figure 7-2. Modified Circuit

 8. Now, press 2PB momentarily again and observe the cylinders.
Cylinder 1 status ______________________________________________

Cylinder 2 status ______________________________________________

 Cylinder 1 will start to extend before cylinder 2. When the one second time
delay times out, cylinder 2 will start to extend. Cylinder 1 will stay extended
until cylinder 2 is fully extended and then they will both retract together.

NOTE
Because of the use of the two limit switches, it does not matter if the
cylinders extend at the same speed. The cylinders will not be allowed to retract
until both limit switches are actuated.

 9. Perform the following substeps to shut down the system.

A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

L11132-AA03UEN-E1-S07, REV. D TIMERS AND ADVANCED SYSTEMS S07-2

Copyright © 2012 Amatrol, Inc.
 SKILL 8 DESIGN A CONTINUOUS-CYCLE MULTIPLE-CYLINDER CIRCUIT

Procedure Overview
In this procedure, you will design, connect, and operate a continuous-cycle
circuit where the cylinders operate together.

 1. Solve the following design problem.

 Design a control circuit that will perform the following functions:
• Both cylinders should cycle together continuously.
• Each cylinder should be controlled by a separate solenoid.
• The circuit should be designed so that both cylinders will not extend until
both are fully retracted, and will not retract until both are fully extended.
 Draw your circuit design on a separate piece of paper.

HINT
You will have to use all four limit switches for this circuit.

 2. Set up the 990-EC1.

 3. Make sure the air supply is connected to the system.
 4. Connect the circuit that you designed in step 1.
 5. Turn on the main power switch and the air supply.
 6. Perform the following substeps to operate the control circuit.
A. Press 1PB and observe both cylinders.
Cylinder 1 status ____________________________________________

Cylinder 2 status ____________________________________________

Both should be continuously reciprocating.
B. Press 2PB and observe both cylinders.
Cylinder 1 status ____________________________________________

Cylinder 2 status ____________________________________________

Both should now retract and stop.
C. Press 1PB again and observe if the cylinders are synchronized.
Cylinders status _________________ (Synchronized/Not synchronized)
If they are synchronized, both extend limit switches must be energized
before the cylinders will retract. Also, both retract limit switches must be
energized before the cylinders can extend again.

L11132-AA03UEN-E1-S08, REV. D TIMERS AND ADVANCED SYSTEMS S08-1

Copyright © 2012 Amatrol, Inc.
SKILL 8 DESIGN A CONTINUOUS-CYCLE MULTIPLE-CYLINDER CIRCUIT

 7. Demonstrate the circuit to your instructor. This is part of your skill assessment.
 8. Place a copy of your circuit design in your portfolio.
 9. Perform the following substeps to shut down the system.
A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

L11132-AA03UEN-E1-S08, REV. D TIMERS AND ADVANCED SYSTEMS S08-2

Copyright © 2012 Amatrol, Inc.
 SKILL 9 CONNECT AND OPERATE A CIRCUIT HAVING BOTH AUTOMATIC
AND MANUAL MODES OF OPERATION

Procedure Overview
In this procedure, you will connect and operate a control circuit that has an
automatic mode and a manual mode of operation.

 1. Set up the 990-EC1.

 2. Make sure the air supply is connected to the system.
 3. Connect the circuit shown in figure 9-1.

MAN AUTO
L1 L2
1SS RET'D EXT'D 1CR
1 3 1LS 4 2LS 5 2
1

1CRA
2

6 2
3 G

1CRB 1-SOL
7 2
4
JOG FWD
1PB
1 8
5

6 2
R

Figure 9-1. A Control Circuit with Automatic and Manual Modes of Operation
 If the circuit is in the automatic mode, the green indicator light will be on and
the cylinder will extend and retract automatically.
 When the manual mode is selected, the red indicator light will be on and the
pushbutton 1PB can be used to manually extend (jog) the cylinder.
 In this case, the mode of operation will be determined by the position of the
selector switch.
 4. Turn on the main power switch and the air supply.

L11132-AA03UEN-E1-S09, REV. D TIMERS AND ADVANCED SYSTEMS S09-1

Copyright © 2012 Amatrol, Inc.
SKILL 9 CONNECT AND OPERATE A CIRCUIT HAVING BOTH AUTOMATIC AND MANUAL MODES OF OPERATION

 5. Perform the following substeps to operate the control circuit in the automatic
mode.
A. Position 1SS to the right hand position and observe the cylinder and the
green indicator lamp.
Cylinder status _________________________ (Cycles/Does not move)

Green Lamp status __________________________________ (On/Off)

The cylinder should be continuously cycling and the green lamp should be
on. This will continue until 1SS is taken out of the automatic position.
In the automatic mode, the N.O. contacts of SS1 on rung 1 close and the
N.C. contacts on rung 4 open. This locks the circuit into the automatic
mode where the cylinder will reciprocate continuously. The manual
controls will have no effect on the circuit at this time.
B. Position 1SS to the mid position and observe the cylinder and the indicator
lamps.
Cylinder status _____________________________ (Extends/Retracts)

Green Lamp status __________________________________ (On/Off)

Red Lamp _________________________________________ (On/Off)

The cylinder should retract and both indicator lamps should be off. This is
the OFF position.
 6. Repeat step 5 to become more familiar with the automatic mode of operation.
 7. Perform the following substeps to operate the circuit in the manual mode.
A. Position 1SS to the left hand position and observe the cylinder and the
lamps.
Cylinder status _____________________________ (Extends/Retracts)
Red Lamp status ____________________________________ (On/Off)
The cylinder should be retracted and the red indicator lamp should be on.
The green indicator should be off.
The set of N.O. contacts used for automatic operation on rung 1 are held
open when the selector switch 1SS is placed in the manual position. At the
same time, the set of N.C. contacts used for manual operation on rung 4
close. This provides a flow of electricity to 1PB which is used to manually
control the cylinder. This manual control of the cylinder is known as
jogging and will be discussed in more detail later in this LAP.

L11132-AA03UEN-E1-S09, REV. D TIMERS AND ADVANCED SYSTEMS S09-2

Copyright © 2012 Amatrol, Inc.
SKILL 9 CONNECT AND OPERATE A CIRCUIT HAVING BOTH AUTOMATIC AND MANUAL MODES OF OPERATION

B. Press and hold 1PB and observe the cylinder.

Cylinder status _____________________________ (Extends/Retracts)
The cylinder should now extend and stay fully extended until 1PB is
released. This is the manual mode.
Pressing 1PB allows electricity to flow to the solenoid-operated directional
control valve, causing it to energize. This changes the direction of air flow
so that the cylinder begins to extend.
C. Release 1PB and observe the cylinder.
Cylinder status _____________________________ (Extends/Retracts)
The cylinder should now retract because the solenoid-operated DCV is
only has two positions. If it had three positions, the cylinder would have
stayed were it was when 1PB was released.
 8. Repeat step 7 to familiarize yourself with the manual mode of operation.
 9. Perform the following substeps to shut down the system.
A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

L11132-AA03UEN-E1-S09, REV. D TIMERS AND ADVANCED SYSTEMS S09-3

Copyright © 2012 Amatrol, Inc.
 SKILL 10 CONNECT AND OPERATE A CONTROL CIRCUIT TO SIMULATE
A TWO-PUSHBUTTON JOG CIRCUIT

Procedure Overview
In this procedure, you will connect and operate a circuit that will simulate
the operation of a simple two-pushbutton jog circuit. The indicator lamps will
be used to simulate the operation of a cylinder as it is jogged forward and in the
reverse. The green lamp will indicate jog forward. The red lamp will indicate
jog reverse.

 1. Set up the 990-EC1.

 2. Connect the circuit shown in figure 10-1.

JOG FWD
L1 1PB L2
1CR
1 3 2
1
JOG REV
2PB
2CR
1 4 2
2

1CRA
1 5 2
3 G FORWARD

2CRA
1 6 2
4 R REVERSE

Figure 10-1. A Two-Pushbutton Jog Control Circuit

L11132-AA03UEN-E1-S10, REV. D TIMERS AND ADVANCED SYSTEMS S10-1

Copyright © 2012 Amatrol, Inc.
SKILL 10 CONNECT AND OPERATE A CONTROL CIRCUIT TO SIMULATE A TWO-PUSHBUTTON JOG CIRCUIT

 3. Turn on the main power switch.

 4. Perform the following substeps to operate the circuit.
A. Press and hold 1PB and observe the indicator lamps.
Green Lamp status __________________________________ (On/Off)

Red Lamp status ____________________________________ (On/Off)

The green lamp should be on because 1PB is the jog forward pushbutton.
The red lamp should be off.
B. Release 1PB and observe the indicator lamps.
Green Lamp status __________________________________ (On/Off)

Red Lamp status ____________________________________ (On/Off)

Both lamps should now be off indicating that the cylinder is holding the
position it was in when the forward jog pushbutton was released.
C. Now, press and hold 2PB and observe the indicator lamps.
Green Lamp status __________________________________ (On/Off)

Red Lamp status ____________________________________ (On/Off)

The red lamp should now be on, indicating that 2PB is the reverse jog
pushbutton. The green lamp should be off.
D. Release 2PB.
 5. Repeat step 4 to get familiar with the circuit’s operation.
 6. Solve the following design problem.
 Design a circuit to perform the following functions:
• Uses the 3-position selector switch on the 990-EC1 to perform the same
operation as the two pushbuttons in figure 10-1.
• The right-hand position of the switch will be jog forward.
• The left-hand position will be jog reverse.
• The center position of the switch should act like both pushbuttons are off.
 Draw your circuit design on a separate piece of paper.
 7. Connect and operate the circuit you designed in step 6.
 8. Perform the following substeps to shutdown the system.
A. Turn off the main power supply.
B. Remove the test leads.

L11132-AA03UEN-E1-S10, REV. D TIMERS AND ADVANCED SYSTEMS S10-2

Copyright © 2012 Amatrol, Inc.
 SKILL 11 CONNECT AND OPERATE A TWO-PUSHBUTTON JOG CIRCUIT THAT
WILL JOG TWO CYLINDERS INDEPENDENTLY

Procedure Overview
In this procedure, you will connect and operate a two pushbutton jog
circuit. 1PB will jog cylinder 1 and 2PB will jog cylinder 2. Try to observe as
many of the guidelines for working with manual control circuits as possible.

 1. Set up the 990-EC1.

 2. Make sure the air supply is connected to the system.
 3. Connect the circuit shown in figure 11-1.

NOTE
Notice that the solenoids are energized through the control relays 1CR and
2CR. This meets the requirements of guideline number 1.

MAN AUTO
L1 L2
1SS RET'D EXT'D 1CR
1 3 1LS 4 2LS 5 2

1CRA

1CRB 1-SOL
6 2
CYLINDER 1
JOG1
1PB
1 7

2CR
3LS 8 4LS 9 2

2CRA

2CRB 2-SOL
10 2
CYLINDER 2
JOG2
2PB

Figure 11-1. A Two-Pushbutton Jog Control Circuit to Jog Two Cylinders

 4. Turn on the main power switch and the air supply.

L11132-AA03UEN-E1-S11, REV. D TIMERS AND ADVANCED SYSTEMS S11-1

Copyright © 2012 Amatrol, Inc.
SKILL 11 CONNECT AND OPERATE A TWO-PUSHBUTTON JOG CIRCUIT THAT WILL JOG TWO CYLINDERS INDEPENDENTLY

 5. Perform the following substeps to operate the circuit.

A. Position 1SS in the right-hand position and observe the cylinders.
Cylinder 1 status ________________________ (Cycles/Does not move)

Cylinder 2 status ________________________ (Cycles/Does not move)

Both cylinders should reciprocate because the automatic mode is selected.
B. Position 1SS in the left-hand position and observe the cylinders.
Cylinder 1 status ____________________________ (Extends/Retracts)

Cylinder 2 status ____________________________ (Extends/Retracts)

Both cylinders will not move until the jog pushbuttons are activated
because the manual mode is now selected. This meets the requirements of
guideline number 5.

NOTE
The automatic mode is locked out because the N.O. contacts of the selector
switch are open. This meets the requirements of guideline number 4.

C. Press and hold 1PB and observe the cylinders.

Cylinder 1 status ____________________________ (Extends/Retracts)

Cylinder 2 status ____________________________ (Extends/Retracts)

Cylinder 1 should extend and stay until 1PB is released because 1PB is the
jog pushbutton for cylinder 1.
Cylinder 2 should not extend or retract because its jog pushbutton has not
been activated.
D. Release 1PB.
E. Press and hold 2PB and observe the cylinders.
Cylinder 1 status ____________________________ (Extends/Retracts)

Cylinder 2 status ____________________________ (Extends/Retracts)

Cylinder 1 will retract and stay. Cylinder 2 will extend and stay until 2PB
is released.
F. Release 2PB and observe cylinder 2.
Cylinder 2 status ____________________________ (Extends/Retracts)

Cylinder 2 will now retract and stay.

NOTE
The manual overrides on the solenoid-operated DCV’s were not used to
jog the cylinders. This meets the requirements of guideline number 3.

L11132-AA03UEN-E1-S11, REV. D TIMERS AND ADVANCED SYSTEMS S11-2

Copyright © 2012 Amatrol, Inc.
SKILL 11 CONNECT AND OPERATE A TWO-PUSHBUTTON JOG CIRCUIT THAT WILL JOG TWO CYLINDERS INDEPENDENTLY

 6. Repeat step 5 to get familiar with the circuit’s operation.

 7. Perform the following substeps to shut down the system.
A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

NOTE
Since there is no way to control the speed of the cylinders on the 990-EC1,
we were unable to observe guideline number 2.

L11132-AA03UEN-E1-S11, REV. D TIMERS AND ADVANCED SYSTEMS S11-3

Copyright © 2012 Amatrol, Inc.
 SKILL 12 DESIGN A CONTINUOUS-CYCLE, SYNCHRONIZED CYLINDER
CIRCUIT WITH A MANUAL MODE

Procedure Overview
In this procedure, you will design a control circuit that will perform a
continuous-cycle, dual-cylinder synchronized operation, with automatic and
manual modes.

 1. Solve the following design problem.

 Design a circuit that will perform the following functions:
• The circuit should perform a continuous dual cylinder operation.
• The retraction of the cylinders should be synchronized.
• The circuit should have both an automatic and a manual mode.
• In the automatic mode, the cylinders should cycle continuously.
• When the manual mode is selected, the automatic circuit is locked out and
each cylinder can be jogged individually by its own jog pushbutton.
 Draw your circuit design on a separate piece of paper.
 2. Set up the 990-EC1.
 3. Make sure the air supply is connected to the system.
 4. Connect the circuit you designed in step 1.
 5. Turn on the main power switch.
 6. Perform the following substeps to operate the circuit.
A. Place the selector switch 1SS in the right-hand position and observe the
cylinders.
Cylinder 1 status _________________________ (Cycling/Not Cycling)
Cylinder 2 status _________________________ (Cycling/Not Cycling)
Both cylinders should be cycling.
B. Notice if the cylinders are synchronized during retraction.
Both cylinders should retract only when both limit switches are energized.
C. Place 1SS in the center position and observe the cylinders.
Cylinder 1 status ____________________ (Cycling/Retracts and stops)

Cylinder 2 status ____________________ (Cycling/Retracts and stops)

Both cylinders should retract and stop because the center position is the
OFF position.

L11132-AA03UEN-E1-S12, REV. D TIMERS AND ADVANCED SYSTEMS S12-1

Copyright © 2012 Amatrol, Inc.
SKILL 12 DESIGN A CONTINUOUS-CYCLE, SYNCHRONIZED CYLINDER CIRCUIT WITH A MANUAL MODE

D. Place 1SS in the left-hand position and observe the cylinders.

Cylinder 1 status ________________________ (Cycles/Does not move)

Cylinder 2 status ________________________ (Cycles/Does not move)

Neither cylinder should be moving at this point because the manual mode
is now selected.
E. Press and hold jog pushbutton 1PB and observe the cylinders.
Cylinder 1 status _______________________ (Extends/Does not move)

Cylinder 2 status _______________________ (Extends/Does not move)

Cylinder 1 should extend and stay until 1PB is released. Cylinder 2 should
not move because its jog button was not pressed.
F. Release 1PB and then press and hold 2PB and observe the cylinders.
Cylinder 1 status ____________________________ (Extends/Retracts)

Cylinder 2 status ____________________________ (Extends/Retracts)

Cylinder 1 should now retract and cylinder 2 should extend and stay until
2PB is released.
G. Release 2PB and observe the cylinders.
Cylinder 1 status _______________________ (Extends/Does not move)

Cylinder 2 status ____________________________ (Extends/Retracts)

Cylinder 1 should not be affected. Cylinder 2 should now retract.
H. Press and hold 1PB and 2PB at the same time and observe the cylinders.
Cylinder 1 status _______________________ (Extends/Does not move)

Cylinder 2 status _______________________ (Extends/Does not move)

Both cylinders should now extend and stay until the pushbuttons are
released.
I. Release both pushbuttons and observe the cylinders.
Cylinder 1 status _______________________ (Stays extended/Retracts)

Cylinder 2 status _______________________ (Stays extended/Retracts)

Both cylinders should now retract.
 7. Demonstrate the circuit to your instructor. This is part of your skill assessment.
 8. Place a copy of your circuit design in your portfolio.
 9. Perform the following substeps to shut down the system.
A. Turn off the main power switch.
B. Remove the test leads.
C. Turn off the air supply.

L11132-AA03UEN-E1-S12, REV. D TIMERS AND ADVANCED SYSTEMS S12-2

Copyright © 2012 Amatrol, Inc.