M02LAP2 Basic Pneumatic Circuits

PNEUMATICS 1
HANDS-ON SKILLS FOR LEARNING ACTIVITY PACKET 2:

BASIC PNEUMATIC CIRCUITS

ITEMS NEEDED FOR HANDS-ON SKILLS

Amatrol Supplied
1 85-BP Basic Pneumatic Training System

School Supplied
1 Compressed Air Supply
1 Adjustable Wrench

FIRST EDITION, LAP 2, REV. B

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Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 2017, 2014 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

LB780-AA02AEN-E1 REV. B BASIC PNEUMATIC CIRCUITS

Copyright © 2017 Amatrol, Inc.
 Activity 1. Basic Operation of a Single-Acting, Spring-Return Cylinder

Procedure Overview
In this procedure, you will connect and cycle a single-acting cylinder. This
will demonstrate the basic operation of the cylinder.

q 1. Before connecting your cylinder circuit, perform the following substeps.

A. Close the shutoff valve if not already closed.
B. Adjust the regulator to minimum by pulling up on the knob to unlock it
and then turning the knob counterclockwise (CCW) fully.
C. If not already attached, connect the compressed air supply source to the
supply connection located on the pneumatic instrumentation module.
q 2. Set up the circuit shown in figure 1-1. In this circuit, the supply manifold is
connected directly to the cylinder.

AIR

PNEUMATIC INSTRUMENTATION MODULE

H L

6
4
2
1
0

BASIC PNEUMATIC MODULE

SHUTOFF
VALVE

Figure 1-1. Pictorial of a Circuit to Extend a Single-Acting, Spring-Return Cylinder

q 3. Open the shutoff valve.
You are now ready to extend the cylinder.

LB780-AA02AEN-E1-A01, REV. B BASIC PNEUMATIC CIRCUITS A01-1

Copyright © 2017 Amatrol, Inc.
ACTIVITY 1. BASIC OPERATION OF A SINGLE-ACTING, SPRING-RETURN CYLINDER

q 4. Lift the knob of the regulator and turn it slowly CW until the cylinder extends
fully.
You should observe that the cylinder starts to extend at low pressure, as shown
in figure 1-2. More pressure is needed to completely extend the cylinder
because the spring is being compressed further.
The supply pressure must provide enough force to overcome the load and
compress the spring. The air on the backside of the piston is allowed to freely
escape through openings in the rod end.

SUPPLY AIR
AIR LINE ESCAPES
CONNECTED

ROD
EXTENDING

Figure 1-2. Single-Acting, Spring Return Cylinder Extending

q 5. Retract the cylinder completely by slowly turning the regulator knob CCW,
reducing the regulator setting to minimum.
You should observe that the spring slowly retracts the cylinder rod as the
regulator bleeds the air from the cylinder, as shown in figure 1-3.

AIR IN THE CAP

END IS FORCED OUT
(EXHAUST)

ROD RETRACTING
DUE TO SPRING
FORCE

Figure 1-3. Single-Acting Cylinder Retracting by Spring Force

As with double-acting cylinders, single-acting cylinders also have piston

seals, rod seals, and a rod bushing.
q 6. Repeat steps 4 and 5 several times to become more familiar with the operation
of the single-acting, spring-return cylinder.
q 7. Close the shutoff valve.
q 8. Disconnect the hoses and store them.

LB780-AA02AEN-E1-A01, REV. B BASIC PNEUMATIC CIRCUITS A01-2

Copyright © 2017 Amatrol, Inc.
 SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC
CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

Procedure Overview
In this procedure, you will set up a basic pneumatic circuit that will
allow you to reciprocate a single-acting, spring-return cylinder using a 3-way
directional control valve.

q 1. Locate the 3/2 DCV.

If your classroom is equipped with the 96-PNE2, it will be attached to the
model 85-IP Intermediate Pneumatic Module. Otherwise, it will be stored
separately.

Figure 3-1. 3/2 DCV

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-1

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

q 2. Set up the circuit shown in figures 1-2 and 1-3.

In this circuit, the 3/2 DCV is connected to provide a normally closed (N.C.)
function. Gauge C will indicate the pressure in the cylinder line.

NOTE
If your classroom is equipped with the 96-PNE2, set up the circuit as
shown in option A. Otherwise set up the circuit as shown in option B.

OPTION PTION B

LOOSE HOSE END FOR

PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE
VALVE EXHAUST

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

FILTER/REGULATOR

6 6
4 4
2 2
1 1
0 0
P

E A

CYLINDER #1
E A CYLINDER #1
MOTOR MOTOR
DIRECTIONAL CONTROL
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL CONTROL VALVE
CONTROL VALVE VALVE #2

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 1-4. Pictorial of a Single-Acting Cylinder Circuit: Option A and Option B

CAUTION
To open the DCV’s exhaust port (E port), you must connect one end of a
hose to this port. When you perform this procedure, tie or hold down the loose
end of this hose to avoid whipping and possible injury.

NOTE
Normally, for this application, the E-port does not have a fitting and
exhausts directly to atmosphere. However, later you will use this valve in a
different application where you will need to connect the supply to this port.
This is why it has a fitting.

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-2

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

Figure 1-5. Schematic of a N.C. Single-Acting Cylinder Circuit

q 3. Connect the compressed air supply source to the male quick-connect plug on
the instrumentation module and open the shutoff valve.
q 4. Turn the regulator adjustment CW until the pressure at the regulator gauge
reads 40 psi/276 kPa.
Compressed air is now at Port P of the DCV. Gauge C should read 0 psi/0
kPa.

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-3

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

Figure 1-4 shows the condition of the 3-way DCV and the single-acting,
spring-return cylinder at this time. The manual operator (push button) is
not pressed. The valve is said to be in the normal or de-energized position.
In this position, supply pressure is blocked and the cylinder port is open to
atmosphere through the exhaust port of the DCV. The cylinder spring holds
the rod retracted. This is also shown in the schematic of figure 1-5.

ROD
RETRACTED
FULLY
MANUAL OPERATOR
(NOT PRESSED)

E A

AIR SUPPLY
BLOCKED

Figure 1-6. Manually-Operated, 3-Way DCV Connected to a Single- Acting,

Spring Return Cylinder

P
A
E

Figure 1-7. Schematic of 3-Way DCV Connected to a Single-Acting Cylinder

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-4

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

q 5. Now test your pneumatic circuit by pressing in on the manual operator to

extend the cylinder rod. Continue to hold the button in.
When the manual operator is pressed, air flows through the valve from Port P
to Port A, as shown in figures 1-6 and 1-7. From Port A, the air enters the cap
end of the cylinder and causes it to extend.
As the cylinder extends, the spring compresses but its force is much less
than the compressed air so it has no effect. The air on the rod side rushes out
through a small air hole.

AIR
ESCAPES
ROD
EXTENDING
MANUAL
OPERATOR
(PRESSED)

EXHAUST TO
FROM CYLINDER
CYLINDER
(BLOCKED)
E A

P
AIR SUPPLY
OPEN

Figure 1-8. Manually-Operated 3-Way DCV in the Energized Position

EXTENDING

P
A
E

Figure 1-9. 3-Way DCV in Energized Position

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-5

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

q 6. Release the manual operator.

In figure 1-8, you should observe that the cylinder retracts. When the valve
shifts to its de-energized condition, Port P is blocked and Port A is connected
to Port E. This causes the pressure on the cap end of the cylinder to drop to
zero. The spring force can now retract the cylinder. As it does, the air in the
cap end is pushed out of the exhaust port into atmosphere.

ROD
RETRACTING

MANUAL OPERATOR
(RELEASED)

EXHAUST FROM
FROM CYLINDER
CYLINDER
A
E

AIR SUPPLY
BLOCKED

Figure 1-10. Manually-Operated 3-Way DCV in the De-Energized Position

q 7. Repeat steps 5 and 6 several times to cycle the cylinder. During one of the
cycles, release the button while the cylinder rod is extending and is in mid-
stroke. What happens? Does the cylinder stop, keep extending, or retract?
_____________________________________________________________

_____________________________________________________________
You should observe that the cylinder retracts because the DCV returns to the
de-energized position, blocking pressure and exhausting the cylinder.
q 8. Turn the regulator adjustment CCW fully to reduce the pressure to a minimum.
q 9. Close the shutoff valve.

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-6

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

q 10. Now switch the hose ends at the DCV, as shown in figure 1-9. In this circuit,
the 3-way DCV is connected to provide the N.O. function.

P E

Figure 1-11. Schematic of a N.O. Single-Acting Cylinder Circuit

CAUTION
To exhaust through the DCV, you must connect one end of a hose to Port P.
When you perform this procedure, tie or hold down the loose end of this hose
to avoid whipping and possible injury.

q 11. Open the shutoff valve.

q 12. Turn the regulator adjustment CW until pressure at the regulator gauge reads
40 psi/276 kPa.
The single-acting, spring-return cylinder should extend fully as regulator
pressure is increased to 40 psi/276 kPa because the 3/2 DCV is providing a
N.O. condition. Supply flows through the DCV directly to the cylinder.

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-7

Copyright © 2017 Amatrol, Inc.
SKILL 31 CONNECT AND OPERATE A SINGLE-ACTING PNEUMATIC CYLINDER USING A 3/2 MANUALLY-OPERATED DCV

q 13. Press and hold in the pushbutton of the 3/2 DCV. When the manual operator
is pressed, supply air is blocked and the cylinder is exhausted through Port P,
as shown in figure 1-10, causing the cylinder to retract.

RETRACTING

P
A
E

Figure 1-12. 3-Way, N.O. DCV in Energized Position

q 14. Release the manual operator.
You should observe that the cylinder extends. When the valve shifts to its
de-energized condition, supply air is reconnected to Port A and the exhaust is
blocked, as shown in figure 1-9.
q 15. Repeat steps 13 and 14 several times to cycle the cylinder to become more
familiar with a 3-way N.O. circuit.
q 16. Turn the regulator adjustment CCW fully to reduce pressure to a minimum.
The cylinder should retract as the pressure is decreased.
q 17. Close the shutoff valve.
q 18. Disconnect and store the hoses.

LB780-AA02AEN-E1-S01, REV. B BASIC PNEUMATIC CIRCUITS S01-8

Copyright © 2017 Amatrol, Inc.
 SKILL 2 CONNECT AND OPERATE A UNI-DIRECTIONAL PNEUMATIC MOTOR
USING A 3-WAY, MANUALLY-OPERATED DCV

Procedure Overview
In this procedure, you will set up a basic pneumatic circuit that will allow
you to operate a motor. The circuit uses a 3-way DCV to control the uni-
directional motor.

q 1. Set up the pneumatic motor circuit shown in figures 2-1 and 2-2.

NOTE
If your classroom is equipped with the 96-PNE2, remember to set up your
circuit as shown in option A. Otherwise set it up as shown in option B.

OPTION PTION B
LOOSE HOSE END FOR
PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE
VALVE EXHAUST

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

6 6
4 4
2 2
1 1
0 0

E A

CYLINDER #1
E A CYLINDER #1
MOTOR DIRECTIONAL CONTROL MOTOR
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL
CONTROL VALVE VALVE #2 CONTROL VALVE

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 2-1. Pictorial of Pneumatic Motor Circuit

CAUTION
To open the DCV E-port, you must connect one end of a hose to this port.
While performing this procedure, tie or hold down the loose end of this hose
to avoid whipping and possible injury.

LB780-AA02AEN-E1-S02, REV. B BASIC PNEUMATIC CIRCUITS S02-1

Copyright © 2017 Amatrol, Inc.
SKILL 2 CONNECT AND OPERATE A UNI-DIRECTIONAL PNEUMATIC MOTOR USING A 3-WAY, MANUALLY-OPERATED DCV

Examine the schematic shown in figure 2-2. Compare it to the pictorial of

figure 2-1.

NOTE
The pictorial and schematic include a muffler which is attached to the air
motor. Operation of the muffler will be covered in the next objective.

GAUGE MOTOR MUFFLER

3 WAY, 2-POSITION
VALVE A

P E
AIR SUPPLY

Figure 2-2. Pneumatic Motor Schematic

q 2. Perform the following substeps to connect the compressed air supply.
A. If not already connected, connect the compressed air supply source to the
male quick-connect on the instrumentation module.
B. Open the shutoff valve.
q 3. Turn the regulator adjustment CW until the pressure at the regulator gauge
reads 30 psi/207 kPa.
Compressed air is now at Port P of the DCV. Gauge C should read 0 psi/0
kPa.
q 4. Test your circuit by pressing in on the manual operator to run the motor.
Continue to hold the button in. If the motor hasn’t been run in a while, you
may have to help it start by spinning the shaft.
You should observe that the motor runs slowly.
Also listen to the noise level as air is exhausted through the muffler.

LB780-AA02AEN-E1-S02, REV. B BASIC PNEUMATIC CIRCUITS S02-2

Copyright © 2017 Amatrol, Inc.
SKILL 2 CONNECT AND OPERATE A UNI-DIRECTIONAL PNEUMATIC MOTOR USING A 3-WAY, MANUALLY-OPERATED DCV

q 5. Record the pressure at Gauge C.

Gauge C______________________________________________ (psi/kPa)
Gauge C pressure should be less than 20 psi/138 kPa because there is no load
on the motor.
q 6. Release the DCV manual operator to block flow to the motor.
You should observe that the motor stops quickly. Also you should observe
that the pressure at Gauge C drops to 0 psi/0 kPa because the motor inlet is
open to the atmosphere.
q 7. Repeat steps 4 and 6 several times to become more familiar with the operation
of the air motor.
q 8. To observe the effect that pressure has on motor operation, adjust the regulator
CW until the pressure at the regulator gauge reads 50 psi / 345 kPa.
q 9. Press in the manual operator of the DCV.
You should observe that motor speed and noise level have increased along
with the pressure at Gauge C.
q 10. Record the pressure at Gauge C.
Gauge C______________________________________________ (psi/kPa)
Gauge C pressure should be higher than it was in step 5. This shows that an
increase in pressure will cause an air motor to increase speed.
q 11. Release the DCV manual operator to stop the motor.
q 12. Turn the regulator adjustment CCW fully to reduce the pressure to a minimum.
q 13. Close the shutoff valve.
q 14. Disconnect and store the hoses.

LB780-AA02AEN-E1-S02, REV. B BASIC PNEUMATIC CIRCUITS S02-3

Copyright © 2017 Amatrol, Inc.
 Activity 2. Air Muffler Operation

Procedure Overview
In this procedure, you will demonstrate the operation of the air motor
without the air muffler.

q 1. Set up the pneumatic motor circuit shown in figure 2-1.

PNEUMATIC INSTRUMENTATION MODULE

GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER

6
4
2
1
0

CYLINDER #1
MOTOR

FLOW CONTROL FLOW CONTROL

#1 #2

CYLINDER #3

DIRECTIONAL
CONTROL VALVE

CYLINDER #2

BASIC PNEUMATIC MODULE

Figure 2-1. Pneumatic Motor Circuit

LB780-AA02AEN-E1-A02, REV. B BASIC PNEUMATIC CIRCUITS A02-1

Copyright © 2017 Amatrol, Inc.
ACTIVITY 2. AIR MUFFLER OPERATION

q 2. If not already connected, connect the compressed air supply source to the
male quick-connect on the instrumentation module and open the shutoff
valve.
q 3. Slowly increase the regulator pressure to 30 psi / 207 kPa. As you do this,
listen to the sound of the motor with the muffler attached. The sound is much
quieter than it would be without the muffler.
q 4. Decrease the regulator setting to its minimum setting to stop the motor.
q 5. Now remove the muffler from the air motor by twisting it CCW with your
hand. Use a pair of pliers if needed.
q 6. Now increase the regulator pressure to 30 psi / 207 kPa and listen to the
motor.
You should notice that it is much louder. This shows why a muffler is an
important component.
q 7. Reduce the regulator pressure to minimum and close the shutoff valve.
q 8. Reattach the muffler.
q 9. Disconnect the hoses and store them.

LB780-AA02AEN-E1-A02, REV. B BASIC PNEUMATIC CIRCUITS A02-2

Copyright © 2017 Amatrol, Inc.
 SKILL 3 IDENTIFY PNEUMATIC SYMBOLS

Procedure Overview
In this procedure, you will be given several pneumatic symbols, which you
have seen previously, and asked to match them with their description.

q 1. Identify and match each symbol with its description. This will help you in
learning the schematic symbols used in pneumatics.

A. __________ AA. Bidirectional Pneumatic Motor

B. __________ BB. Lever Operator

C. __________ CC. Tee

D. __________ DD. Enclosure Line

E. __________ EE. Muffler

F. __________ FF. Double-Acting Cylinder

G. __________ GG. Blocked Line

H. __________ HH. Spring

I. __________ II. Flow Direction

LB780-AA02AEN-E1-S03, REV. B BASIC PNEUMATIC CIRCUITS S03-1

Copyright © 2017 Amatrol, Inc.
SKILL 3 IDENTIFY PNEUMATIC SYMBOLS

J. __________ JJ. 2-Way, DCV, N.O.

K. __________ KK. Single-Acting Cylinder

L. __________ LL. Exhaust Line

M. __________ MM. Main Conductor

N. __________ NN. Regulator

O. __________ OO. 3-Way DCV, N.C.

P. __________ PP. Quick-Connect

Q. __________ QQ. Pressure Gauge

R. __________ RR. Hose

S. __________ SS. 3/2 DCV, N.O.

T. __________ TT. Filter

U. __________ UU. Shutoff Valve

V. __________ VV. Unidirectional Pneumatic Motor

LB780-AA02AEN-E1-S03, REV. B BASIC PNEUMATIC CIRCUITS S03-2

Copyright © 2017 Amatrol, Inc.
SKILL 3 IDENTIFY PNEUMATIC SYMBOLS

W. __________ WW. Cross

X. __________ XX. Pilot Line

Y. __________ YY. 5/3 DCV, Manually-Operated

Z. __________ ZZ. 2/2 DCV, N.C.

LB780-AA02AEN-E1-S03, REV. B BASIC PNEUMATIC CIRCUITS S03-3

Copyright © 2017 Amatrol, Inc.
 SKILL 4 DRAW A PNEUMATIC SCHEMATIC FROM THE ACTUAL CIRCUIT
CONNECTIONS ON THE MACHINE

Procedure Overview
In this procedure, you will draw schematics by looking at actual circuit
connections on pictorials. This is a common requirement in industry because
the schematics are not often readily available.

q 1. Draw the circuit schematic on a copy of figure 4-2 for the pictorial shown in
figure 4-1. Start from the supply manifold as shown. You may show flexible
tubing as a rigid connector (i.e. a straight line) and leave out all quick-connect
symbols.

PNEUMATIC INSTRUMENTATION MODULE

H L

6
4
2
1
0

BASIC PNEUMATIC MODULE

Figure 4-1. Pictorial of a Basic Pneumatic Cylinder Circuit

Figure 4-2. Schematic of a Basic Pneumatic Cylinder Circuit

LB780-AA02AEN-E1-S04, REV. B BASIC PNEUMATIC CIRCUITS S04-1

Copyright © 2017 Amatrol, Inc.
SKILL 4 DRAW A PNEUMATIC SCHEMATIC FROM THE ACTUAL CIRCUIT CONNECTIONS ON THE MACHINE

q 2. Draw the circuit schematic on a copy of figure 4-4 for the pictorial shown in
figure 4-3. Start from the supply manifold. You may show flexible tubing as a
rigid connector (i.e. a straight line) and leave out all quick-connect symbols.

PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

6 6
4 4
2 2
1 1
0 0

E A

CYLINDER #1
E A CYLINDER #1
MOTOR DIRECTIONAL CONTROL MOTOR
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL
CONTROL VALVE VALVE #2 CONTROL VALVE

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 4-3. Pictorial of a Basic Pneumatic Motor Circuit

Figure 4-4. Schematic of a Basic Pneumatic Motor Circuit

LB780-AA02AEN-E1-S04, REV. B BASIC PNEUMATIC CIRCUITS S04-2

Copyright © 2017 Amatrol, Inc.
SKILL 4 DRAW A PNEUMATIC SCHEMATIC FROM THE ACTUAL CIRCUIT CONNECTIONS ON THE MACHINE

q 3. Draw the circuit schematic on a copy of figure 4-6 for the pictorial shown in
figure 4-5. Start from the supply manifold. You may show flexible tubing as a
rigid connector (i.e. a straight line) and leave out all quick-connect symbols.

PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

6 6
4 4
2 2
1 1
0 0
P

E A

CYLINDER #1
E A CYLINDER #1
MOTOR DIRECTIONAL CONTROL MOTOR
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL
CONTROL VALVE VALVE #2 CONTROL VALVE

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 4-5. Pictorial of a Pneumatic Circuit

Figure 4-6. Schematic of a Pneumatic Circuit

LB780-AA02AEN-E1-S04, REV. B BASIC PNEUMATIC CIRCUITS S04-3

Copyright © 2017 Amatrol, Inc.
 SKILL 5 CONNECT A PNEUMATIC CIRCUIT GIVEN A SCHEMATIC

Procedure Overview
In this procedure, you will draw on a pictorial of the pneumatic trainer the
actual circuit connections given a schematic. This will help you develop your
skills in reading schematics.

q 1. Draw the circuit hose connections between circuit components on a copy of

the pictorial shown in figure 5-2 given the schematic of figure 5-1.

Figure 5-1. Schematic of a Pneumatic Power Circuit

PNEUMATIC INSTRUMENTATION MODULE

H L

6
4
2
1
0

BASIC PNEUMATIC MODULE

Figure 5-2. Pictorial of a Pneumatic Power Circuit

LB780-AA02AEN-E1-S05, REV. B BASIC PNEUMATIC CIRCUITS S05-1

Copyright © 2017 Amatrol, Inc.
SKILL 5 CONNECT A PNEUMATIC CIRCUIT GIVEN A SCHEMATIC

q 2. Draw the circuit hose connections between circuit components on a copy of

the pictorial shown in figure 5-4 given the schematic of figure 5-3.

Figure 5-3. Schematic of a Pneumatic Circuit

PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

6 6
4 4
2 2
1 1
0 0
P

E A

CYLINDER #1
E A CYLINDER #1
MOTOR DIRECTIONAL CONTROL MOTOR
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL
CONTROL VALVE VALVE #2 CONTROL VALVE

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 5-4. Pictorial of a Pneumatic Circuit

LB780-AA02AEN-E1-S05, REV. B BASIC PNEUMATIC CIRCUITS S05-2

Copyright © 2017 Amatrol, Inc.
SKILL 5 CONNECT A PNEUMATIC CIRCUIT GIVEN A SCHEMATIC

q 3. Draw the circuit hose connections between circuit components on a copy of

the pictorial shown in figure 5-6 given the schematic of figure 5-5.

Figure 5-5. Air Flow From the Compressor

PNEUMATIC INSTRUMENTATION MODULE PNEUMATIC INSTRUMENTATION MODULE

GAUGE A GAUGE B GAUGE C GAUGE A GAUGE B GAUGE C

FILTER/REGULATOR ROTAMETER MANOMETER FILTER/REGULATOR ROTAMETER MANOMETER

6 6
4 4
2 2
1 1
0 0
P

E A

CYLINDER #1
E A CYLINDER #1
MOTOR DIRECTIONAL CONTROL MOTOR
VALVE #3 VENTURI

FLOW CONTROL FLOW CONTROL FLOW CONTROL FLOW CONTROL

#1 #2 #1 #2
CAM VALVE CAM VALVE
#1 #2

CYLINDER #3 CYLINDER #3

DIRECTIONAL DIRECTIONAL
DIRECTIONAL CONTROL
CONTROL VALVE VALVE #2 CONTROL VALVE

CHECK VALVE

CYLINDER
CYLINDER #2 LOAD DEVICE CYLINDER #2

BASIC PNEUMATIC MODULE INTERMEDIATE PNEUMATIC MODULE BASIC PNEUMATIC MODULE

WITH 96-PNE2 WITHOUT 96-PNE2

Figure 5-6. Air Flow From the Compressor

LB780-AA02AEN-E1-S05, REV. B BASIC PNEUMATIC CIRCUITS S05-3

Copyright © 2017 Amatrol, Inc.
 SKILL 6 DESIGN A MULTIPLE ACTUATOR PNEUMATIC CIRCUIT

Procedure Overview
Now that you have learned how to draw schematics, you will get a chance
to combine this skill with your creativity to design a more complex pneumatic
circuit.

q 1. Read the following scenario.

Scenario: You have been assigned to design a pneumatic circuit to operate
the automated drill machine shown in figure 6-1. Provide the following
operations:
•• Clamp cylinder opens and closes to clamp parts in position.
•• An eject cylinder extends and retracts to remove parts from the drill station.
•• A drill cylinder extends and retracts to drill the parts.

DRILL
CYLINDER

DRILL

CLAMP
CYLINDER

PART

EJECT
CYLINDER

Figure 6-1. Automated Drill Station

LB780-AA02AEN-E1-S06, REV. B BASIC PNEUMATIC CIRCUITS S06-1

Copyright © 2017 Amatrol, Inc.
SKILL 6 DESIGN A MULTIPLE ACTUATOR PNEUMATIC CIRCUIT

Each cylinder should be separately controlled by its own DCV. Use lever-
operated DCVs.
Notice that the clamp cylinder is a single-acting, spring-extend type. The
reason for this is so the part will stay clamped (cylinder extended) if pneumatic
power is lost. If you used a double-acting cylinder, it could lose its clamping
power while the drill is drilling. When you design circuits, you should always
look at the operation of the design during emergency states as well as normal
states.
Design the drill cylinder circuit so the drill automatically retracts if you
release the lever of the DCV.
q 2. Draw the circuit schematic that will perform the operations described in step
1. Start with the air supply line shown in figure 6-2. Add a filter and regulator.

DRILL CYLINDER

CLAMP CYLINDER

EJECT CYLINDER

AIR
SUPPLY

Figure 6-2. Circuit Schematic

LB780-AA02AEN-E1-S06, REV. B BASIC PNEUMATIC CIRCUITS S06-2

Copyright © 2017 Amatrol, Inc.