Exercise 4-2

Counting of Actuator Cycles

EXERCISE OBJECTIVE

 To describe the operation of an electrical counter;

 To assemble and test a continuous reciprocation system;
 To extend and retract a cylinder a definite number of times using an electrical
counter;
 To describe the operation of a photoelectric switch;
 To measure the rotation speed of a motor using an electrical counter.

DISCUSSION

Electrical Counters

Electrical counters are used in electrically controlled pneumatic systems when parts
of the system must be activated or deactivated after a definite number of events
have occurred. They are widely used in industry to count quantities produced during
process and control operations. They are also used in machine maintenance
scheduling to control the number of machine operations.

A typical application is an automated packaging system that stacks and counts

production items into groups. The usual method is for one cylinder to continuously
extend and retract, picking and stacking one item on each cycle, and for a counter
to count the number of cycles which have been made by the cylinder. When the
required count is reached, the counter generates a switching signal which causes
another cylinder to push the stack away.

Basic Counter Operation

An electrical counter basically consists of one or more NO and NC contacts, a

control terminal to receive input count pulses, a reset terminal to which a
momentary pulse can be applied to reset the counter to zero, and some means to
preset the counter value, usually thumbwheel switches.

The counter preset value specifies the value which the counter must reach before
activating its output contacts. Each time a pulse is received at the control terminal,
the count is incremented by one. Additional input pulses continue to increment the
count. Momentary activation of the reset input deactivates the counter contacts and
resets the count to zero.

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Pneumatic Trainer Counter

As was said in Exercise 3-4, the Time-Delay Relay / Counter supplied with your
trainer can be programmed for the counting function by configuring the thumbwheel
switches on top of the unit accordingly. To program the Time-Delay Relay / Counter
for the counting function, three parameters must be configured: the counting mode,
the preset count, and the counting interval, as shown in Figure 4-7.

RESET

CONTROL

DISPLAY AREA

R C

ON
1 4
NC NO

2 5

C
A 0 0 5 O

3 6

7 8
THUMBWHEEL
+ - SWITCHES

COUNTING INTERVAL PRESET COUNT COUNTER MODE

A, D TO J: NORMAL 001 TO 999 CO: OPERATE AT PRESET COUNT
B: DIVIDE BY 10 CR: RELEASE AT PRESET COUNT
C: DIVIDE BY 100

Figure 4-7. Time-Delay Relay / Counter in Counting Mode.

The "counter mode" switch selects between the following operation modes:

 Operate at Preset Count (switch set to CO): each time the CONTROL (C) input
is switched to common ( ) and then disconnected from common, the counter
value is incremented by one count. When the preset count is reached, both sets
of relay contacts are shifted to their activated state. Additional input pulses
continue to increment the displayed count. Momentarily switching the RESET (R)
input to common deactivates the relay contacts and resets the counter value to
zero.

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Counting of Actuator Cycles

 Release at Preset Count (switch set to CR): momentarily switching the RESET
input to common activates the relay contacts. Operation is similar to CO mode
except that the relay contacts are deactivated when the preset count is reached.

The "preset count" switches specify the value which the counter must reach before
the relay contacts are activated (CO operation) or deactivated (CR operation). Can
be set between 001 and 999.

The "counting interval" switch selects the interval counted by the counter. Selectable
as Normal, Divide by 10, or Divide by 100:

 Normal (switch set to A, or D to J): the counter value is incremented each time
an input signal is received at the CONTROL input.

 Divide by 10 (switch set to B): the counter value is incremented for every
10 input signals for a maximum count of 9990.

 Divide by 100 (switch set to C): the counter value is incremented for every
100 input signals for a maximum count of 99 900.

Continuous Reciprocation of a Cylinder

Many automated processes involving machining operations require that a cylinder

be extended and retracted indefinitely after the process is started. This is called
"continuous reciprocation", and a simple electrical control circuit can be used to
control this action.

Continuous reciprocation systems are usually started manually. The cylinder then
extends and retracts continuously until a signal stops the cycling process. This
signal could come from an operator, a counter, a timer, or an emergency circuit.

As an example, Figure 4-8 shows a continuous reciprocation system featuring

single-cycle reciprocation and counting functions. The "single-cycle reciprocation
function" allows the cylinder to extend and retract only one time, allowing initial
set-up and testing of the machine. The counting function allows the cycling process
to be stopped after a pre-definite number of cycles.

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PX1 PX2
SOL-A

DV1

FCV1

PNEUMATIC DIAGRAM

(+) (−)
START
PB1 PX1, NO PX2, NC

1 CR1

CONTINUOUS
CR2-A DV1-SOL-A

L1
HOLD
CR1-A

CONTINUOUS
MODE
PB2 STOP
CR1-B PB3
2 CR2

CR2-B CT1-A

CR1-C

C
3 + CT1 −
R CT1-B

LADDER DIAGRAM

Figure 4-8. Single-Cycle and Continuous Cylinder Reciprocation System.

Depressing the START pushbutton will cause the cylinder to extend and retract one
time, allowing initial set-up and testing of the system. Depressing the START
pushbutton PB1, and then the CONTINUOUS MODE pushbutton PB2 while the
cylinder is extending will cause the cylinder to reciprocate continuously until the
STOP pushbutton is depressed.

Detailed circuit action is as follows:

 Depressing the START pushbutton PB1 causes relay coil CR1 to energize.
Holding relay contact CR1-A closes to lock in relay coil CR1 so as to energize
solenoid DV1-SOL-A and extend the cylinder. NO contact CR1-C closes and the
counter is incremented by one count.

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Counting of Actuator Cycles

 When the cylinder becomes fully extended, magnetic proximity switch PX2
opens, thus deenergizing relay coil CR1. This deenergizes solenoid DV1-SOL-A,
causing the cylinder to retract.

 When the cylinder becomes fully retracted, it activates magnetic proximity

switch PX1. If the CONTINUOUS MODE pushbutton PB2 has been depressed
during cylinder extension, NO contact CR2-A in rung 1 will be closed and the
cylinder will reciprocate until the pre-definite number of cycles set on the counter
is executed, NC contact CT1-A will then open and the cylinder will stop. If PB2
has not been depressed, rung 1 will be open and the cylinder will stop.

The NO contact CT1-B allows the counter to be reset by connecting the RESET (R)
input to common when the pre-definite number of cycles is attained.

Photoelectric Switches

A photoelectric switch is a sensing element that uses a light beam to sense the
presence or motion of an object. Unlike a mechanical limit switch, it can perform
these functions without physical contact. Photoelectric switches have several useful
applications, including cylinder position sensing, level sensing, product detection
and counting, and speed monitoring.

The photoelectric switch consists of a light source, a receiver, and one or more sets
of NO and NC contacts. The light source and receiver can be in the same casing
or separate casings. The light source projects a light beam, which may be visible or
infrared. The receiver picks up the light from the source, but ignores ambient light.

Figure 4-9 shows the Diffuse Reflective Photoelectric Switch supplied with your
trainer. This switch is of the proximity type. It consists of a visible light source and
a receiver combined in the same casing. When powered by a 24-V dc voltage, the
light source projects a beam of red light. When no object is within the detection zone
of the switch, the receiver sees dark and keeps the switch contacts deactivated.
When a reflective object such as a cylinder rod enters the detection zone, light
reflects off the object back to the receiver. This causes the receiver to activate the
switch contacts and to keep them activated until the object is removed from the
detection zone. A red LED at the rear of the switch indicates the status of the
contacts. When it is on, the LED indicates that the switch contacts are activated.

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Counting of Actuator Cycles

LIGHT-SENSING
RECEIVER

VISIBLE LIGHT PNEUMATIC DIAGRAM SYMBOL

SOURCE

NO TERMINAL

COMMON
TERMINAL
DETECTION
RANGE
DETECTION NC TERMINAL
ZONE
LADDER DIAGRAM SYMBOL

Figure 4-9. Photoelectric Switch.

The trainer Diffuse Reflective Photoelectric Switch has a detection range of 10.2 cm
(4 in), which means that it is able to detect objects located within 10.2 cm (4 in) of
it. This range will vary slightly depending upon the reflectance, or ability to reflect
light, of objects. The more reflective an object, the farther the detection range. The
reflectance of an object depends on its surface material, color, and texture.

Procedure Summary

In the first part of the exercise, you will test the operation of an electrical counter.

In the second part of the exercise, you will connect and test a system that uses an
electrical counter to extend and retract a cylinder a definite number of times.

In the third part of the exercise, you will test the operation of a photoelectric switch.

In the fourth part of the exercise, you will use an electrical counter to measure the
rotation speed of a pneumatic motor.

EQUIPMENT REQUIRED

Refer to the Equipment Utilization Chart, in Appendix A of this manual, to obtain the
list of equipment required to perform this exercise.

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PROCEDURE

Operation of an Electrical Counter

* 1. Connect the circuit shown in Figure 4-10.

(+) (−)
COUNT
PB1

COUNTER

CONTROL (C)

1 + CT1 −
RESET (R)

RESET
PB2

L1
CT1-A
2

Figure 4-10. Testing the Operation of an Electrical Counter.

* 2. On the Time-Delay Relay / Counter, set the thumbwheel switches to

A005  , This will program the Time-Delay Relay / Counter for the CO
(Operate at Preset Count) counting function, set the preset value to 5, and
select a normal counting interval.

* 3. Turn on the DC Power Supply.

* 4. What is the count value shown on the Time-Delay Relay / Counter display?

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Counting of Actuator Cycles

* 5. Depress momentarily the COUNT pushbutton PB1. What happens to the

displayed count? Why? Explain by referring to the ladder diagram in
Figure 4-10.

* 6. While observing pilot lamp L1, depress pushbutton PB1 several times until
the displayed count reaches the preset value of 5. What happens to
lamp L1 when the displayed count reaches 5? Why? Explain by referring
to the ladder diagram in Figure 4-10.

* 7. Again depress pushbutton PB1 several times while observing the displayed
count. Do additional input pulses continue to increment the displayed
count?

* Yes * No

* 8. Momentarily depress the RESET pushbutton, PB2. What happens to the

displayed count? To pilot lamp L1? Why?

* 9. While observing the displayed count, depress and hold pushbutton PB1 for
a few seconds, then release PB1. Is the displayed count incremented
immediately when PB1 is depressed or after PB1 is released?

* 10. Based on the observation you made in the previous step, is the counter
value incremented each time the CONTROL (C) input is switched to
common ( ) and then disconnected from common?

* Yes * No

* 11. Turn off the DC Power Supply. Disconnect all leads and components.

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Counting of Actuator Cycles

Continuous Reciprocation of Cylinders

* 12. Connect the circuit shown in Figure 4-8.

* 13. Mount the Magnetic Proximity Switches on the cylinder so that PX1 is
activated when the cylinder rod is fully retracted, and PX2 activated when
the cylinder rod is fully extended. Refer to exercise 2-3 if necessary.

* 14. On the Time-Delay Relay / Counter, make sure the thumbwheel switches
are set to A005  .

* 15. Verify the status of the trainer according to the procedure given in
Appendix F.

* 16. Close Flow Control Valve FCV1 by turning the control knob fully clockwise.
Then open the valve by turning the control knob two turns
counterclockwise.

* 17. Open the shutoff valve and the branch shutoff valves at the manifold and
set the pressure at 400 kPa (or 60 psi) on the regulated pressure gauge.

* 18. Turn on the DC Power Supply, and start the system by depressing the
START pushbutton momentarily. The cylinder rod should automatically
extend and retract 1 time, then it should stop at the home position. Record
whether you observe this or not.

* Yes * No

* 19. Restart the system several times to become familiar with the operation.
What causes the cylinder rod to extend when the START pushbutton is
depressed? Explain by referring to the ladder diagram in Figure 4-8.

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Counting of Actuator Cycles

* 20. Depress the START pushbutton and observe the count value on the Time-
Delay Relay / Counter display. Is the displayed count incremented by one
each time the cylinder rod becomes fully extended? Why?

* 21. Is the counter value automatically reset to zero at the moment when the
cylinder completes its fifth extension stroke? Why?

* 22. Depress simultaneously the START pushbutton and the CONTINUOUS

MODE pushbutton while the cylinder is extending. Observe the operation
of the system in continuous mode. Does the cylinder rod extend and retract
five times, then stop at the home position? Record whether you observe
this or not.

* Yes * No

* 23. Depress the STOP pushbutton while the cylinder rod is extending. Does the
rod stop immediately? Explain why.

* 24. Try to start the cylinder rod by depressing the CONTINUOUS MODE
pushbutton. What happens? Explain why.

* 25. Turn off the DC Power Supply.

* 26. On the Conditioning Unit, close the shutoff valves, and turn the regulator
adjusting knob completely counterclockwise.

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Counting of Actuator Cycles

* 27. Disconnect all leads and components.

Operation of a Photoelectric Switch

* 28. Clamp the Diffuse Reflective Photoelectric Switch to the work surface.
Connect the () and ( ) terminals of the switch to the corresponding
terminals of the DC Power Supply. Turn on the DC Power Supply, which
will power the light source inside the switch.

* 29. Pass your hand in front of the photoelectric switch. Does the red LED at the
rear of the switch turn on, indicating the switch contacts are activated?

* Yes * No

* 30. Slowly move your hand away from the photoelectric switch. Does the
switch LED turn off, indicating the switch contacts are deactivated?

* Yes * No

* 31. Turn off the DC Power Supply.

Counting of Motor Revolutions

* 32. Position the pneumatic motor so that it is perpendicular to the photoelectric

switch at a distance of 10 cm (4 in) (2 rows of perforations) as shown in
Figure 4-11. The beam of the photoelectric switch must be pointing in the
direction of the white sticker on the motor shaft. Clamp the motor in place.

Note: Ensure that a white sticker is present on the motor shaft.

Ask your instructor to install a new one if it is not the case. The
reflective properties of the sticker activates the receiver of the
photoelectric switch each time the sticker enters the detection
zone.

* 33. Turn on the DC Power Supply.

* 34. Manually turn the motor shaft to check that the photoelectric switch is
activated when it senses the white sticker of the motor shaft and
deactivated when it senses the grey.

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Counting of Actuator Cycles

PNEUMATIC
MOTOR

PHOTOELECTRIC
SWITCH

DC POWER
SUPPLY

Figure 4-11. Photoelectric Switch Positioning.

* 35. Turn off the DC Power Supply. Connect the circuit shown in Figure 4-12.
Be careful not to modify the mounting positions of the motor and
photoelectric switch.

* 36. On the Time-Delay Relay / Counter, set the thumbwheel switches to

B000  . This will program the Time-Delay Relay / Counter for the
CO counting function, set the preset value to 0, and select a divide-by-10
counting interval.

* 37. Open the shutoff valve and the branch shutoff valves at the manifold. Open
Flow Control Valve FCV1 by turning the control knob fully
counterclockwise.

* 38. Turn on the DC Power Supply, and depress the START pushbutton PB1
to energize valve solenoid A and start the motor. Increase the regulated
pressure until the motor turns at a constant speed.

Note: If the LED on the photoelectric switch seems to skip,

reduce the rotation speed of the motor by decreasing the air flow
with FCV1.

* 39. Observe the count value on the Time-Delay Relay / Counter display. Since
a divide-by-10 counting interval has been selected, the displayed count is
incremented by one for every 10 revolutions of the motor.

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Counting of Actuator Cycles

SOL-A

DV1
PE1

FCV1

PNEUMATIC DIAGRAM

(+) (−)
START
PB1 STOP
PB2
1 CR1

CR1-A DV1-SOL-A

L1

PE1,NO

C
2 CT1 −
+ R RESET
PB3

LADDER DIAGRAM

Figure 4-12. Counting of Motor Revolutions.

* 40. Using a stopwatch, measure the rotation speed of the motor by performing
the following steps:

 Depress the RESET pushbutton, PB3, and simultaneously start the

stopwatch.

 Let the motor turn for 60 s, then stop the motor by depressing the
STOP pushbutton, PB2.

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Counting of Actuator Cycles

 Multiply the displayed count by 10 to obtain the motor speed, in

revolutions per minute (r/min). Record the motor speed.

Motor speed: r/min

* 41. Again depress pushbutton PB1 to start the motor. Place a tachometer on
the motor shaft and measure the motor speed. Does this speed
approximately correspond to the speed recorded in the previous step?

* Yes * No

* 42. Turn off the DC Power Supply.

* 43. On the Conditioning Unit, close the shutoff valves, and turn the regulator
adjusting knob completely counterclockwise.

* 44. Disconnect and store all leads and components.

CONCLUSION

In the first part of the exercise, you tested the operation of an electrical counter
placed in the CO (Operate at Preset Count) mode of operation. You saw that the
electrical counter does not shift its contacts to the activated state until a preset
count is reached. It returns them to the deactivated state when the accumulated
count is reset.

In the second part of the exercise, you learned that an electrical counter can cause
a cylinder to repeat a cycle a definite number of times. This function is often used
when parts of the system must be activated or deactivated after a definite number
of events have occurred.

In the third part of the exercise, you tested the operation of a photoelectric switch.
You saw that the photoelectric switch detects the presence of objects within a
specific range and zone.

In the fourth part of the exercise, you determined the speed of rotation of a
pneumatic motor by counting the number of revolutions performed in one minute.

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REVIEW QUESTIONS

1. Give two ways an electrical counter is used in electrically controlled pneumatic

systems.

2. Describe the basic operation of an electrical counter.

3. What is meant by "preset value"?

4. Once the preset value is reached, do additional input pulses continue to

increment the counter?

5. How can the counter value be returned to zero?

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