Workbook TP201 EN 541090

Workbook
TP201
EN
541090

Use for intended purpose

The training system from Festo Didactic has been developed and produced exclusively for training and
further education in the field of automation and technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.

Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment in situations which serve any purpose
other than training and/or further education, unless such damages have been caused by Festo Didactic due
to malicious intent or gross negligence.

Order no. 541090
Status: 06/2009
Authors: M. Pany, S. Scharf
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 01/2010

Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2010
Internet: www.festo-didactic.com
e-mail: did@de.festo.com

The reproduction, distribution and utilisation of this document, as well as the communication of its contents
to others without explicit authorisation, is prohibited. Offenders will be held liable for compensation of
damages. All rights reserved, in particular the right to file patent, utility model and registered design
applications. Portions of this documentation may be duplicated by an authorised user exclusively for
training purposes.

Festo Didactic GmbH & Co. KG 541090 III
Table of Contents

Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Safety precautions and work instructions ____________________________________________________ VIII
Technology module for electro-pneumatics (TP200) ______________________________________________X
Learning objectives for the basic level (TP201) _________________________________________________ XI
Overview of learning objectives per exercise __________________________________________________ XII
Equipment set for the basic level (TP201) ____________________________________________________ XIII
Allocation of equipment per exercise _______________________________________________________ XVII
Practical tools for the trainer ______________________________________________________________ XVIII
Structure of the exercises ________________________________________________________________ XVIII
Designations of the components ___________________________________________________________ XVIII
CD ROM contents ________________________________________________________________________ XIX
Equipment set for the advanced level (TP202) _________________________________________________ XXI
Learning objectives for the advanced level (TP202) ____________________________________________ XXII

Solutions

Exercise 1: Inspecting beverage cases _________________________________________________________ 1
Exercise 2: Opening and closing a supply pipe ________________________________________________ 13
Exercise 3: Sealing plastic cans _____________________________________________________________ 23
Exercise 4: Packing plastic pellets___________________________________________________________ 33
Exercise 5: Diverting packages _____________________________________________________________ 41
Exercise 6: Pushing wooden boards out of a stacking magazine __________________________________ 51
Exercise 7: Sorting packages _______________________________________________________________ 61
Exercise 8: Sanding wooden boards _________________________________________________________ 69
Exercise 9: Diverting bottles _______________________________________________________________ 77
Exercise 10: Stamping taper keys ___________________________________________________________ 87
Exercise 11: Palletising roof tiles ___________________________________________________________ 99
Exercise12: Eliminating a malfunction at a pallet loading station _________________________________ 107

IV Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090 V
Preface

Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The training packages are therefore broken down as follows:
Basic modules impart basic, interdisciplinary, technological knowledge.
Technology modules address the important topics of open and closed-loop control technology.
Function modules explain the fundamental functions of automated systems.
Application modules enable training and further education that is aligned to real-life practice.

The technology modules deal with various technologies including pneumatics, electro-pneumatics,
programmable logic controllers, automation using a personal computer, hydraulics, electro-hydraulics,
proportional hydraulics and applications technology (handling).

The modular design of the training system makes it possible to focus on applications above and beyond
those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.

VI Festo Didactic GmbH & Co. KG 540671
All training modules have the same structure:
Hardware
Courseware
Software
Seminars

The hardware is comprised of industrial components and systems that are specially designed for training
purposes.
The structure of the courseware corresponds to that of the training hardware. It includes:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, supplementary instructions and solutions)
Transparencies and videos (for dynamic instruction)

The working materials for TP201 consist of 19 exercises and a workbook. Each exercise has its own set of
ready-to-use worksheets. The solutions are included in the workbook, which also has the worksheets and a CD
ROM. The exercises can be purchased without the workbook and are used as consumables. They can thus be
easily made available to trainees. Data sheets for the hardware components are made available along with the
training module and on the CD ROM.

The teaching and learning media are available in several languages. Theyre intended for use in classroom
instruction, but are also suitable for self-study.

Where software is concerned, computer training programs and programming software are made available
for programmable logic controllers.

A wide range of seminars covering the contents of the technology module round off the programme for
training and further education.

Festo Didactic GmbH & Co. KG 541090 VII
Introduction

This workbook is part of the training system for automation and technology from Festo Didactic GmbH & Co.
KG. The system provides a solid basis for practical training and further education. The TP200 technology
module only includes electro-pneumatic control systems.

The TP201 basic level is suitable for basic training in the field of electro-pneumatic control technology. It
covers the fundamentals of electro-pneumatics as well as the function and use of electro-pneumatic
equipment. Simple electro-pneumatic control systems can be set up with the equipment set.

The TP202 advanced level is targeted at vocational training in the field of electro-pneumatic control
technology. The two equipment sets can be used to set up extensive combinatory circuits with linking of the
input and output signals, as well as programme control systems.

A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the
control systems. The profile plate has 14 parallel T-slots at 50 mm intervals. A power supply with short-
circuit protection is used as a direct voltage source (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A portable
compressor with silencer (230 V, max. 8 bar = 800 kPa) can be used for compressed air supply.

Working pressure should not exceed 6 bar (600 kPa).

Ideal reliability can be achieved by operating the control system at a working pressure of 5 bar (500 kPa)
without oil.

All the control systems for the 12 exercises are set up using the equipment set for the TP201 basic level. The
theoretical fundamentals for understanding this collection of exercises are included in the textbook:

Electro-pneumatics

Data sheets for the individual components are also available (cylinders, valves, measuring instruments etc.).

VIII Festo Didactic GmbH & Co. KG 540671
Safety precautions and work instructions

General
Trainees should only work with the control systems under the supervision of a trainer.
Observe specifications included in the data sheets for the individual components and in particular all safety
instructions!

Mechanical
Mount all of the components securely onto the profile plate.
Limit switches may not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Only reach into the set-up when its at a complete standstill.

Electrical
Electrical connections must only be established and interrupted in the absence of voltage!
Use connector cables with safety plugs only for electrical connections.
Use low-voltage only (max. 24 V DC).

Pneumatics
Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
Do not switch on the compressed air until all the tubing connections have been completed and secured.
Do not disconnect tubing while under pressure.
Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
Danger of accident due to tubing slipping off!
Use shortest possible tubing connections.
Wear safety glasses.
In the event that tubing slips off:
Switch compressed air supply off immediately.
Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
Switch compressed air supply off before dismantling the circuit.
Dismantling pneumatic circuits:
Press the blue release ring down, after which the tubing can be pulled out.

Festo Didactic GmbH & Co. KG 540671 IX
The mounting boards for the components are equipped with mounting variants A through D:

Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the component
into the slot on the profile plate. Release the component from the slot by actuating the blue lever.

Variant B, bolt system
Components with medium load capacity (e.g. drives). These components are clamped to the profile plate
using T-head bolts. The blue, knurled nut is used for clamping and loosening.

Variant C, screw system
For components with high load capacity and components which are seldom removed from the profile plate
(for example on-off valve with filter regulator). These components are secured with socket head screws
and T-head bolts.

Variant D, plug-in system
Lightweight components with locking pins that are not load-bearing (e.g. indicators). These are secured
using plug adapters.

Observe specifications in the data sheets regarding the individual components.

X Festo Didactic GmbH & Co. KG 540671
Technology module for electro-pneumatics (TP200)

The TP200 technology packet consists of a multitude of training materials and seminars. The subject matter
is entirely focused on electro-pneumatic control systems. Individual components included in the TP200
technology module can also be included in any of the other modules.

Important elements of the TP200:
Permanent workstation with Festo Didactic profile plate
Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)
Equipment sets or individual components
Optional training materials
Practical training models
Complete laboratory set-ups

Training documentation
Textbooks TP201 basic level
Fundamentals of pneumatic control technology
Maintenance of pneumatic equipment and systems
Workbooks TP201 basic level
TP202 advanced level
Optional courseware Set of transparencies and overhead projector
Magnetic symbols, drawing template
Electro-pneumatics WBT, pneumatics WBT
Electrical engineering WBTs 1 and 2, electronics WBTs 1 and 2
Set of cutaway models with storage case
FluidSIM
pneumatic simulation software

Seminars
P100 Basic pneumatics knowledge for machine operators
P111 Fundamentals of pneumatics and electro-pneumatics
P121 Maintenance and troubleshooting for pneumatic and electro-pneumatic systems
P-OP Tracking down waste economic use of pneumatics
P-NEU Pneumatics refresher and update
IW-PEP Repair and maintenance in the field of control technology pneumatic and electro-pneumatic systems
P-AL Pneumatics for further education
P-AZUBI Pneumatics and electro-pneumatics for trainees

Please refer to the current seminar planner for locations, dates and prices.

Youll find further training materials in our catalogue and on the Internet. The training system for automation
and technology is continuously updated and expanded. Transparencies, videos, CD ROMs and DVDs, as well
as textbooks, are offered in several languages.

Festo Didactic GmbH & Co. KG 541090 XI
Learning objectives for the basic level (TP201)

Become familiar with the set-up and mode of operation of a single-acting cylinder.
Become familiar with the set-up and mode of operation of a double-acting cylinder.
Be able to calculate piston forces based on specified values.
Become familiar with the set-up and mode of operation of a 3/2-way solenoid valve.
Become familiar with the set-up and mode of operation of a double solenoid valve.
Be able to select solenoid valves based on the specified requirements.
Be able to recognise and sketch the various types of actuation for directional control valves.
Be able to convert solenoid valves.
Be able to explain and set up direct actuation.
Be able to explain and set up indirect actuation.
Become familiar with logic operations and be able to set them up.
Become familiar with various types of end-position control and learn to select the appropriate type.
Be able to calculate characteristic electrical values.
Become familiar with latching circuits with varying performance features.
Be able to explain and set up an electrical latching circuit with dominant shutdown signal.
Be able to set up a pressure-dependent control system.
Become familiar with the set-up and mode of operation of magnetic proximity switches.
Become familiar with displacement-step diagrams and learn to create them for specific problems.
Be able to implement sequence control with two cylinders.
Be able to detect and eliminate errors in simple electro-pneumatic control systems.

XII Festo Didactic GmbH & Co. KG 541090
Overview of learning objectives per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning objectives
Become familiar with the set-up and mode of
operation of a single-acting cylinder.

operation of a double-acting cylinder.

Learn to calculate piston forces based on specified
values.

operation of a 3/2-way valve.

operation of a double solenoid valve.

Be able to select solenoid valves based on the
specified requirements.

Be able to recognise and sketch the various types of
actuation for directional control valves.

Be able to convert solenoid valves.
Be able to explain and set up direct actuation.
Be able to explain and set up indirect actuation.
Become familiar with various types of end-position
control and learn to select the appropriate type.

Become familiar with logic operations and be able to
set them up.

Be able to calculate characteristic electrical values.
Become familiar with latching circuits with varying
performance features.

Be able to explain and set up an electrical latching
circuit with dominant breaking signal.

Be able to set up a pressure-dependent control
system.

operation of magnetic proximity switches.

Become familiar with displacement-step diagrams and
learn to create them for specific problems.

Be able to implement sequence control with two
cylinders.

Be able to detect and eliminate errors in simple
electro-pneumatic control systems.

Festo Didactic GmbH & Co. KG 541090 XIII
Equipment set for the basic level (TP201)

The equipment set has been put together for basic training in the field of electro-pneumatic control
technology. It includes all the elements that are necessary for mastering the specific learning objectives and
can be supplemented with any other equipment sets. A profile plate, an electrical power supply unit and a
source of compressed air are also required in order to set up functional control systems.

Equipment set for the basic level (TP201)

Designation Order no. Quantity
2 x 3/2-way solenoid valve, normally closed 539776 1
5/2-way double solenoid valve 539778 2
5/2-way solenoid valve 539777 1
Blanking plug 153267 10
Double-acting cylinder 152888 2
One-way flow control valve 193967 4
Pressure sensor 539757 1
Single-acting cylinder 152887 1
On-off valve with filter regulator 540691 1
Limit switch, electrical, actuated from left 183322 1
Limit switch, electrical, actuated from right 183322 1
Plastic tubing, 4 x 0.75, 10 m 151496 2
Proximity switch, electronic 540695 2
Proximity switch, optical 178577 1
Relay, 3-way 162241 2
Signal input, electrical 162242 1
Push-in sleeve 153251 10
Push-in T-connector 153128 20
Distributor block 152896 1

XIV Festo Didactic GmbH & Co. KG 541090
Equipment set symbols

Designation Symbol
Relay, 3-way

14 12 24 22 34 32
32
44 42
11 21 31 41
A1
A2
14 12 24 22 34 44 42
11 21 41
A1
A2
31
14 12 24 22 34 32 44 42
11 21 31 41
A1
A2

Signal input, electrical

13 21
14 22
13 21
14 22
13 21
14 22
13 21
14 22

3/2-way solenoid valve,
normally closed

2
1M1
3 1
1M1
12

Festo Didactic GmbH & Co. KG 541090 XV
Designation Symbol
5/2-way double solenoid
valve

5/2-way solenoid valve

Proximity switch, electronic

Pressure sensor

p

Proximity switch, optical

Electrical limit switch

4 2
1

One-way flow control valve

2 1

XVI Festo Didactic GmbH & Co. KG 541090
Designation Symbol
Single-acting cylinder

Double-acting cylinder

On-off valve with filter
regulator

2
3
1

Distributor block

Connectors

Festo Didactic GmbH & Co. KG 541090 XVII
Allocation of equipment per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Components
Cylinder, single-acting 1 1 1 1
Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1
One-way flow control valve 1 2 2 1 2 2 2 2 2 2 3 3
3/2-way solenoid valve, normally closed 1 (1) 1 1
5/2-way solenoid valve 1 1 1 1
5/2-way double solenoid valve 1 1 1 1 1 1 1
Pressure sensor 1
Limit switch, electrical 1 2
Proximity switch, normally open 2 2 1 2
Proximity switch, optical 1 1
Pushbutton, electrical, normally open 1 1 1 2 2 1 1 1 1 1 1 1
Pushbutton, electrical, normally closed 1 1
Relay 1 1 2 2 3 1 3 3 3 3
Distributor block 1 1 1 1 1 1 1 1 1 1 1 1
On-off valve with filter regulator 1 1 1 1 1 1 1 1 1 1 1 1
Power supply unit, 24 V DC 1 1 1 1 1 1 1 1 1 1 1 1
5/2-way solenoid valve 1 1 1 1

XVIII Festo Didactic GmbH & Co. KG 540671
Practical tools for the trainer

Learning objectives
The basic learning objectives for the exercises in this module are the systematic sketching of circuit
diagrams as well as the practical set-up of a control system on the profile plate. This direct interaction
involving both theory and practice ensures faster, long-term learning. Each exercise has its own individual
learning objectives; the specific learning objectives are documented in the matrix.

Required time
The time required for the exercises depends on the trainees previous knowledge of the subject matter. For
training a skilled labourer in metalworking or electrical installation: approx. 2 weeks. For training a
technician or engineer: approx. 1 week.

Equipment sets
The exercises and the equipment sets match each other. For all the exercises youll only need the
components included in the equipment set for the TP201 basic level.
Each exercise in the basic level can be set up on a profile plate.

Structure of the exercises
All 12 exercises in part A have the same structure and are broken down into:
Title
Learning objectives
Presentation of the problem
Layout
Parameters
Project assignment
Worksheets

The solutions for all the 12 exercises are included in the trainers manual.

Designations of the components
Pneumatic components are designated in circuit diagrams to DIN ISO 1219 2. All the components included
in any given circuit have the same primary identifying number. Letters are assigned depending on each
respective type of component. Consecutive numbers are assigned if several components of the same type
are included within a single circuit. Pressure lines are designated with a P and are numbered separately.

Drives: 1A1, 2A1, 2A2 ...
Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
Sensors: 1B1, 1B2 ...
Signal input: 1S1, 1S2 ...
Accessories: 0Z1, 0Z2, 1Z1 ...
Pressure lines: P1, P2 ...

Festo Didactic GmbH & Co. KG 541090 XIX
CD ROM contents

The CD ROM provides you with additional media. The contents of parts A (exercises) and C (solutions) have
been saved as PDF files.

The CD ROM has the following structure:
Operating instructions
Data sheets
Demo
Festo catalogue
FluidSIM
circuit diagrams
Industrial applications
Presentations
Product information
Videos

Operating instructions
Operating instructions for various components included in the technology module are available. These
instructions are helpful when using and commissioning the equipment.

Data sheets
The data sheets for the components included in the technology module are available as PDF files.

Demo
A demo version of the FluidSIM
pneumatics software package is included on the CD ROM. Even this demo

version is suitable for testing control systems developed by the user.

Festo catalogue
The relevant pages from the Festo catalogue will be provided with selected components. The
representations and descriptions of the components are intended to demonstrate how the components are
presented in an industrial catalogue. Additional information regarding the components is also included.

FluidSIM
circuit diagrams
The FluidSIM
circuit diagrams for all 12 exercises included in the technology module are contained in this
directory.

Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks. Project presentations can also be supplemented with these illustrations.

Presentations
Contains short presentations of the components included in the technology module. These can be used, for
example, to create project presentations.

XX Festo Didactic GmbH & Co. KG 540671
Product information
This directory contains product information and data sheets from Festo AG & Co. KG for the components
included in this technology module. This is intended to demonstrate which information and data are
available for industrial components.

Videos
Several videos of industrial applications complete the media provided with the technology module. Short
clips demonstrate the applications in their actual industrial environments.

Festo Didactic GmbH & Co. KG 541090 XXI
Equipment set for the advanced level (TP202)

The equipment set for the advanced level has been put together for vocational training in the field of electro-
pneumatic control technology. The two equipment sets (TP201 and TP202) include components that are
necessary for mastering the predefined learning objectives and can be supplemented as required with other
equipment sets from the training system for automation and technology.

Equipment set for the advanced level (TP202, order no. 540713)

Quantity Designation Order no.
2 Relay, 3-way 162241
1 Signal input, electrical 162242
1 Time relay, 2-way 162243
1 Preset counter, electrical 162355
1 Proximity switch, inductive 178574
1 Proximity switch, capacitive 178575
1 Emergency-stop button 183347
1 Valve terminal with 4 valve slices (MMJJ) 540696
2 Non-return valve, piloted 540715

XXII Festo Didactic GmbH & Co. KG 540671
Learning objectives for the advanced level (TP202)

Describe the structure and application of valve terminals
Implement sequence controls with overlapping signals solution according to group method
Implement sequence controls with overlapping signals solution with step sequence using spring
return valves
Implement sequence controls with overlapping signals solution with step sequence using double pilot
valve (with control step)
Describe and set up modes of operation (single/continuous cycle)
Describe the function and application of a preset counter
Explain and implement the emergency stop function with spring return valves
Implement special emergency stop conditions: actuators must come to a standstill during an emergency
stop
Explain function and use of a 5/3-way solenoid valve
Describe and set up the Set operating mode
Execute troubleshooting in complex electro-pneumatic circuits

Festo Didactic GmbH & Co. KG 541090 1
Exercise 1: Inspecting beverage cases

Learning objectives
After completing this exercise:
Youll be familiar with the set-up and mode of operation of a single-acting cylinder.
Youll be familiar with the set-up and mode of operation of a 3/2-way solenoid valve.
Youll be able to recognise and sketch the various types of actuation for directional control valves.
Youll be able to explain and set up direct actuation.

Beverage cases are inspected for completeness with a test device. Incomplete cases are pushed off of the
roller conveyor by pressing a pushbutton. Develop a control system with which this process can be
executed.

Layout

Test device

2 Festo Didactic GmbH & Co. KG 540671
Parameters
A single-acting cylinder is to be used.
The cylinder will be actuated using a pushbutton.
In the event of a power failure, the cylinders piston rod should move to the retracted end position.

Control sequence
1 After pressing a pushbutton, the piston rod of a single-acting cylinder pushes the beverage case from
the conveyor.
2 When the pushbutton is released, the piston rod moves to its retracted end position.

Project assignment
1 Answer the questions and complete the tasks for the learning topics.
2 Draw the pneumatic and electrical circuit diagrams.
3 Create an equipment list.
4 Set up the pneumatic and electrical circuits.
5 Check the circuit sequence.

Function of pneumatic power components
Pneumatic power components can be subdivided into two groups:
Power components with straight motion
Power components with rotary motion

Describe the power components shown below, as well as their functions.

Symbol Function

Single-acting cylinder, reset spring in piston chamber, return stroke by means of compressed air,
forward stroke by means of reset spring.

Function
The piston rod of this single-acting cylinder moves to its retracted end position by activating the
compressed air. After deactivating the compressed air, the piston moves to its advanced end
position by a reset spring in the piston chamber (2 operating positions).

Single-acting cylinder, reset spring in piston chamber, forward stroke by means of compressed air,
return stroke by means of reset spring.

Function
The piston rod of the single-acting cylinder moves to its advanced end position when the
compressed air has been activated. After deactivating the compressed air, the piston moves to its
retracted end position by a reset spring (2 operating positions).

Pneumatic quarter turn actuator (rotary drive) with limited swivel angle

Function
This swivel cylinder is double-acting and reverses by alternately activating the compressed air at
either end (2 operating positions).

Complete the symbols for solenoid valves

Complete the individual symbols with the help of the descriptions of the respective components.

Description Symbol
Directly actuated 3/2-way solenoid valve, normally open,
with manual override, spring return

2
1M1
3 1
10

Pilot actuated 3/2-way solenoid valve, normally closed,
with manual override, spring return

2
1M1
3 1
12

Normal positions of directional control valves
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position
(unactuated) or the switched position (actuated). The valve can be either closed or open in its normal position.
The single-acting cylinder depicted below is controlled by an electrically actuated 3/2-way solenoid valve.

Describe how the two different normal positions affect the motion sequence of the cylinder shown below:

3/2-way solenoid valve, normally closed 3/2-way solenoid valve, normally open
The solenoid valve used is reversed by applying voltage to the
solenoid coil; flow is enabled from supply port 1 to working port
2. After the signal has been stopped, the valve returns to its
normal position by a reset spring and supply port 1 is closed, thus
stopping flow. If the directional control valves solenoid coil is de-
energised, the cylinder chamber is vented via exhaust port 3 at
the directional control valve. The piston rod is retracted. When
the solenoid coil is energised, the directional control valve
switches and the cylinder chamber is pressurised. The piston rod
advances. When the solenoid coil is de-energised, the valve
switches back again. The cylinder chamber is exhausted and the
piston rod is retracted.
The motion sequence is thus as follows: 1A1+ 1A1-.
The solenoid valve used is reversed by applying voltage to the
solenoid coil; supply port 1 is closed, thus stopping flow. After
stopping the signal, the valve returns to its normal position by a
reset spring and flow from supply port 1 to working port 2 is
enabled. If the directional control valves solenoid coil is de-
energised, the cylinder chamber is pressurised via the directional
control valve. The piston rod is advanced. When the solenoid coil is
energised the directional control valve switches and the cylinder
chamber is exhausted via exhaust port 3 at the directional control
valve. The piston rod is retracted. When the solenoid coil is de-
energised, the valve switches back again. The cylinder chamber is
pressurised and the piston rod is advanced.
The motion sequence is thus as follows: 1A1- 1A1+.

Direct and indirect actuation
An electrically actuated solenoid valve can be directly or indirectly actuated.

Describe the difference on the basis of the following example: electrical actuation of a 3/2-way solenoid
valve with spring return using a pushbutton.

Direct actuation Indirect actuation
When the pushbutton is activated, current flows through the
valves solenoid coil. The solenoid is energised and the valve
switches to the actuated position.
The flow of electrical current is interrupted when the pushbutton
is released. The solenoid is de-energised and the valve switches
to the normal position.
In the case of indirect actuation, current flows through a relay coil
when a pushbutton is activated. The relays contacts are closed
and the valve switches. The valve remains in this switching
position as long as electrical current flows through the solenoid
coil or the relay coil. The relay drops out when the flow of
electrical current through the relay coil is interrupted and the
valve switches to its normal position.
More complicated indirect actuation is used when the control
circuit and the primary circuit use different voltages, when current
flowing through the directional control valves solenoid coil is
greater than permissible current for the pushbutton, when
several valves are switched with a single pushbutton or pressure
switch or if extensive logic operations are required amongst the
signals from various pushbuttons.

Design and function of electrical switches
In principle, switches are subdivided into two types, namely pushbuttons and control switches and function
as NC contacts, NO contacts or change-over contacts.

Describe the design and function of the switches depicted below.

Symbol Design / function
3
4

Design:
Pushbutton with normally open contacts

Function:
In the case of a pushbutton, the selected switching position is only retained as long as the pushbutton is
activated. The pushbutton shown here has a normally open function. With normally open contacts, the electrical
circuit is interrupted when the pushbutton is in its normal position, i.e. in the unactivated state. When the
control stem is actuated, the electrical circuit is closed and current flows to the consuming device. When the
control stem is released, the pushbutton is returned to its normal position by means of spring force and the
electrical circuit is interrupted.

Design:
Control switch with normally closed contacts

Function:
Control switches are mechanically locked into the two switching positions. The respective switching position is
retained until the switch is once again activated. The control switch shown here has a normally closed function.
In the case of normally closed contacts, the electrical circuit is closed when the control switch is held in its
normal position by means of spring force. When the control switch is activated, the electrical circuit is
interrupted and reactivation closes the circuit again.
4 2
1

Design:
Pushbutton with change-over contacts

Function:
In the case of a pushbutton, the selected switching position is only retained as long as the pushbutton is
activated. The pushbutton shown here has a change-over function. In the case of change-over contacts, NC and
NO functions are combined into a single component. An electrical circuit is closed and another is interrupted
with a single switching operation. Both circuits are briefly interrupted during switching.

Mode of operation of various valve types
Electrically actuated directional control valves are switched by means of solenoids. In principle, they can be
subdivided into two groups:
Solenoid valves with spring return
Double solenoid valves

Explain the difference between the two groups with regard to function and performance in the event of a
power failure.

Valve type Mode of operation
Solenoid valve with spring
return
The actuated switching position is only retained as long as electrical current flows through the solenoid
coil. The normal position is clearly defined by the reset spring. If there is no electrical power, the valve
returns to its normal position by the spring. This may cause dangerous machine motion.
For example, the piston rod of a pneumatic cylinder could be returned to its normal position, thus
releasing a previously clamped workpiece.
Double solenoid valve Only a brief signal is required in order to reverse the valve and the last switching position is retained
even in the de-energised state as the result of static friction. All solenoid coils are de-energised in the
normal position and the normal position cannot be clearly defined. The valve stays in its last switching
position in the event of a power failure. No dangerous machine motion can be triggered as a result.
For example, the piston rod of a pneumatic cylinder is kept in its operating position and workpiece
clamping is thus retained.

Identifying valve ports
In order to prevent incorrect tubing connections at directional control valves, the valve ports (working and pilot
lines) are identified in accordance with ISO 5599-3 on the valves themselves, as well as in the circuit diagram.

Explain the meanings and functions of the port designations listed below.

Port identification Meaning and function
3 Exhaust port
12
Pilot line, function for pilot actuated or pneumatically actuated directional control valves when
actuated: supply port 1 and working port 2 are connected
10
actuated: supply port 1 is closed

Complete the pneumatic and electrical circuit diagrams

Complete the pneumatic and electrical circuit diagrams for the sorting system.

1V2
2
2
1
1M1
3 1
1A1
1V1

1M1
1
S1
13
14
+24 V
0 V
Pneumatic circuit diagram Electrical circuit diagram

Create an equipment list
In addition to the circuit diagram, complete project documentation also includes an equipment list.

Create an equipment list by entering the required components in the table below.

Quantity Designation
1 Cylinder, single-acting
1 One-way flow control valve
1 3/2-way solenoid valve, normally closed
1 Pushbutton (normally open)
1 Distributor block
1 On-off valve with filter regulator
1 Compressed air source
1 Power supply unit, 24 V DC
Equipment list


Exercise 2: Opening and closing a supply pipe

Learning objectives
Youll be familiar with the set-up and mode of operation of a double-acting cylinder.
Youll be able to explain and set up direct actuation.

Numerous pipes have to be opened and closed in a water treatment system with the help of shut-off
components. During the test set-up an actuation option for the shut-off valve will be sought.

Layout

Shut-off device

Parameters
A double-acting cylinder will be used.
The cylinder will be actuated using a pushbutton.
In the event of a power failure, the cylinders piston rod should move to its retracted end position.

Project assignment
3 Simulate the electro-pneumatic circuit diagram and test it for correct functioning.

Control sequence
1 The gate is opened when a pushbutton is pressed.
2 When the pushbutton is released, the gate is closed again.

Comparing directly actuated and pilot actuated valves
With regard to the type of valve piston actuation, differentiation is made between directly actuated and pilot
actuated solenoid valves.

Compare these two valve types and list their respective advantages and disadvantages.

Directly-actuated valve Pilot-actuated valve
Flow to the consuming device is enabled by the solenoids
armature. A relatively large armature is required in order to
ensure an adequately large cross section for the opening, thus
allowing for sufficient flow. Hence a correspondingly powerful
reset spring is required and the solenoid must also generate
considerable force. The solenoid is thus large and has high power
consumption.
Flow to the consuming device is switched by the primary stage. The
valve piston is set into motion by means of an air duct from supply
port 1.
This only requires minimal flow so that a relatively small armature
with minimal actuating force can be used. Only minimal supply
pressure is required in order to actuate the piston against the
force of the spring.
A smaller solenoid can be used than that required for a directly
actuated valve.
Power consumption and heat emission are less.

Identify valve ports
In order to prevent incorrect tubing of directional control valves, the valve ports (working and pilot lines) are
identified in accordance with ISO 5599-3 on the valves themselves, as well as in the circuit diagram.

Explain the meanings and functions of the designations listed below.

Designation Meaning and function
4 Working line, consumer port
14
actuated: supply port 1 and consumer port 4 are connected
82/84
actuated: auxiliary pilot air exhaust

Mode of operation of a solenoid valve
A valve symbol indicates how the valve functions, i.e. how many ports it has, its switching positions and the
type of actuation, but it says nothing about its constructional design.

1M1
2 4
3 5
1

Describe the mode of operation of the directional control valve shown above.

The valve is a pilot actuated 5/2-way solenoid valve with manual override and spring return.
Mode of operation:
The piston is at the left-hand limit stop when the valve is in its normal position and ports 1 and 2 (supply
port and consumer port), as well as ports 4 and 5 (consumer port and exhaust port), are connected. If the
solenoid coil is energised, the valve piston moves to the right-hand limit stop. In this position, ports 1
and 4, as well as 2 and 3 (exhaust port) are connected (the internal pilot line for pilot control is
designated 14, function when actuated: supply port 1 and consumer port 4 are connected).
When the solenoid coil is de-energised, the valve piston is returned to its normal position by means of
spring force and pilot air is vented. In the de-energised state, the valve can be switched by means of
manual override.

IP designation
Depending on installation circumstances and ambient conditions, electrical operating equipment is
protected by housings and covers. The required degree of protection against dust, moisture and foreign
matter must be specified.

The designation IP 65 appears on a solenoid coil.

Explain the meaning of this designation.

The designation for a degree of protection in accordance with DIN-VDE 470-1 consists of the two letters IP
(International Protection) and two numbers.
The first number indicates the degree of protection against the ingress of foreign matter and the second
number specifies the degree of protection against moisture and water.
And thus the designation IP 65 means protection against the ingress of dust (i.e. complete protection
against contact with energised components and internal moving parts, protection against the ingress of
dust) and water jets (i.e. water jets sprayed at the housing from all directions should not cause any
damage).

Symbols for pneumatic cylinders
Cylinders with piston rods which move in straight lines can be subdivided into two groups.
Single-acting cylinders
Double-acting cylinders

Explain the meanings of the cylinder symbols shown below.

Symbol Meaning

Symbol 1
Double-acting multi-position cylinder, reversed by alternately pressurising the
respective ends with compressed air.
Travel to 3 positions is made possible by connecting 2 cylinders with the same piston
diameter but different stroke lengths. Direct travel to the third position is possible from
the first position, or it can be approached via the intermediate (second) position.
However, the downstream cylinder stroke must always be larger than the upstream
stroke. During the return stroke, travel to an intermediate position is only possible with
corresponding actuation (3 operating positions). The shorter stroke length is half the
length of the longer stroke.

Symbol 2
Double-acting cylinder, reversed by alternately pressurising the respective ends with
compressed air, adjustable end-position cushioning (2 operating positions).
If large loads are moved by a cylinder, cushioning is used in the end position. Before
reaching the end position, a cushioning piston prevents exhausting the air directly into
the atmosphere. The trapped exhaust air reduces piston speed during the last part of
the stroke.


Complete the pneumatic and electrical circuit diagrams for the sorting system.

1M1
1A1
1V1
2 4
3 5
1
1V2 1V3
1 1
2 2

1M1
1
S1
13
14
+24 V
0 V

Sequence description

Describe the control systems operating sequence.

Initial position
The cylinder is in the retracted end position.

Step 1-2
After activating pushbutton S1 (NO contact), solenoid coil 1M1 at 5/2-way solenoid valve 1V1 is
energised. Valve 1V1 is reversed. The piston end of cylinder 1A1 is now filled with compressed air and the
piston rod end is exhausted. Cylinder 1A1 advances.

Step 2-3
As soon as pushbutton S1 (NO contact) is no longer actuated, coil 1M1 is de-energised, valve 1V1 is
returned to its initial position by the reset spring, the piston end of cylinder 1A1 is exhausted and the
piston rod end is filled with compressed air. The cylinder returns to its retracted end position.



1 Cylinder, double-acting
1 5/2-way solenoid valve
1 Distributor block
Equipment list

Exercise 3: Sealing plastic cans

Learning objectives
Youll be familiar with the set-up and mode of operation of double-acting cylinders.
Youll be able to make use of indirect electrical actuation.

At a filling system plastic cans with wall and ceiling paint. After filling, lids are pressed onto the plastic
buckets.

Layout

Can filling

Parameters
The cylinder will be actuated indirectly and using a pushbutton. In the event of a power failure, the
cylinders piston rod should move to its retracted end position.

Project assignment
1 Answer the questions and complete the tasks for learning topics.
4 Set up the control system, both pneumatically and electrically and describe the control sequence.
5 Double check the control sequence.

Control sequence
1 The press-on stamp is advanced after pressing a pushbutton and the lid is pressed into place.
2 When the pushbutton is released, the stamp is returned to its initial position.

Mode of operation of a relay
Relays are part of the units in the signal processing section. Their essential components include:
Coil with core
Coil winding
Set of contacts
Retracting spring
Armature
Terminal lugs

The following graphic is a sectional view of a relay.

1 2 4 A1 A2
2 3
1
5
6 7
4

Sectional view of a relay

Match up the numbers in the above graphic to the components in the table below.

Number Component
7 Terminal lugs
3 Coil winding
5 Set of contacts
2 Retracting spring
4 Armature
6 Terminal lugs
1 Coil with core

Set-up and mode of operation of a relay

Describe the mode of operation of a relay.

A relay is an electromagnetically actuated switch. An electromagnetic field is generated when the coil is
energised. This in turn draws the moving armature towards the core.

The armature acts on the relays contacts, which are then opened or closed depending on the relays
configuration. When the flow of electrical current to the coil is interrupted, a spring causes the armature
to return to its initial position.

One or more contacts can be switched with a single relay coil. Depending on the required function, relays
with normally closed, normally open or change-over contacts are used.

Describe the layouts, contact types and functions of the relays shown in the table.

Description Symbol
Layout, contact type:
Relay with two NC contacts and two NO contacts
Function:
When the relay is energised, up to two current paths are interrupted and up to
two additional current paths are closed by the four relay contacts.

Layout, contact type:
Relay with four change-over contacts
Function:
When the relay is energised, up to four current paths are opened or closed by
the four relay contacts.
Great flexibility and a wide variety of contact combinations are possible.
14 12 24 22 34 32 44 42
11 21 31 41
A1
A2


Write down the different ways in which relays can be used in electrical and electro-pneumatic control
systems.

Signal multiplying
Voltage and current amplification
Delaying and conversion of signals
Linking of information
Interruption of the control circuit and the primary circuit
Interruption of DC and AC circuits in strictly electrical control systems


Complete the pneumatic and electrical circuit diagrams for the lid press by completing the circuit
diagram below and adding the component and port designations.

1M1
1A1
1V1
2 4
3 5
1
1V2 1V3
1 1
2 2

1M1
1
S1
13
14
+24 V
0 V
K1
2
A1
A2
K1
14 12
11
12
22
32
42
.2
14
24
34
44
11
21
31
41



Set up the control system and describe its operating sequence.

Initial position
Cylinder 1A1 is in the retracted end position.

Step 1-2
After activating pushbutton S1 (NO contact) relay K1 is energised, change-over contact K1 (connected as
an NO contact) is closed and solenoid coil 1M1 at 5/2-way valve 1V1 is energised. Valve 1V1 is reversed.
The rear chamber of cylinder 1A1 is now filled with compressed air and the front chamber is exhausted.
Cylinder 1A1 advances.

Step 2-3
As soon as pushbutton S1 (NO contact) is no longer activated, relay K1 is de-energised and change-over
contact K1 (connected as an NO contact) is opened. Coil 1M1 is de-energised as a result and valve 1V1 is
returned to its initial position by the reset spring. The rear chamber of cylinder 1A1 is exhausted and the
front chamber is filled with compressed air. The cylinder returns to its retracted end position.


Create an equipment list by entering the required components and their quantities in the table below.

1 Relay
1 Distributor block
Equipment list


Exercise 4: Packing plastic pellets

Learning objectives
Youll be able to set up indirect actuation.
Youll be familiar with logic operations.
Youll be able to select solenoid valves based on the specified requirements.
Youll be able to convert solenoid valves

Plastic pellets need to be packed from a storage silo. The silo is opened and closed with a flap. The process
will be started from two locations.

Layout

Packing plastic pellets

Parameters
A single-acting cylinder is to be used.
The cylinder will be actuated indirectly and using a pushbutton.
In the event of a power failure, the cylinders piston rod should advance to the advanced end position.

Project assignment

Control sequence
1 The flap is opened by pressing either one of two pushbuttons and the material slides out of the
container.
2 When the pushbutton is released, the flap is closed.

Converting solenoid valves
A great many demands are placed on valves in actual industrial use. If a valve with all of the desired
characteristics is not available, a valve with a different number of ports can often be used in order to fulfil
the specified function. The following table shows a selection of directional control valves which are
frequently used in industrial applications.

1M1
2 4
3 5
1
14

Describe the valve types depicted in the table below.
Tick off all the solenoid valves which can be replaced by a 5/2-way valve of the type shown above. If
conversion is required in order to fulfil the required function, describe the work to be done.

Symbol Description: valve type Replacement
possible
Description: required
conversion

2
1M1
1
12

Pilot actuated 2/2-way solenoid valve with
spring return and manual override
X
Replacement possible, no
conversion required?

2
1M1
3 1
12

spring return and manual override,
normally closed
X
Replacement possible,
conversion: close consumer port
2 with a blanking plug

2
1M1
3 1
10

spring return and manual override,
normally open
X
Replacement possible, no
conversion required

4
1M1
3 1
14
2

spring return and manual override
X
Replacement possible,
conversion: close consumer port
4 with a blanking plug

Note
The term conversion includes even very simple measures, for example closing consumer port 2 or 4
with a blanking plug.

Selecting solenoid valves
A valve is selected on the basis of the following criteria:
Task
Required performance in the event of a power failure
Lowest possible overall costs

The following valves are available for actuating a single-acting cylinder.
A pilot actuated 3/2-way solenoid valve with spring return and manual override
A pilot actuated 5/2-way solenoid valve with spring return and manual override

Select a valve and justify your decision.

Valve type Reason
Pilot actuated 5/2-way
solenoid valve with spring
return and manual override
5/2-way solenoid valves can be used in a broad range of applications. In practice, this means that only
one valve type is required for a variety of requirements or applications. This, in turn, results in
considerable cost reductions as larger quantities lead to more favourable valve procurement and
stocking of spare parts.
Compared with maintenance for a single valve type, servicing a variety of valves is considerably more
expensive. 3/2-way valves can only be used to actuate single-acting cylinders, but 5/2-way valves can
be used with single as well as double-acting cylinders. That is why the 5/2-way valve is the right choice.
The fact that a 3/2-way valve is usually about 5% less expensive than a 5/2-way valve is not decisive
due to the above mentioned advantages of the 5/2-way valve.

Note
In addition to the costs mentioned above, the overall costs of a valve also include expenses for
installation and maintenance, as well as warehousing costs for replacement parts.

Logic operations the OR function
It should be possible to make the piston rod of a cylinder advance using two pushbuttons, namely S1 and
S2. When at least one of the two pushbuttons is activated solenoid coil 1M1 is energised, solenoid valve
1V1 switches to the actuated position and the piston rod advances. When both pushbuttons are released,
the valve is switched to its normal position and the piston rod is retracted.

Create the associated functions table and the logic symbol.

S1 S2 1M1 1V1
0 0 (not actuated) 0 (not actuated) 0 (not actuated)
0 (not actuated) 1 (actuated) 1 (actuated) 1 (actuated)
1 (actuated) 0 (not actuated) 1 (actuated) 1 (actuated)
1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)
Functions table

S1
S2
1M1
1

Logic symbol

Note
0 means that the pushbutton is not activated and the piston does not advance.
1 means that the pushbutton is activated and the piston advances.


Complete the pneumatic and electrical circuit diagrams.

K1
14 12
11
1
S1 S2
K1 1M1
+24 V 3 2
0 V
A1
A2
K1
13 13
14 14
12
22
32
42
.3
14
24
34
44
11
21
31
41



Set up the control system and describe the operating sequence.

Initial position
In its normal position, cylinder 1A1 is in the advanced end position and the rear chamber is filled with
compressed air.

Step 1-2
By activating pushbutton S1 or S2 (both laid out as NO contacts) relay K1 is energised, change-over
contact K1 (connected as an NO contact) is closed and solenoid coil 1M1 at 5/2-way valve 1V1 is
energised. Valve 1V1 is reversed. The rear chamber of cylinder 1A1 is exhausted and the spring forces the
cylinder into its retracted end position.

Step 2-3
As soon as pushbutton S1 or S2 (both laid out as NO contacts) is no longer activated, relay K1 is de-
energised and change-over contact K1(connected as an NO contact) is opened. Coil 1M1 is de-energised
as a result and valve 1V1 is returned to its initial position by the reset spring. The rear chamber of
cylinder 1A1 is filled with compressed air; the cylinder returns to the advanced end position.



1 Relay
1 Distributor block
Equipment list

Exercise 5: Diverting packages

Learning objectives
Youll be familiar with the set-up and mode of operation of a double-acting cylinder.
Youll be familiar with the set-up and mode of operation of a double solenoid valve.

Packages will be diverted from one conveyor belt to another by means of a diverting device.

Layout

Diverting device

Parameters
The cylinder will be controlled indirectly and using a pushbutton. In the event of a power failure, the
cylinders piston rod should remain in its current end position.

Project assignment

Control sequence
1 The diverting device is advanced when one of the pushbuttons is activated. The package is transferred
and transported further.
2 The diverting device is returned to its initial position when another pushbutton is activated.

Using solenoid valves
Two factors need to be taken into consideration when deciding which type of valve will be used for a specific
application.
Duration or timeframe
Number or frequency of required switching operations

In order to make the best possible use of a directional control valve, it must be decided on a case-by-case
basis which is more economical for the respective application:
A double solenoid valve or
A directional control valve with spring return

Decide whether a double solenoid valve or a solenoid valve with spring return is more economical for
each of the applications listed below and give reasons for your decision.

Application 1
The clamping cylinder in a milling station must clamp a workpiece for the duration of the milling process
(approx. 10 minutes with 60 clamping operations per day).

Valve type Reason
Double solenoid valve The signal must be stored for switching operations of long duration. In the case of double solenoid
valves, this is accomplished by means of static friction and in the case of directional control valves with
spring return by continuously energising the solenoid coil. Clamped workpieces must not be released in
the event of an emergency stop, which is why solenoid valves with spring return must not be used for
this application.

Application 2
The ejecting cylinder in a sorting system needs to push defective workpieces off a conveyor belt (duration of
approx. 1 second, 600 push-out operations per day).

Valve type Reason
Solenoid valve with spring
return
The signal need not be stored for switching operations of short duration. Solenoid valves with spring
return have the following advantage: only one solenoid coil needs to be actuated, i.e. energised, in
order to switch the valve.

Mode of operation of a solenoid valve

1M1 1M2
2 4
3 5
1

Describe the mode of operation of the directional control valve shown above.

Pilot actuated 5/2-way double solenoid valve with manual override
When the piston is at the left-hand limit stop, ports 1 (supply port) and 2 (consumer port), as well as
ports 4 (consumer port) and 5 (exhaust port), are connected. If the left-hand solenoid coil is energised,
the piston moves to the right-hand limit stop and ports 1 and 4, as well as ports 2 and 3 (exhaust port)
are connected (pilot line, 14 and 12, function when actuated: supply port 1 and consumer port 4 or 2 are
connected). If the valve needs to be switched back to its initial position, its not enough to simply
interrupt electrical power to the left-hand solenoid coil. In fact, the right-hand solenoid coil must also be
energised. If neither of the solenoids is actuated, the piston remains in its last position (signal control in
the power section) due to friction. This is also the case when both solenoids are energised at the same
time, because they work against each other with identical force.
In the de-energised state, the valve can be switched via the manual override.

Calculating the current consumption of a solenoid coil
A solenoid valve with spring return needs to be switched with pushbutton S1.

Calculate current and power consumption for solenoid coil 1M1 based on a 24 V DC power supply and a
coil resistance of 48 (Ohm).

1M1
1
S1
13
14
+24 V
0 V

Current consumption at 1M1

In accordance with Ohms law, U = R I, current consumption of 0.5 A (ampere) is calculated as follows:
A 5 , 0
48
V 24
R
U
I =
= =

Power consumption at 1M1

Power consumption of 12 W (watt) is calculated as follows: P = U I = 24 V 0.5 A = 12 W
Calculating the current consumption of a solenoid coil

If the solenoid coil in question were connected to 24 V AC, would power consumption at 1M1 be higher
or lower? Give reasons for your answer.

Equal Higher Lower Reason

X
The magnetic fields caused by alternating current generate an induction voltage in
the coils windings which counteracts the applied voltage and increases coil
resistance. This resistance in the AC coil (impedance) is made up of Ohmic
resistance and so-called inductive reactance. As a result, effective current is
reduced.

Complete the circuit diagrams

Complete the pneumatic circuit diagram for the diverting device.

Pneumatic circuit diagram

Complete the electrical circuit diagram for the diverting device.

K1
14 14 12 12
11 11
1M1 1M2
1 2
S1 S2
+24 V
0 V
K1 K2
3 4
A1 A1
A2 A2
K2
13 13
14 14
12 12
22 22
32 32
42 42
.4 .3
14 14
24 24
34 34
44 44
11 11
21 21
31 31
41 41

Electrical circuit diagram



Initial position
In its initial position, cylinder 1A1 is in the retracted end position.

Step 1-2
an NO contact) is closed and solenoid coil 1M1 at 5/2-way double pilot valve 1V1 is energised. Valve 1V1
is reversed. The rear chamber of cylinder 1A1 is now filled with compressed air and the front chamber is
exhausted. Cylinder 1A1 advances.

contact K1 (connected as an NO contact) is opened. As a result, coil 1M1 is also de-energised.

Step 2-3
After activating pushbutton S2 (NO contact) relay K2 is energised and change-over contact K2 (connected
as an NO contact) is closed. Coil 1M2 is energised as a result and valve 1V1 is switched back to its initial
position. The front chamber of cylinder 1A1 is filled with compressed air and the rear chamber is
exhausted. Cylinder 1A1 returns to its retracted end position.




1 5/2-way double solenoid valve
2 Relay
1 Distributor block
Equipment list


Exercise 6: Pushing wooden boards out of a stacking magazine

Learning objectives
Youll be able to make use of double-acting cylinders.
Youll be familiar with the set-up and mode of operation of a double solenoid valve.
Youll be familiar with one option for end-position sensing in cylinders.

Wooden boards need to be pushed out of a stacking magazine and into a mounting device.

Layout

Stacking magazine

Parameters
The cylinders advanced end position needs to be sensed.

Project assignment
4 Set up the control system, both pneumatically and electrically.

Control sequence
1 A wooden board is pushed out of the stacking magazine with a slide after pressing a pushbutton.
2 After reaching the advanced end position, the slide is returned to its initial position.

Components included in an electro-pneumatic system
The components included in an electro-pneumatic system are represented in the pneumatic and/or the
electrical circuit diagram.

Tick off the type of diagram in which the following components need to be represented.

Component Pneumatic circuit diagram Electrical circuit diagram
Manually operated pushbutton X
Cylinder X
Valve X
Solenoid coil X X
Relay X
Electromechanical limit switch X X
Electronic proximity switch X X
Indicator X

Components included in an electro-pneumatic system
The purpose of sensors in electro-pneumatic control systems is to acquire information and forward it to
signal processing.

Which function(s) can an electromechanical limit switch in an electro-pneumatic control system carry
out?

Sensing piston rod end positions in cylinder drive units
Detecting the presence or the position of a workpiece

Representation of limit switches
Limit switches can be actuated in different ways. They function as NC, NO or change-over contacts and can
be actuated or unactuated when the system is in its neutral position.

Describe the design and function of the symbols shown below. Enter the descriptions to the table.

Description: design/function Symbol
Roller actuated limit switch with NC function, unactuated
1
2
Roller actuated limit switch with NO function, unactuated
3
4

Creating a switching elements table
One way of recording the contacts controlled by a relay is to list them in a switching elements table.

Create switching elements tables for relays K6 and K9.

K1
14 12
11
K5
14 12
11
K6 K7 K8 K9
10
A1 A1 A1 A1
A2 A2 A2 A2
K6 K7 K8 K9 K6 K7
14 14 14 14 34 34 14 14 14
24 24 34 34 24
12 12 12 12 32 32 12 12 12
22 22 32 32 22
11 11 11 11 31 31 11 11 11
21 21 31 31 21
1M1 2M1
12 14 16 18 19 13 15 17 11
K2 K4 K3
K6 K7 K9 K8 K9
+24 V
. . .
. . .
0 V
24 22
21
K8


Switching element Description
K6

Relay K6 actuates the following switching elements:
1 NO contact in current path 11
K9
18
10 17

Relay K6 actuates the following switching elements:
1 NC contact in current path 10
1 NC contact in current path 18
Switching elements table
Creating a switching elements table
Another way of recording the contact sets controlled by a relay is shown in the following circuit diagram.

NA
NOT-AUS
K1
14 12
11
K5
K11 K11 K11
14
14 24 34
12
12 22 32
11
11 21 31
K6 K7 K8 K9
11 25 27
A1 A1 A1 A1
A2 A2 A2 A2
12 12 12 12
22 22 22 22
32 32 32 32
42 42 42 42
.13 .15 .17 .19
.20
.26
.24
.14 .16 .18
.24
.23
.22 .23
.22
14 14 14 14
24 24 24 24
34 34 34 34
44 44 44 44
11 11 11 11
21 21 21 21
31 31 31 31
41 41 41 41
K6 K7 K8 K9
14 14 14 14 14 14 14
24 24 24 24
12 12 12 12 12 12 12
22 22 22 22
11 11 11 11 11 11 11
21 21 21 21
16 18 17 19 13 12
K4 K3
K6 K10 K7 K8
S1
Start
K1 K2 K3 K4 K5 K11
+24 V 2 4 6 8 10 1 3 5 7 9
0 V
1B1 1B2 2B1 2B2
A1 A1 A1 A1 A1 A1
A2 A2 A2 A2 A2 A2
13
21
14
22
12 12 12 12 12 12
22 22 22 22 22 22
32 32 32 32 32 32
42 42 42 42 42 42
.12
.20
.14 .18
.27
.12 .11
.25
.27
.16
14 14 14 14 14 14
24 24 24 24 24 24
34 34 34 34 34 34
44 44 44 44 44 44
11 11 11 11 11 11
21 21 21 21 21 21
31 31 31 31 31 31
41 41 41 41 41 41
2M1
1A1+ 2A1- 2A1+ 1A1-
K6 K8 K7 K9 K3
34 34 34 34 24 32 32 32 32 22
31 31 31 31 21
22 24 23 26
44 44 44 34 42 42 42 32
41 41 41 31
K7 K9 K8 K10
K10
A1
A2
12
22
32
42
.21
.12
.26
14
24
34
44
11
21
31
41
K10
14 24
24
12 22
22
11 21
21
20 21
K1
K9
1M1 1M2 2M2


Complete the entries for the relays listed in the table beneath. Designate the current path within which the
respective contact is used, as well as the function fulfilled by the set of contacts (normally open or
normally closed).

Relay Current path Function: NO Function: NC
Relay K9 Current path 19 X
Current path 20 X
Current path 24 X
Current path 26 X
Relay K10 Current path 12 X
Current path 21 X
Current path 26 X


Complete the pneumatic circuit by adding the valve actuation and designating it.

1M1 1M2
1A1
1V1
2 4
3 5
1
1V2 1V3
1B2
1 1
2 2


Complete the electrical circuit diagram.

4 2
1
K1 K2
14 14 12 12
11 11
1M1 1M2
1 2
S1 1B2
+24 V
0 V
K1 K2
3 4
A1 A1
A2 A2
13
14
12 12
22 22
32 32
42 42
.4 .3
14 14
24 24
34 34
44 44
11 11
21 21
31 31
41 41




Initial position
In its normal position, cylinder 1A1 is in the retracted end position

Step 1-2
By activating pushbutton S1 (NO contact) relay K1 is energised, change-over contact K1 (connected as an
NO contact) is closed and solenoid coil 1M1 at 5/2-way solenoid valve 1V1 is energised. Valve 1V1 is
reversed. The rear chamber of cylinder 1A1 is now filled with compressed air and the front chamber is
exhausted. Cylinder 1A1 advances.

When pushbutton S1 (NO contact) is no longer activated, relay K1 is de-energised and change-over

Step 2-3
When the cylinder reaches its advanced end position, the piston rod actuates electrical limit switch 1B2.
Change-over contact 1B2 (connected as an NO contact) is closed and relay K2 is energised. Change-over
contact K2 (connected as an NO contact) is closed and solenoid coil 1M2 is energised. Valve 1V1 is
returned to its normal position.

The front chamber of cylinder 1A1 is filled with compressed air and the rear chamber is exhausted. The
cylinder returns to the retracted end position.

As soon as electrical limit switch 1B2 (change-over contact, connected as an NO contact) is no longer
actuated, relay K2 is de-energised and change-over contact K2 (connected as an NO contact) is opened.
As a result, coil 1M2 is also de-energised.



1 Limit switch (normally open)
2 Relay
1 Distributor block
Equipment list

Exercise 7: Sorting packages

Learning objectives
Youll be able to calculate piston forces based on specified values.
Youll be able to calculate characteristic electrical values.
Youll be able to make use of indirect actuation.
Youll be familiar with the logic AND operation and be able to set it up.

Packages are directed past workstations on a roller conveyor. The packages can be diverted by means of
deflectors at specific points.

Layout

Conveyor for packages

Parameters
The cylinder will be controlled indirectly using pushbuttons and electromechanical limit switches.
The cylinder can only advance when the piston rod is in the retracted end position.

Project assignment

Control sequence
1 The cylinders piston rod should advance automatically as soon as pushbutton S1 is activated.
2 When the pushbutton is no longer activated, the piston rod must return to the retracted end position.

Calculating piston force
The piston of a double-acting cylinder has a diameter of 20 mm and the piston rod has a diameter of 8 mm.
Friction loss in the cylinder amounts to 10%.

Calculate the effective piston force for both the forward and the return stroke at an operating pressure
of 6 bar (600 kPa).

Calculate for: Solution
Forward stroke F = 188 N
Return stroke F = 158 N

Calculating characteristic electrical values
The coil in a relay has a power rating of 1 W. Measurement of resistance between terminals A1 and A2
resulted in a value of 580 .

Calculate the relays operating voltage.

The following applies to electrical power:
P = I U or P =
R
U
2
or P = R I
2

As power and resistance are known:
P =
R
U
2
U
2
= R P U
2
= 580 1 U
2
= 580 U = 580
U = 24.083189157584590960256482060757
U
max
~ 24 V
Basic principles
It should be possible to make the piston rod of a cylinder to advance using two pushbuttons, namely S1 and
S2. When both pushbuttons are activated simultaneously, solenoid coil 1M1 is energised, solenoid valve
1V1 switches to the actuated position and the piston rod advances. When one of the two pushbuttons is
released, the valve is switched to its normal position and the piston rod is retracted.

Create the associated functions table and draw the logic symbol.

Note
0 means that the pushbutton is not activated and the piston does not advance.
1 means that the pushbutton is activated and the piston advances.

S1 S2 1M1 1V1
0 (not actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)
0 (not actuated) 1 (actuated) 0 (not actuated) 0 (not actuated)
1 (actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)
1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)
Functions table

S1
S2
1M1 &

Logic symbol


Set up the pneumatic control system in accordance with the circuit diagram.



4 2
1
4 2
1
1 B2
K3 1M2
1 2
1B1
+24 V
0 V
K1
14 12
11
K2
14 12
11
K1 K2
3 4
A1 A1
A2 A2
12
22
32
42
.4
14
24
34
44
11
21
31
41
12
22
32
42
.4
14
24
34
44
11
21
31
41
12
22
32
42
.5
14
24
34
44
11
21
31
41
K3
14 12
11
5
1M1
S1
13
14




Initial position

When cylinder 1A1 is in its retracted end position, electrical limit switch 1B1 is actuated (change-over
contact, connected as an NO contact), change-over contact 1B1 is closed and relay K2 is energised.

Step 1-2
an NO contact) is closed and solenoid coil 1M1 at 5/2-way solenoid valve 1V1 is energised. Double
solenoid valve 1V1 is reversed. The piston end of cylinder 1A1 is filled with compressed air while the
piston rod end is exhausted. Cylinder 1A1 advances.

As soon as cylinder 1A1 leaves its retracted end position, limit switch 1B1is no longer actuated and
change-over contact 1B1 is opened. NO contact K2 is opened as a result and solenoid coil 1M1 is no
longer energised. The double solenoid valve remains in the right-hand switching position.

Step 2-3
When the cylinder reaches its advanced end position, the piston rod actuates electrical limit switch 1B2
(change-over contact, connected as an NO contact). Change-over contact 1B2 is closed. Relay K3 is
energised. Due to the fact that change-over contact K3 is closed (connected as an NO contact), solenoid
coil 1M2 is also energised. Valve 1V1 is reversed.

The piston rod end of cylinder 1A1 is pressurised with compressed air while the piston end is exhausted.
The cylinder returns to the retracted end position.

As soon as electrical limit switch 1B2 (change-over contact, connected as an NO contact) is no longer
actuated, relay K3 is de-energised and change-over contact K3 (connected as an NO contact) is opened.
As a result, coil 1M2 is also de-energised. The cylinder remains in the retracted end position.



2 Limit switch (normally open)
3 Relay
1 Distributor block
Equipment list

Exercise 8: Sanding wooden boards

Learning objectives
Youll be familiar with logic operations and be able to set them up.
Youll be able to explain and set up an electrical latching circuit with dominant breaking signal.

Wooden boards are put onto a sliding platform manually. The boards are pushed under a belt sander by a
pneumatic drive.

Layout

Sliding platform

Parameters
The cylinder will be actuated indirectly.

Project assignment

Control sequence
1 The piston rod of a cylinder must advance when pushbutton S1 is activated.
2 The piston rod is retracted when pushbutton S2 is activated.

Signal storage
If the piston rod of a cylinder also needs to be advanced when the pushbutton is pressed only briefly,
activation of the pushbutton must be stored. The signal can be stored either in the power section or in the
signal control section of the circuit.

Described how signal storage is implemented in the power section or the signal control section.

Signal storage location Description: signal storage
Signal storage in the power
section
A double solenoid valve is used for storage.

As a result of the pistons static friction, the double solenoid valve is retained in is position, even
when the respective solenoid coil is no longer energised.
Signal storage in the signal
control section
By means of a solenoid valve with spring return and a relay with self-latching loop

The relay coil is energised and a contact closes. When the on pushbutton is released, current
continues to flow through the coil via the closed contact, the relay is retained in the activated position
and thus the solenoid valve with spring return remains in the actuated position. The electrical circuit
is interrupted when an off pushbutton is activated. Depending on how the two pushbuttons are
arranged, we differentiate between dominantly setting and dominantly resetting self-latching loops.

Analysing circuits

Describe the performance of the specified circuit (piloted 5/2-way solenoid valve with spring return,
double-acting cylinder) in the event of a power failure and pressure failure.

Electrical power supply failure Pressure failure
The solenoid valve with spring return is switched to its normal
position and the double-acting cylinder returns to the retracted
end position.

The solenoid valve and thus the cylinder as well, can be switched
by means of manual override.
The solenoid valve returns to its normal position due to a lack of
adequate operating pressure.

The double-acting cylinder is unpressurised and assumes an
undefined position.

Logic operations
Lamp P1 should always light up when pushbutton S1 is not activated.

Create the associated functions table and the logic symbol.

S1 P1
0 (not actuated) 1 (actuated)
1 (actuated) 0 (not actuated)
Functions table

S2 P1
1

Logic symbol

Note
0 means pushbutton S1 not activated or lamp 1 off.
1 means pushbutton S1 activated or lamp 1 on.


Complete the pneumatic circuit diagram for the sliding table.


Complete the electrical circuit diagram for the sliding table.




Initial position

Step 1-2
When pushbutton S1 (NO contact) is activated, relay K1 is energised and change-over contact K1
(connected as an NO contact) in current path 2 closes and activates the self-latching loop in relay K1.
Furthermore, change-over contact K1 in current path 3 closes and solenoid coil 1M1 at 5/2-way solenoid
1V1 is energised. Valve 1V1 is reversed. The piston end of cylinder 1A1 is now filled with compressed air
and the piston rod end is exhausted. Cylinder 1A1 advances.

Step 2-3
When pushbutton S2 (NC contact) is activated, self-latching at relay K1 is terminated. Change-over
contact K1 (connected as an NO contact) in current path 3 opens and relay K1 is de-energised. Valve 1V1
is reset by the reset spring.

The piston rod end of cylinder 1A1 is filled with compressed air while the piston end is exhausted. The
cylinder returns to the retracted end position.



1 Pushbutton (normally closed)
1 Relay
1 Distributor block
Equipment list

Exercise 9: Diverting bottles

Learning objectives
Youll be familiar with various types of end-position control and learn to select the appropriate type.
Youll be familiar with latching circuits with varying performance features.

Bottles need to be diverted from a conveyor belt with a diverting device to another conveyor belt in a
linearly indexed fashion. Once switched on, the system should run continuously. It should not be switched
off until a stop signal is generated.

Layout

Diverting device for bottles

Parameters
The latching circuit used should demonstrate dominant off characteristics.

Project assignment

Control sequence
1 The sequence is started by pressing a pushbutton. If 3 bottles are present, the diverting cylinders
piston rod is advanced.
2 The bottles are diverted and transported to a second conveyor belt.
3 The sequence is stopped by pressing a second pushbutton.

Latching circuits
A relay circuit with self-latching loop is required in order to store a signal in the signal control section.
The relay coil is energised when pushbutton S1 is activated.

12
22
32
42
.2
14
24
34
44
11
21
31
41
K1
14 12
11
1
S1
K1
+24 V 2
0 V
A1
A2
13
14

Complete the electrical circuit diagram so that the relay is self-latched after releasing pushbutton S1
and describe the circuits function.

When pushbutton S1 is activated, coil K1 is energised and activates the change-over contact. Current
path 2 is closed as a result, the coil remains energised and the change-over contact is retained in its
current switching position. The circuit is self-latching as long as power supply is available.

Latching circuits
In order to terminate self-latching, the power supply to the coil must be interrupted. A separate NC contact
is required to this end.
Depending on how this NC contact is arranged, we differentiate between two types of self-latching.
Dominantly setting self-latching
Dominantly resetting self-latching

Complete the following electrical circuit diagram so that self-latching is reliably terminated when
pushbutton S2 is activated.

12
22
32
42
.2
14
24
34
44
11
21
31
41
K1
14 12
11
1
K1
+24 V 2
0 V
A1
A2
S2
31
32
S1
13
14
12
22
32
42
.2
14
24
34
44
11
21
31
41
K1
14 12
11
1
K1
+24 V 2
0 V
A1
A2
S2
31
32
S1
13
14

Electrical circuit diagram, left: dominantly resetting self-latching, right: dominantly setting self-latching

Latching circuits
Different signal storing circuits have different characteristics:
For simultaneous occurrence of setting and resetting conditions
In the event of failure of electrical control energy or broken wire

Complete the table by indicating how each respective valve responds.

Signal storage via a double
solenoid valve
Signal storage via an electrical latching circuit combined with
spring return valve
Dominantly setting Dominantly resetting
Simultaneous setting and
resetting signal
Valve position remains
unchanged.
The valve is actuated.
The valve returns to its normal
position.
Electrical power supply failure
Valve position remains
unchanged.
position.
position.

Limit switches and proximity switches
The purpose of limit switches and proximity switches is to acquire information and forward it to signal
processing.
They include:
Mechanical position switches (limit switches)
Magnetic proximity switches
Inductive proximity switches
Optical proximity switches
Capacitive proximity switches

Match the terms with the corresponding circuit symbols in the table.

Circuit symbol Designation
BN
BU
BK

Magnetic proximity switch
BN
BU
BK

Optical proximity switch
BN
BU
BK

Inductive proximity switch
4 2
1

Mechanical position switch (limit switch)
BN
BU
BK

Capacitive proximity switch


Complete the pneumatic circuit.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1B1 1B2
1 1
2 2


12 12 12
22 22 22
32 32 32
42 42 42
.2 .7 .8
.7
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
K3
14 12
11
K1
24
21
K2
14 12
11
K1
14 12
11
1
S1
K3 K2 K1 1M1 1M2
+24 V 3 5 7 8 2 4 6
0 V
1B1 1B2
A1 A1 A1
A2 A2 A2
S2
22
31
13
32
14
BN
BU
BK
BN
BU
BK


Describe the control systems operating sequence.

Initial position
When cylinder 1A1 is in its retracted end position, magnetic proximity switch 1B1 is actuated (NO
contact), relay K2 is energised and change-over contact K2 (connected as an NO contact) in current path 7
closes.

Step 1-2
When pushbutton S1 (NO contact) is activated, relay K1 is energised and change-over contact K1
(connected as an NO contact) in current path 2 closes and activates the self-latching loop in relay K1.
Furthermore, change-over contact K1 (connected as an NO contact) in current path 7 closes and solenoid
coil 1M1 at 5/2-way double solenoid valve 1V1 is energised. Double solenoid valve 1V1 is reversed. The
rear chamber of cylinder 1A1 is now filled with compressed air and the front chamber is exhausted.
Cylinder 1A1 advances. As soon as cylinder 1A1 leaves its retracted end position, proximity switch 1B1 is
no longer actuated (NO contact). Change-over contact K2 (connected as an NO contact) in current path 7
is opened as a result and solenoid coil 1M1 is no longer energised. The double solenoid valve
nevertheless remains in the right-hand switching position.

Step 2-n
When the cylinder reaches the advanced end position, magnetic proximity switch 1B2 is activated (NO
contact) and relay K3 is energised. Change-over contact K3 (connected as an NO contact) in current path
8 is closed and solenoid coil 1M2 is energised. As a result, valve 1V1 is returned to its normal position
and cylinder 1A1 is returned to its retracted end position. As soon as proximity switch 1B2 (NO contact) is
no longer activated, relay K3 is de-energised and change-over contact K3 (connected as an NO contact) in
current path 8 is opened. As a result, coil 1M2 is also de-energised.

As the electrical latching circuit at relay K1 is still active, solenoid coil 1M1 once again receives a
switching signal when the retracted end position is reached, so that cylinder 1A1 advances again
immediately.

Step n-(n+1)
Oscillating motion of cylinder 1A1 can be interrupted by activating pushbutton S2 (NC contact). Self-
latching at relay K1 is terminated as a result. The cylinder returns to the retracted end position and
remains there.


Create an equipment list by entering the required components and their quantities in the table below.

1 Double solenoid valve, 5/2-way
1 Pushbutton (normally closed)
3 Relay
1 Distributor block
Equipment list


Exercise 10: Stamping taper keys

Learning objectives
Youll be able to set up pressure-dependent reversing.
Youll be familiar with the set-up and mode of operation of magnetic proximity switches.

Taper keys are required for the production of door frames. The keys will be stamped with a stamping system.

Layout

Stamping system

Parameters
Stamping pressure should be 5.5 bar (550 kPa).

Project assignment

1 The stamping tool is advanced after pressing a pushbutton and a taper key is stamped.
2 After stamping pressure is reached, the stamping tool is advanced to its starting position.

As opposed to limit switches, proximity switches are contact-free and require no external actuating force.

Describe the set-up and function of a magnetic proximity switch (reed switch).

Description: design and function Circuit symbol Schematic drawing
Reed switches are magnetically actuated proximity switches.
They consist of two contact reeds which are located in a glass
tube which is filled with inert gas. When a magnetic force is
applied, the two reeds make contact enabling electrical current
to flow.
In the case of reed switches, which function as NC contacts, the
contact blades are preloaded with small magnets. This
preloading is overpowered by the significantly stronger
switching magnet.
Reed switches have a long service life and minimal switching
times (approx. 0.2 ms).
Theyre maintenance free, but they should not be used in the
presence of strong magnetic fields (e.g. close to resistance
welding units).
BN
BU
BK

As regards the polarity of the output signal, there are two different types of electronic proximity switches:
PNP and NPN.

Explain the difference between these two different designs.

PNP NPN
In the case of negative switching proximity switches, power
supply is present at the output when there are no parts within the
switchs response range. When a workpiece or machine
component approaches the switch, the output is switched to 0 V.
In the case of positive switching proximity switches, zero voltage
is present at the output when there are no parts within the
switchs response range. When a workpiece or machine
component approaches the switch, the output is switched and
power supply is present.

24 V
1
3
4
B

24 V
1
3
4
B

Pressure switches
Pressure-sensitive sensors, so-called pressure switches, are used in order to measure and monitor pressure
within the system.

Describe the mode of operation of a pressure switch.

A pneumatic pressure signal switches an electrical signal generator (usually laid out as a change-over
contact) in the pressure switch, i.e. a pneumatic input signal is read out as an electrical signal.

Pressure switches are available with fixed, as well as adjustable switching pressures.

Pressure switches
Pressure sensors can be subdivided into two groups. Differentiation is made between:
Pressure sensors with mechanical contact (mechanical mode of operation)
Pressure sensors with electronic switching (electronic mode of operation)

Describe the task and function of the pressure switch depicted below.

Description: task and function Circuit symbol Schematic drawing
Pressure switches are used in order to
generate an electrical output signal when
a specified pressure is reached.
In the case of this mechanical pressure
switch, pressure acts on the surface of a
piston. If the force generated by prevailing
pressure exceeds the force of the spring
used, the piston moves and actuates the
change-over contact points. Switching
pressure can be adjusted by preloading
the spring, which is why this pressure
sensor is called a pressure switch.
Electrical
p
1
3
4
2
U

Pneumatic
p

2
4
1
X

Selecting proximity switches
The end positions of a cylinder drive are to be sensed with proximity switches. The proximity switches must
fulfil the following requirements:
The piston rods end positions must be sensed in a contactless fashion.
The proximity switches must be insensitive to dust.
The cylinders piston rod and trip cam are made of metal.

Make your selection and indicate which proximity switches fulfil the specified requirements. Enter your
selection in the table below and justify your choice.

Proximity switch Reason
Inductive proximity switch Both proximity switches are contactless and require no mechanical actuation. Due to the fact
that the trip cam is made of metal, the inductive proximity switch can be used.
It functions in a contactless manner and is insensitive to contamination.


Complete the pneumatic circuit by drawing in the pressure sensor and the associated compressed air
line.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1B1 1B2
1B3
1 1
2 2
1
3
4
2
U



K1
14 12
11
K3
14 12
11
K2
14 12
11
7
S1
K2 K3 K1 1M1 1M2
+24 V 1 3 5 8 2 4 6
0 V
1B1 1B2 1B3
A1 A1 A1
A2 A2 A2
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .8 .7
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK
p
U
RD
BU
WH
BK




Initial position
When cylinder 1A1 is in its retracted end position, magnetic proximity switch 1B1 is actuated (NO
contact), relay K1 is energised and change-over contact K1 (connected as an NO contact) in current path 7
is closed.

Step 1-2
After activating pushbutton S1 (NO contact), solenoid coil 1M1 at 5/2-way double solenoid valve 1V1 is
energised. Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances. As soon as cylinder 1A1 leaves
its retracted end position, proximity switch 1B1 is no longer actuated (NO contact). Change-over contact
K1 (connected as an NO contact) in current path 7 is opened as a result and solenoid coil 1M1 is no
longer energised. The double solenoid valve remains in the right-hand switching position.

Step 2-3
When the cylinder reaches the advanced end position, magnetic proximity switch 1B2 is activated (NO
8 is closed. In the meantime, pressure sensor 1B3 measures pressure at cylinder 1A1. If pressure is equal
to or greater than the selected setpoint, the pressure sensor is switched, relay K3 is energised and
change-over contact K3 (connected as an NO contact) in current path 8 is closed. Solenoid coil 1M2 is
now energised. As a result, valve 1V1 is returned to its normal position and cylinder 1A1 is returned to its
retracted end position.

As soon as proximity switch 1B2 (NO contact) is no longer actuated, relay K2 is de-energised and change-
over contact K2 (connected as an NO contact) is opened.

If the selected setpoint is fallen short of, the pressure sensor (programmed as an NO contact) is switched
off, relay K3 is de-energised and change-over contact K3 (connected as an NO contact) in current path 8 is
opened. As a result, coil 1M2 is also de-energised.



2 Proximity switch, electronic
1 Pressure sensor
3 Relay
1 Distributor block
Equipment list


Exercise 11: Palletising roof tiles

Learning objectives
Youll be able to make use of an optical sensor.
Youll be familiar with displacement-step diagrams and learn to create them for specific problems.
Youll be able to implement sequence control with two cylinders.

Stacks of roof tiles are strapped together. The resulting sets are then transported to a pallet loading station
where theyre transferred to Euro pallets.

Layout

Pallet loading station

Parameters
Adjust the one-way flow control valve so that both cylinders are retracted at the same speed.
The advanced end position of the single-acting cylinder will be detected with an optical sensor.

Project assignment
2 Draw the displacement-step diagram.
3 Create the associated function diagram and the function chart.

Control sequence
1 When pushbutton S1 is activated, cylinder 1A1 is advanced. An individual set is transported to the
loading station as a result and sensor 1B2 is actuated.
2 Cylinder 2A1 is advanced, actuates sensor 2B2 and pushes the individual set onto the pallet.
3 If 2B2 is actuated and S1 is unactuated, cylinder 1A1 is retracted, 1B2 is no longer actuated and cylinder
2A1 is retracted.
The overall sequence is thus as follows:
1A1+ 2A1+ 1A1
2A1

Optical proximity switch, technical data

Describe the mode of operation of the included optical proximity switch by entering its technical data in
the table below. Use the respective data sheet to this end.

Technical data
Switching voltage 10 to 30 V DC
Residual ripple Max. 10%
Nominal switching distance 0 to 100 mm (adjustable)
Switching frequency Max. 200 Hz
Output function Normally open, positive switching

Write down what needs to be observed when setting up the circuit with regard to the position of the
sensor.

The sensor must be positioned so that only the cylinders trip cam is detected.
There shouldnt be any other objects within the sensors sensing range.
Optical proximity switch, connection

Sketch the power supply into the drawing shown below and connect the terminals at the optical sensor
to the power supply. Enter the connections in the table.

24 V
RD
BU
BK

Circuit diagram, optical proximity switch

Socket Connection
Red 24 V
Black Relay (coil)
Blue 0 V

Creating a displacement-step diagram
When pushbutton S1 is activated, cylinder 1A1 is advanced. An individual packet is transported to the
loading station as a result and sensor 1B2 is actuated. Cylinder 2A1 is advanced, actuates sensor 2B2 and
pushes the individual packet onto the pallet. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 is
retracted, 1B2 is no longer actuated and cylinder 2A1 is retracted.

1A1+ 2A1+ 1A1
2A1

Draw a displacement-step diagram for the task described above.

1A1
0
1
2A1
0
1
1 2 3 4=1
1B2
S1
2B2

Displacement-step diagram


Complete the pneumatic circuit diagram for the pallet loading station.
Complete the electrical circuit diagram for the pallet loading station.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1B2
2B2
2V2
2
2M1
3 1
2A1
2V1
1 1
2 2
2
1


K3
14 12
11
K2
14 12
11
K1
14 12
11
K2 K1 K3 1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
S1
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .7 .6
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK



Initial position
In their initial position, cylinders 1A1 and 2A1 are in the retracted end position.

Step 1-2
When pushbutton S1 (NO contact) is activated, relay K3 is energised. Change-over contact K3 (connected
as an NO contact) is closed and solenoid coil 1M1 at 5/2-way double solenoid valve 1V1 is energised.
Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances. As soon as pushbutton S1 (NO contact) is
no longer activated, relay K3 is de-energised and change-over contact K3 (connected as an NO contact) is
opened.
As a result, coil 1M1 is also de-energised.

Step 2-3
As soon as cylinder 1A1 reaches the advanced end position, magnetic proximity switch 1B2 (NO contact)
is switched and relay K1 is energised. Change-over contact K1 (connected as an NO contact) in current
path 8 is closed and solenoid coil 2M1 at 3/2-way solenoid valve 1V2 is energised. Valve 2M1 is reversed
and cylinder 2A1 advances.

Step 3-4
When cylinder 2A1 reaches the advanced end position, optical proximity switch 2B2 is activated (NO
7 is closed. Solenoid coil 1M2 is now energised. As a result, valve 1V1 is returned to its normal position
and cylinder 1A1 is returned to its retracted end position.

As soon as cylinder 1A1 has left its advanced end position, relay K1 is de-energised. NO contact K1 in
current path 8 opens and solenoid coil 2M1 is de-energised. Valve 1V1 is returned to its normal position
by the reset spring and cylinder 2A1 is returned to its retracted end position.



1 Proximity switch, electronic
1 Proximity switch, optical
3 Relay
1 Distributor block
Equipment list

Exercise12: Eliminating a malfunction at a pallet loading station

Learning objectives
Youll be able to detect and eliminate errors in simple electro-pneumatic control systems.

The pallet loading station comes to a standstill during operation. A malfunction has occurred and must be
eliminated. Afterwards, the pallet loading station must be restarted.

Layout

Pallet loading station

Parameters
A malfunction has occurred.

Project assignment
1 Describe the control systems performance. Compare this with the correct performance. Make use of the
displacement-step diagram.
2 Narrow down possible causes of the malfunction. Make use of the pneumatic and electrical circuit
diagrams.
3 Pinpoint the malfunction at the control system and eliminate it.
4 Put the control system back into service.

Control sequence
1 When pushbutton S1 is activated, cylinder 1A1 is advanced. An individual set is transported to the
loading station as a result and sensor 1B2 is actuated.
2 Cylinder 2A1 is advanced, actuates sensor 2B2 and pushes the individual set onto the pallet.
3 If 2B2 is actuated and S1 is unactuated, cylinder 1A1 is retracted, 1B2 is no longer actuated and cylinder
2A1 is retracted.
1A1+ 2A1+ 1A1
2A1

Troubleshooting simple electro-pneumatic circuits
The following error occurs in the control system depicted below:
The piston rods in cylinders 1A1 and 2A1 advance and remain in the advanced end position.

Describe the possible causes of this error.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1B2
2B2
2V2
2
2M1
3 1
2A1
2V1
1 1
2 2
2
1


K3
14 12
11
K2
14 12
11
K1
14 12
11
K2 K1 K3 1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
S1
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .7 .6
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK


List of possible causes
Sensor 2B2 at cylinder 2A1 is incorrectly adjusted, defective sensor
Current path 3 is interrupted (e.g. broken wire or loose connection)
The signal cable from sensor 2B2 is interrupted, current path 4 (e.g. broken wire or loose connection)
Earth cable 1M2 is interrupted, current path 7 (e.g. broken wire or loose connection), solenoid coil 1M2 is defective
Earth cable at relay K2 is interrupted, current path 4 (e.g. broken wire or loose connection), relay K2 is defective
Interruption of current path 7, supply line to relay contact 14 (relay K2) or supply line to relay contact 11 (relay K2) downstream from
solenoid coil 1M2 (e.g. broken wire or loose connection)

Troubleshooting simple electro-pneumatic circuits
Conductors are interrupted at the points identified in the circuit shown below.

Explain which effects a broken wire would have on the circuits function at each of the identified points.

K3
14 12
11
K2
14 12
11
K1
14 12
11
K2 K1 K3 1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
S1
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .7 .6
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK


Error Effects of the error
Broken earth wire at relay
K1, current path 2
Piston rod in cylinder 1A1 advances, sensor 1B2 is actuated => relay K1 is not picked up => relay
contact in current path 8 (change-over contact, connected as NO contact) does not switch => piston rod
in cylinder 2A1 does not advance to the advanced end position (remains retracted), sensor 2B2 is not
actuated => piston rod in cylinder 1A1 remains advanced because 1M2 is not actuated.
Broken signal wire at
sensor 2B2, current path 4
Piston rod in cylinder 1A1 advances, sensor 1B2 is actuated => piston rod in cylinder 2A1 advances to
the advanced end position, sensor 2B2 is actuated => relay K2 is not picked up => relay contact in
current path 7 (change-over contact, connected as NO contact) does not switch => piston rods in
cylinders 1A1 and 2A1 remain in the advanced position.
Broken supply line to relay
K3, current path 5
Current path 5 is not closed, relay K3 is not picked up, no reaction to start signal => piston rods in
cylinders 1A1 and 2A1 remain in the retracted position.
Broken supply line to relay
contact 14 (relay K2),
current path 7
Piston rod in cylinder 1A1 advances, sensor 1B2 is actuated => piston rod in cylinder 2A1 advances to
the advanced end position, sensor 2B2 is actuated => relay K2 is picked up, relay contact in current
path 7 (change-over contact, connected as NO contact) switches, but solenoid coil 1M2 is not energised
due to broken wire => piston rods in cylinders 1A1 and 2A1 remain in the advanced position.
Earth wire 2M1 broken,
current path 8
Piston rod in cylinder 1A1 advances => sensor 1B2 is actuated => relay K1 is picked up, relay contact in
current path 8 (change-over contact, connected as NO contact) switches, but solenoid coil 2M1 is not
energised due to broken wire => piston rod in cylinder 2A1 remains retracted, piston rod in cylinder 1A1
remains advanced.
Error list for possible error simulation by the trainer
The following is a list of errors which you can incorporate into a control system. The corresponding printed
forms for troubleshooting are in the student workbook.

Error simulation Cause of error Effects of the error
Push sensor 1B2 at cylinder 1A1 towards
the retracted end position.
Sensor 1B2 at cylinder 1A1 is incorrectly
adjusted.
Piston rod in cylinder 1A1 advances,
sensor 1B2 is briefly actuated => piston rod
in cylinder 2A1 does not advance into the
advanced end position, sensor 2B2 is not
actuated => piston rod in cylinder 1A1
remains advanced because 1M2 is not
actuated.
Disconnect the signal cable from sensor
1B2 or push the sensor beyond the
advanced end position.
Broken signal cable at sensor 1B1 or
incorrectly adjusted sensor.
Piston rod in cylinder 1A1 advances => no
sensor signal or sensor 1B2 is not actuated
=> piston rod in cylinder 2A1 remains
retracted, piston rod in cylinder 1A1
remains advanced.
Disconnect the signal cable from sensor
2B2 or push the sensor beyond the
advanced end position.
Broken signal cable at sensor 2B1 or
incorrectly adjusted sensor.
Piston rod in cylinder 1A1 advances,
sensor 1B2 is actuated => piston rod in
cylinder 2A1 advances into the advanced
end position, no sensor signal or sensor
2B2 is not actuated => piston rods in
cylinders 1A1 and 2A1 remain in the
advanced position.
Interrupt current path 2 (e.g. earth wire
from relay K1), signal line or current path 8,
e.g. disconnect supply lines to relay
contact 14 or 11 (relay K1) and earth wire
2M1.
Broken earth wire 2M1, K1 and supply
lines to relay contact 11 and 14 (relay K1)
Piston rod in cylinder 1A1 advances => 2A1
remains retracted because current paths 2
and 8 are interrupted.
For example, interrupt earth wire from
relay K2 and current path 4 or 7, or
disconnect relay K2 and supply lines to
relay contacts 14 and 11 (relay K2) and
earth wire1M2.
Broken earth wire 1M2, K2 and supply
lines to relay contact 11 and 14 (relay K12)
The piston rods in cylinders 1A1 and 2A1
advance and remain in the advanced end
position.
Interrupt earth wire from relay K3, current
path 5 or 8, 1M1, or disconnect K3 and
supply lines to relay contact 14 and K3.
Broken earth wire 1M1, K3 and broken
supply lines to relay contact 14 to K3
No reaction to start signal => piston rods in
cylinders 1A1 and 2A1 remain in the
retracted position.

Notes for the trainer
Its advisable to carry out this task after setting up the control system, because correct set-up of the
control system has then been completed and tested.

The error can be directly incorporated into the control system by the trainer (see error simulation list).
Its important to make sure that the trainees proceed in an orderly fashion during troubleshooting.

Alternative
If a fully set-up control system is not available, troubleshooting can also be conducted theoretically.
The trainer explains the malfunction (cylinder 1A1 advances and then the control system jams).
The trainees narrow down the possible errors based on the function chart.
The trainees prepare a list of possible causes of the error and describe how they will proceed during
troubleshooting (where must measurements be performed, what must be tested).

Determine target status

Create a displacement-step diagram of the target status with the help of the necessary documentation.

Zeit
Benennung Signal
Kenn-
zeichnung
Bauglieder
Schritt
1 2 3 4 5 6 7 8 9 10


Troubleshooting: actual versus target status comparison

Determine the actual status of the system on the basis of the following documentation:
Layout with description of the problem
Graphic representation
If correct functioning is not ensured (actual versus target status comparison), clearly mark the point in
the diagram where the error occurs.

Zeit
Benennung Signal
Kenn-
zeichnung
Bauglieder
Schritt
1 2 3 4 5 6 7 8 9 10


Troubleshooting: description of the error
You marked the point at which the error occurs in the diagram on the worksheet for the actual versus target
status comparison.

Describe in a few words the sequence up to the point that the station or system comes to a standstill.

_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Troubleshooting: pinpointing pneumatic errors
After having determined the systems actual status, think about what might have caused the error. In which
pneumatic tubing connections might the error be located?

Enter all possibilities. Specify elements at the beginnings and ends of tubing connections in order to
ensure clear identification.

Error possibility
no.
Tubing connection,
beginning
Tubing connection,
end

Possible errors

Troubleshooting: pinpointing electrical errors
After having determined the systems actual status, think about what might have caused the error.
In which current paths might the error be located?
What is the function of the current path?

Enter all possible errors in the table.

Error possibility
no.
Current path no. Function of the current path

Possible errors

Troubleshooting: narrowing down pneumatic errors
Examine the possible pneumatic causes of error which you have discovered. Use the same error numbering
you used on the worksheet for pinpointing pneumatic errors. Document the procedure used for inspecting
the tubing connections.

Enter the results of your inspection in the following table.

Measuring and test report
Error possibility
no.
Tubing connection,
beginning
Tubing connection,
end
Inspection Results


Troubleshooting: narrowing down electrical errors
Examine the possible electrical causes of error which you have discovered. Use the same error numbering
you used in the worksheet for pinpointing electrical errors.

Document the procedure used for inspecting the wiring connections by entering your results in the
table.

Error possibility
no.
Current path no. Measuring points Inspection Results


Error elimination
After pinpointing the error, document the procedure for eliminating the error on this worksheet.

Describe each step as completely as possible.

_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Note
If the system does not fulfil the desired function, go back to the first worksheet and repeat the
troubleshooting process.

Use new worksheets for this.

Commissioning
After having detected, localised and eliminated the error or errors, re-start the system in accordance with
the target status. Reset the specified setpoint times.

Describe your procedure in a few words.

_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
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pneumatic simulation software

pneumatics software package is included on the CD ROM. Even this demo

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