Sie sind auf Seite 1von 34

Electropneumatics

Basic Level

Festo worldwide

Austria
Festo Gesellschaft m.b.H.
Linzer Strae 227
1140 Wien
Tel. ++43 (0)1/9 10 75-0, Fax 9 10 75-250
E-mail: automation@festo.at
Belarus
IP Festo
Minsk, 220035
Mascherov Prospekt, 78
Belarus
Tel. ++375 (0)17/204 85 58, Fax 204 85 59
E-mail: info_by@festo.com
Belgium
Festo Belgium sa/nv
Rue Colonel Bourg 101
1030 Bruxelles/Brussel
Tel. ++32 (0)2/702 32 11, Fax 702 32 09
E-mail: info_be@festo.com
Brazil
Festo Automao Ltda.
Rua Guiseppe Crespi, 76
KM 12,5 - Via Anchieta
04183-080 So Paulo SP-Brazl
Tel. ++55 (0)11/50 13 16 00, Fax 50 13 18 68
E-mail: info_br@festo.com
Bulgaria
Festo EOOD
1592 Sofia
9, Christophor Kolumb Blvd.
Tel. ++359 (0)2/960 07 12, Fax 960 07 13
E-mail: info_bg@festo.com
Canada
Festo Inc.
5300 Explorer Drive
Mississauga, Ontario L4W 5G4
Tel. ++1 (0)905/624 90 00, Fax 624 90 01
E-mail: info_ca@festo.com
Chile
Festo S.A.
Mapocho 1901
6500151 Santiago de Chile
Tel. ++56 (0)2/690 28 00, Fax 695 75 90
E-mail: info.chile@cl.festo.com
China
Festo (China) Ltd.
1156 Yunqiao Road
Jinqiao Export Processing Zone
Pudong,
201206 Shanghai, PRC
Tel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00
E-mail: info_cn@festo.com
Colombia
Festo Ltda.
Avenida El Dorado No. 98-43
Bogot
Tel. ++57 (0)1/404 80 88, Fax 404 81 01
E-mail: festo@festo.com.co

Japan
Festo K.K.
1-26-10 Hayabuchi, Tsuzuki-ku
Yokohama 224-0025
Tel. ++81 (0)45/593 56 10, Fax 593 56 78
E-mail: info_jp@festo.com

Singapore
Festo Pte. Ltd.
6 Kian Teck Way
Singapore 628754
Tel. ++65/62 64 01 52, Fax 62 61 10 26
E-mail: info_sg@festo.com

Finland
Festo OY
Mkituvantie 9, P.O. Box 86
01511 Vantaa
Tel. ++358 (09)/87 06 51, Fax 87 06 52 00
E-mail: info_fi@festo.com

Korea South
Festo Korea Co., Ltd.
470-1 Gasan-dong, Geumcheon-gu
Seoul #153-803
Tel. ++82 (0)2/850 71 14, Fax 864 70 40
E-mail: info_kr@festo.com

Slovakia
Festo spol. s r.o.
Gavlovicov ul. 1
83103 Bratislava 3
Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11
E-mail: info_sk@festo.com

France
Festo Eurl
Numro Indigo Tel. 0820/204640, Fax 204641
ZA des Maisons Rouges
8 rue du Clos Sainte Catherine
94367 Bry-sur-Marne cedex
Tel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01
E-mail: info_fr@festo.com

Latvia
Festo SIA
Deglava 60
1035 Riga
Tel. ++371 67/57 78 64, Fax 57 79 46
E-mail: info_lv@festo.com

Slovenia
Festo d.o.o. Ljubljana
IC Trzin, Blatnica 8
1236 Trzin
Tel. ++386 (0)1/530 21 00, Fax 530 21 25
E-mail: info_si@festo.com

Lithuania
Festo UAB
Karaliaus Mindago pr. 22
3000 Kaunas
Tel. ++370 (8)7/32 13 14, Fax 32 13 15
E-mail: info_lt@festo.com

South Africa
Festo (Pty) Ltd.
22-26 Electron Avenue, P.O. Box 255
Isando 1600
Tel. ++27 (0)11/971 55 00, Fax 974 21 57
E-mail: info_za@festo.com

Malaysia
Festo Sdn.Berhad
10 Persiaran Industri
Bandar Sri Damansara, Wilayah Persekutuan
52200 Kuala Lumpur
Tel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11
E-mail: info_my@festo.com

Spain
Festo Pneumatic, S.A.
Tel. 901243660 Fax 902243660
Avenida Granvia, 159
Distrito econmico Granvia L'H
ES-08908 Hospitalet de Llobregat, Barcelona
Tel. ++ 3493/261 64 00, Fax 261 64 20
E-mail: info_es@festo.com

Germany
Festo Didactic GmbH & Co. KG
Postfach 10 07 10
73707 Esslingen
Rechbergstrae 3
73734 Esslingen
Tel. ++49 (0)711/3467-0
Fax ++49 (0)711/347-54 88500
E-mail: did@de.festo.com
Greece
Festo Ltd.
40 Hamosternas Ave.
11853 Athens
Tel. ++30 210/341 29 00, Fax 341 29 05
E-mail: info_gr@festo.com
Hong Kong
Festo Ltd.
Unit C&D, 7/F, Leroy Plaza
15 Cheung Shun Street
Cheung Sha Wan, Kowloon
Hong Kong
Tel. ++ 852/27 43 83 79, Fax 27 86 21 73
E-mail: info_hk@festo.com
Hungary
Festo Kft.
Csillaghegyi t 32-34.
1037 Budapest
Tel. ++36 1/436 51 11, Fax 436 51 01
E-mail: info_hu@festo.com
India
Festo Controls Private Ltd.
237B,
Bommasandra Industrial Area,
Bangalore Hosur Highway,
Bangalore 560 099
Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58
E-mail: info_in@festo.com
Indonesia
PT. Festo
JL. Sultan Iskandar Muda No.68
Arteri Pondok Indah
Jakarta 12240
Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98
E-mail: info_id@festo.com
Iran
Festo Pneumatic S.K.
# 2, 6th street, 16th avenue,
Tehran 1581975411
Km 8, Special Karaj Road, P.O.Box 15815-1485
Tehran 1389793761
Tel. ++98 (0)21 44 52 24 09,
Fax ++98 (0)21 44 52 24 08
E-mail: Mailroom@festo.ir

Mexico
Festo Pneumatic, S.A.
Av. Ceyln 3
Col. Tequesquinahuac
54020 Tlalnepantla, Edo. de Mxico
Tel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55
E-mail: festo.mexico@mx.festo.com

Sweden
Festo AB
Stillmansgatan 1, P.O. Box 21038
20021 Malm
Tel. ++46 (0)40/38 38 40, Fax 38 38 10
E-mail: info_se@festo.com

Netherlands
Festo B.V.
Schieweg 62
2627 AN Delft
Tel. ++31 (0)15/251 88 99, Fax 261 10 20
E-mail: info@festo.nl

Switzerland
Festo AG
Moosmattstrasse 24
8953 Dietikon ZH
Tel. ++41 (0)44/744 55 44, Fax 744 55 00
E-mail: info_ch@festo.com

New Zealand
Festo Limited
MT. Wellington
Auckland NZ
Tel. ++64 (0)9/574 10 94, Fax 574 10 99
E-mail: info_nz@festo.com

Taiwan
Festo Co., Ltd.
Head Office
24450, No. 9, Kung 8th Road
Linkou 2nd Industrial Zone
Linkou Hsiang, Taipei Hsien, Taiwan, R.O.C.
Tel. ++886 (0)2 26 01 92 81,
Fax ++886 (0)2 26 01 92 86-7
E-mail: festotw@festo.com

Nigeria
Festo Automation Ltd.
Motorways Centre, First Floor, Block C
Alausa, Ikeja,
Lagos, NIGERIA
Tel. ++234 (0)1/794 78 20, Fax 555 78 94
E-mail: info@ng-festo.com
Norway
Festo AS
Ole Deviks vei 2
0666 Oslo, Norway
Tel. ++47 22 72 89 50, Fax ++47 22 72 89 51
E-mail: info_no@festo.com
Peru
Festo S.R.L.
Calle Amador Merino Reyna #480, San Isidro
Lima, Per
Tel. ++51 (0)1/222 15 84, Fax 222 15 95
Philippines
Festo Inc.
KM 18, West Service Road
South Superhighway
1700 Paranaque City, Metro Manila
Tel. ++63 (0)2/776 68 88, Fax 823 42 19
E-mail: info_ph@festo.com

With CD-ROM

+24 V

Turkey
Festo San. ve Tic. A.S.
Tuzla Mermerciler Organize
Sanayi Blgesi, 6/18 TR
34956 Tuzla - Istanbul/TR
Tel. ++90 (0)216/585 00 85, Fax 585 00 50
E-mail: info_tr@festo.com
Ukraine
Festo Ukraina
Borisoglebskaja 11
Kiev 04070
Tel. ++380 (0)44/239 24 33, Fax 463 70 96
E-mail: info_ua@festo.com
United Kingdom
Festo Limited
Applied Automation Centre, Caswell Road
Brackmills Trading Estate
Northampton NN4 7PY
Tel. ++44 (0)1604/66 70 00, Fax 66 70 01
E-mail: info_gb@festo.com

Croatia
Festo d.o.o.
Nova Cesta 181
10000 Zagreb
Tel. ++385 (0)1/619 19 69, Fax 619 18 18
E-mail: info_hr@festo.com
Czech Republic
Festo, s.r.o.
Modansk 543/76
147 00 Praha 4
Tel. ++420 261 09 96 11, Fax 241 77 33 84
E-mail: info_cz@festo.com

Israel
Festo Pneumatic Israel Ltd.
P.O. Box 1076, Ha'atzma'ut Road 48
Yehud 56100
Tel. ++972 (0)3/632 22 66, Fax 632 22 77
E-mail: info_il@festo.com

Romania
Festo S.R.L.
St. Constantin 17
010217 Bucuresti
Tel. ++40 (0)21/310 29 83, Fax 310 24 09
E-mail: info_ro@festo.com

United States
Festo Corporation (New York)
Call Toll-free 800/993 3786
Fax Toll-free 800/963 3786
395 Moreland Road, P.O.Box 18023
Hauppauge, N.Y. 11788
Tel. ++ 1(0)314/770 01 12, Fax 770 16 84
E-mail: info_us@festo.com

Denmark
Festo A/S
Islevdalvej 180
2610 Rdovre
Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10
E-mail: info_dk@festo.com

Italy
Festo S.p.A
Via Enrico Fermi 36/38
20090 Assago (MI)
Tel. ++39 02/45 78 81, Fax 488 06 20
E-mail: info_it@festo.com

Russia
Festo-RF OOO
Michurinskiy prosp., 49
119607 Moskow
Tel. ++7 495/737 34 00, Fax 737 34 01
E-mail: info_ru@festo.com

Venezuela
Festo C.A.
Av. 23, Esquina calle 71, No. 22-62
Maracaibo, Edo. Zulia
Tel. ++58 (0)261/759 09 44, Fax 759 04 55
E-mail: festo@festo.com.ve

13
S1

12

14

K1
11

14

A1

K1

A2

0V
11

12
14 .2

21

22
24

31

32
34

41

42
44

1M1

1A1

Thailand
Festo Ltd.
67/1 Moo 6 Phaholyothin Road
Klong 1, Klong Luang,
Pathumthani 12120
Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33
E-mail: info_th@festo.com

Ireland
Festo Limited
Unit 5 Sandyford Park
Sandyford Industrial Estate
Dublin 18
Tel. ++ 353(0)1/295 49 55, Fax 295 56 80
E-mail: info_ie@festo.com

Poland
Festo Sp. z o.o.
Janki k/Warszawy, ul. Mszczonowska 7
05090 Raszyn
Tel. ++48 (0)22/711 41 00, Fax 711 41 02
E-mail: info_pl@festo.com

Workbook
TP 201

1V2

Workbook TP 201

Australia
Festo Pty. Ltd.
Head Office (Melbourne)
179-187 Browns Road, P.O. Box 261
Noble Park Vic. 3174
Call Toll Free 1300 88 96 96
Fax Toll Free 1300 88 95 95
Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87
E-mail: info_au@festo.com.au

Estonia
Festo OY AB Eesti Filiaal
Laki 11B
12915 Tallinn
Tel. ++372 666 15 60, Fax ++372 666 15 61
E-mail: info_ee@festo.com

Electropneumatics, Basic level

Argentina
Festo S.A.
Edison 2392
(B1640 HRV) Martinez
Prov. Buenos Aires
Tel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82
E-mail: info@ar.festo.com

1V1

1V3

1M1
5

Festo Didactic
541090 EN

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.
Status:
Authors:
Editor:
Graphics:
Layout:

541090
06/2009
M. Pany, S. Scharf
Frank Ebel
Doris Schwarzenberger
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.

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

Festo Didactic GmbH & Co. KG 541090

III

IV

Festo Didactic GmbH & Co. KG 541090

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.

Festo Didactic GmbH & Co. KG 541090

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.

VI

Festo Didactic GmbH & Co. KG 540671

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 shortcircuit 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.).

Festo Didactic GmbH & Co. KG 541090

VII

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.

VIII

Festo Didactic GmbH & Co. KG 540671

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.

Festo Didactic GmbH & Co. KG 540671

IX

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

Optional courseware

TP201 basic level


TP202 advanced level
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 540671

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.

Festo Didactic GmbH & Co. KG 541090

XI

Overview of learning objectives per exercise


Exercise

10

11

12

Learning objectives
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.

Learn to calculate piston forces based on specified


values.
Become familiar with the set-up and mode of
operation of a 3/2-way 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 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.

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

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

5/2-way double solenoid valve

539778

5/2-way solenoid valve

539777

Blanking plug

153267

10

Double-acting cylinder

152888

One-way flow control valve

193967

Pressure sensor

539757

Single-acting cylinder

152887

On-off valve with filter regulator

540691

Limit switch, electrical, actuated from left

183322

Limit switch, electrical, actuated from right

183322

Plastic tubing, 4 x 0.75, 10 m

151496

Proximity switch, electronic

540695

Proximity switch, optical

178577

Relay, 3-way

162241

Signal input, electrical

162242

Push-in sleeve

153251

10

Push-in T-connector

153128

20

Distributor block

152896

Festo Didactic GmbH & Co. KG 541090

XIII

Equipment set symbols


Designation

Symbol

Relay, 3-way

A1

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

A2
A1

A2
A1

A2

Signal input, electrical

13

21

14

22

13

21

14

22

3/2-way solenoid valve,


normally closed

13

21

14

22

13

21

14

22

12
1M1

1M1

XIV

Festo Didactic GmbH & Co. KG 541090

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


2

4
1

One-way flow control valve

Festo Didactic GmbH & Co. KG 541090

XV

Designation

Symbol

Single-acting cylinder

Double-acting cylinder

On-off valve with filter


regulator

1
2

Distributor block

Connectors

XVI

Festo Didactic GmbH & Co. KG 541090

Allocation of equipment per exercise


Exercise

10

11

12

Components
Cylinder, single-acting

Cylinder, double-acting
One-way flow control valve

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

1
1

(1)
1

5/2-way double solenoid valve

1
1

Pressure sensor

1
1

Limit switch, electrical

Proximity switch, normally open

Proximity switch, optical


Pushbutton, electrical, normally open

Pushbutton, electrical, normally closed


Relay

Distributor block

On-off valve with filter regulator

Power supply unit, 24 V DC

5/2-way solenoid valve

Festo Didactic GmbH & Co. KG 541090

XVII

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:
Valves:
Sensors:
Signal input:
Accessories:
Pressure lines:

XVIII

1A1, 2A1, 2A2 ...


1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
1B1, 1B2 ...
1S1, 1S2 ...
0Z1, 0Z2, 1Z1 ...
P1, P2 ...

Festo Didactic GmbH & Co. KG 540671

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.

Festo Didactic GmbH & Co. KG 541090

XIX

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.

XX

Festo Didactic GmbH & Co. KG 540671

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 electropneumatic 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.

Relay, 3-way

162241

Signal input, electrical

162242

Time relay, 2-way

162243

Preset counter, electrical

162355

Proximity switch, inductive

178574

Proximity switch, capacitive

178575

Emergency-stop button

183347

Valve terminal with 4 valve slices (MMJJ)

540696

Non-return valve, piloted

540715

Festo Didactic GmbH & Co. KG 541090

XXI

Learning objectives for the advanced level (TP202)

XXII

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 540671

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.

Presentation of the problem


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

Festo Didactic GmbH & Co. KG 541090

Exercise 1: Inspecting beverage cases

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

1
2
3
4
5

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

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.

Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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).

Festo Didactic GmbH & Co. KG 541090

Exercise 1: Inspecting beverage cases

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

10
1M1

Pilot actuated 3/2-way solenoid valve, normally closed,

with manual override, spring return

12
1M1

Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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

The solenoid valve used is reversed by applying voltage to the

solenoid coil; flow is enabled from supply port 1 to working port

solenoid coil; supply port 1 is closed, thus stopping flow. After

2. After the signal has been stopped, the valve returns to its

stopping the signal, the valve returns to its normal position by a

normal position by a reset spring and supply port 1 is closed, thus reset spring and flow from supply port 1 to working port 2 is
stopping flow. If the directional control valves solenoid coil is de- enabled. If the directional control valves solenoid coil is deenergised, the cylinder chamber is vented via exhaust port 3 at

energised, the cylinder chamber is pressurised via the directional

the directional control valve. The piston rod is retracted. When

control valve. The piston rod is advanced. When the solenoid coil is

the solenoid coil is energised, the directional control valve

energised the directional control valve switches and the cylinder

switches and the cylinder chamber is pressurised. The piston rod

chamber is exhausted via exhaust port 3 at the directional control

advances. When the solenoid coil is de-energised, the valve

valve. The piston rod is retracted. When the solenoid coil is de-

switches back again. The cylinder chamber is exhausted and the

energised, the valve switches back again. The cylinder chamber is

piston rod is retracted.


The motion sequence is thus as follows: 1A1+ 1A1-.

pressurised and the piston rod is advanced.


The motion sequence is thus as follows: 1A1- 1A1+.

Festo Didactic GmbH & Co. KG 541090

Exercise 1: Inspecting beverage cases

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

In the case of indirect actuation, current flows through a relay coil

valves solenoid coil. The solenoid is energised and the valve

when a pushbutton is activated. The relays contacts are closed

switches to the actuated position.

and the valve switches. The valve remains in this switching

The flow of electrical current is interrupted when the pushbutton

position as long as electrical current flows through the solenoid

is released. The solenoid is de-energised and the valve switches


to the normal position.

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.

Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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
Design:
Pushbutton with normally open contacts

3
4

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.
Design:
Pushbutton with change-over contacts

4
1

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.

Festo Didactic GmbH & Co. KG 541090

Exercise 1: Inspecting beverage cases

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.

Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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

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

Pilot line, function for pilot actuated or pneumatically actuated directional control valves when
actuated: supply port 1 is closed

Festo Didactic GmbH & Co. KG 541090

Exercise 1: Inspecting beverage cases

Complete the pneumatic and electrical circuit diagrams

Complete the pneumatic and electrical circuit diagrams for the sorting system.
1A1
+24 V

1V2

13

2
S1

14

1
1V1
1M1

3
1M1

0V
Pneumatic circuit diagram

10

Electrical circuit diagram

Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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

Cylinder, single-acting

One-way flow control valve

3/2-way solenoid valve, normally closed

Pushbutton (normally open)

Distributor block

On-off valve with filter regulator

Compressed air source

Power supply unit, 24 V DC

Equipment list

Festo Didactic GmbH & Co. KG 541090

11

Exercise 1: Inspecting beverage cases

12

Festo Didactic GmbH & Co. KG 540671