Electropneumatics Advanced level - Festo Didactic · Electropneumatics Advanced level K5 12 14 11 K1 12 14 11 ... The training package for electropneumatics may only be used:

Workbook

TP 202

With CD-ROM

Festo Didactic

541091 EN

ElectropneumaticsAdvanced level

K5

1412

11

K1

1412

11

K6 K7 K8 K9

8

A1 A1 A1 A1

A2 A2 A2 A2

12 12 12 12

22 22 22 22

32 32 32 32

42 42 42 42

.9 .11 .13 .15

.16

.20

.10 .12 .14

.19

.20 .21

.18 .18

.19

1A1+ 2A1+ 2A1- 1A1-

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 1414 14 14

2414 24 24

12 12 12 1212 12 12

2212 22 22

11 11 11 1111 11 11

2111 21 21

10 12 1411 13 159

K2 K4 K3

K6K10 K7 K8

+24 V... ...

... ...0 V

K10A1

A2

12

22

32

42

.8

.17

.21

14

24

34

44

11

21

31

41

K10

2424

24

2222

22

2121

21

16 17

K1

K9

Use for intended purpose

The training package for electropneumatics may only be used:

• For its intended purpose in teaching and training applications

• When its safety functions are in flawless condition

The components included in the training package are laid out in accordance with the latest technology, as

well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and

the components may be impaired, if they are used improperly.

The training system from Festo Didactic has been developed and manufactured exclusively for training and

vocational education in the field of automation 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 sets in situations which serve any

purpose other than training and/or vocational education, unless such damages have been caused by Festo

Didactic due to malicious intent or gross negligence.

Order no. 541091

Revision level: 10/2009

Authors: W. Haring, M. Metzger, R.-C. Weber

Editor: Frank Ebel

Graphics: Doris Schwarzenberger

Layout: 02/2010

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2010

Internet: www.festo-didactic.com

e-mail: [email protected]

The reproduction, distribution and utilisation of this document, as well as the communication of its contents

to others without explicit authorisation, is prohibited. Violators will be held liable for compensation of

damages. All rights reserved, in particular the right to file patent, utility model and registered design

applications.

© Festo Didactic GmbH & Co. KG 541091 III

Table of contents

Preface _________________________________________________________________________________ V

Introduction ____________________________________________________________________________ VII

Work instructions and safety precautions ____________________________________________________ VIII

Technology package for electro-pneumatics (TP 200) _____________________________________________X

Learning objectives for the advanced level (TP 202) _____________________________________________ XI

Allocation of learning objectives per exercise _________________________________________________ XII

Equipment set for the advanced level (TP 202) ________________________________________________ XIV

Allocation of components per exercise ______________________________________________________ XVII

Tools for the trainer _____________________________________________________________________ XVIII

Structure of the exercises ________________________________________________________________ XVIII

Designations of the components ____________________________________________________________ XIX

CD-ROM contents ________________________________________________________________________ XIX

Learning goals for the basic level (TP 201) ____________________________________________________ XXI

Solutions

Exercise 1: Implementing a diverting device ____________________________________________________ 1

Exercise 2: Placing beverage bottles _________________________________________________________ 11

Exercise 3: Implementing a sorting station ____________________________________________________ 19

Exercise 4: Machining key blanks ___________________________________________________________ 31

Exercise 5: Bending mounting brackets ______________________________________________________ 41

Exercise 6: Sorting out empty jars from a filling system _________________________________________ 51

Exercise 7: Bonding components ___________________________________________________________ 61

Exercise 8: Selecting operating modes _______________________________________________________ 69

Exercise 9: Machining key blanks with emergency stop function __________________________________ 79

Exercise 10: Bending mounting brackets with emergency stop function ____________________________ 89

Exercise 11: Transporting chocolate bars with emergency stop function ____________________________ 97

Exercise 12: Eliminating a malfunction at a machining station ___________________________________ 107

IV © Festo Didactic GmbH & Co. KG 541091

Exercises













© Festo Didactic GmbH & Co. KG 541091 V

Preface

Festo Didactic’s training system for automation technology is geared towards various educational

backgrounds and vocational requirements. The training system is therefore broken down as follows:

• Technology-oriented training packages

• Mechatronics and factory automation

• Process automation and control technology

• Robotino® – training and research with mobile robots

• Hybrid learning factories

The technology packages deal with various technologies including pneumatics, electro-pneumatics,

hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,

electrical engineering and electric drives.

The modular design of the training system allows for applications which go above and beyond the

limitations of the individual packages, such as, for example, PLC actuation of pneumatic, hydraulic and

electric drives.

VI © Festo Didactic GmbH & Co. KG 541091

All training modules have the same structure:

• Hardware

• Teachware

• Software

• Seminars

The hardware is comprised of industrial components and systems that are specially designed for training

purposes.

The structure of the teachware corresponds to that of the hardware. It includes:

• Textbooks (with exercises and examples)

• Workbooks (with practical exercises, supplementary instructions and solutions)

• Transparencies and videos (for dynamic instruction)

The teaching and learning media are available in several languages. They’re intended for use in classroom

instruction, but are also suitable for self-study.

Where software is concerned, computer training programs, as well as simulation, visualisation, project

engineering, design engineering and programming software, are made available.

A wide range of seminar offerings covering the contents of the training packages round off the programme

for training and vocational education.

If you have any suggestions or feedback about this manual,

please send us an e-mail at [email protected].

The authors and Festo Didactic look forward to your feedback.

© Festo Didactic GmbH & Co. KG 541091 VII

Introduction

This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic

GmbH & Co. KG. This system provides a solid basis for practice-oriented vocational and further training.

Technology package TP 200 is comprised exclusively of electropneumatic control systems.

Advanced Level TP 202 focuses on further training in electropneumatic control technology. The two

equipment sets enable you to construct complex combinational circuits with logic operations of input and

output signals and program controls

Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate.

A short-circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is used for DC

voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar (800 kPa) can be used for

compressed air supply.

Optimum operational reliability is achieved if the control system is operated unlubricated at a working

pressure of p = 5 bar = 500 kPa.

The equipment set of Basic Level TP 201 is used to construct complete control systems for all of the 12

problem definitions. The theoretical fundamentals to help you understand this collection of exercises can be

found in the

• textbook Electropneumatics

Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices,

etc.).

VIII © Festo Didactic GmbH & Co. KG 541091

Work instructions and safety precautions

General

• Trainees should only work with the circuits under the supervision of a trainer.

• Observe specifications included in the data sheets for the individual components and in particular all

safety instructions!

• Faults which may impair safety must not be generated in the training environment and must be

eliminated immediately.

Mechanical setup

• Mount all the components securely onto the profile plate.

• Adhere to instructions regarding positioning of the components.

Electrical setup

• Use low voltage only (max. 24 V DC).

• Electrical connections must only be established and interrupted in the absence of voltage!

• Only use connecting cables with safety plugs for electrical connections.

• Only pull the plug when disconnecting connecting cables – never pull the cable.

Pneumatics

• Do not exceed the maximum permissible pressure of 6 bar (600 kPa).

• Do not switch on the compressed air until all of 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 the pneumatic circuit:

Press the blue release ring down, after which the tubing can be pulled out.

© Festo Didactic GmbH & Co. KG 541091 IX

Mounting technology

The mounting boards for the components are equipped with mounting variant A, B or C:

• Variant A, snap-in system

Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply

clip the components into the slots on the profile plate. Release the components from the slots by

turning the blue lever.

• Variant B, bolt system

Components with medium load capacity (e.g. pneumatic cylinders). These components are clamped to

the profile plate with 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 (e.g. on-off valve with filter regulator). The components are secured with socket head screws and

T-head bolts.

X © Festo Didactic GmbH & Co. KG 541091

Technology package for electro-pneumatics (TP 200)

The TP 200 technology package consists of a multitude of training materials and seminars. The subject

matter of this package is electro-pneumatic controllers. The individual components included in the TP 200

technology package can also be included in other modules.

Important elements of the TP 200

• Permanent workstation with Festo Didactic profile plate

• Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)

• Equipment sets or individual components

• Visual training materials

• Practical training models

• Complete laboratory setups

Training documentation

Textbooks TP 201 basic level

Fundamentals of pneumatic control technology

Maintenance of pneumatic components and systems

Workbooks TP 201 basic level

TP 202 advanced level

Optional teachware 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® Pneumatik 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 vocational education

P-AZUBI Pneumatics and electro-pneumatics for trainees

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

You’ll find further training materials in our catalogue and on the Internet. The training system for automation

technology is continuously updated and expanded. Transparency sets, videos, CD-ROMs and DVDs, as well

as textbooks, are offered in several languages.

© Festo Didactic GmbH & Co. KG 541091 XI

Learning objectives for the advanced level (TP 202)

• Become familiar with the setup and function of valve terminals.

• Be able to use valve terminals in accordance with specified requirements.

• Be able to create a displacement-step diagram for sequence controls.

• Be able to convert a function chart into a GRAFCET chart.

• Be able to resolve overlapping signals in sequence controls using the group method.

• Recognise overlapping signals in sequence controls.

• Be able to setup a step sequence using valves with spring return.

• Be able to setup a step sequence using double pilot valves.

• Become familiar with the modes of operation of various proximity switches.

• Be able to select proximity switches which are appropriate for the conditions.

• Become familiar with logic operations and implement them.

• Become familiar with the setup and function of a pneumatic-electric converter.

• Become familiar with options for querying pressure and time in electro-pneumatic controllers.

• Become familiar with the possible uses of an on-delay timing relay.

• Become familiar with operating modes and learn to set up circuits with which single cycle and

continuous cycle operating modes can be implemented.

• Become familiar with the function of an electrical preset counter and learn to use it in circuits.

• Be able to develop and set up the emergency stop function for a controller using valves with spring

return.

• Be able to develop and set up the emergency stop function for a controller using double pilot valves.

• Be able to develop and set up a specified motion sequence in the event of an emergency stop.

• Be able to set up the following emergency stop condition: “cylinder remains in its momentary position

in the event of an emergency stop”.

• Become familiar with the setup and mode of operation of a 5/3-way solenoid valve.

• Be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.

• Be able to integrate the reset operating mode into a controller.

• Learn to detect and eliminate errors in complex electro-pneumatic controllers.

XII © Festo Didactic GmbH & Co. KG 541091

Allocation of learning objectives per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Learning objectives

Become familiar with the setup and function of valve

terminals.

• •

Be able to use valve terminals in accordance with

specified requirements.

• •

Be able to resolve overlapping signals in sequence

controls using the group method.

•

Be able to create a displacement-step diagram for

sequence controls.

• • •

Be able to convert a function chart into a GRAFCET

chart.

•

Be able to setup a step sequence using valves with

spring return.

•

Recognise overlapping signals in sequence controls. •

Be able to setup a step sequence using double pilot

valves.

•

Become familiar with the modes of operation of

various proximity switches.

•

Be able to select proximity switches which are

appropriate for the conditions.

•

Become familiar with logic operations and implement

them.

•

Become familiar with options for querying pressure

and time in electro-pneumatic controllers.

•

Become familiar with the setup and function of a

pneumatic-electric converter.

•

Become familiar with the possible uses of an on-delay

timing relay.

•

© Festo Didactic GmbH & Co. KG 541091 XIII

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Learning goals

Become familiar with operating modes and learn to set

up circuits with which single cycle and continuous

cycle operating modes can be implemented.

• •

Become familiar with the function of an electrical

preset counter and learn to use it in circuits.

•

Be able to develop and set up the emergency stop

function for a controller using valves with spring

return.

•

Be able to develop and set up the emergency stop

function for a controller using double pilot valves.

•

Be able to develop and set up a specified motion

sequence in the event of an emergency stop.

•

Be able to set up the following emergency stop

condition: “cylinder remains in its momentary position

in the event of an emergency stop”.

•

Become familiar with the setup and mode of operation

of a 5/3-way solenoid valve.

•

Be able to replace a 5/3-way solenoid valve with 3/2-

way solenoid valves.

•

Be able to integrate the reset operating mode into a

controller.

•

Be able to detect and eliminate errors in complex

electro-pneumatic controllers.

•

XIV © Festo Didactic GmbH & Co. KG 541091

Equipment set for the advanced level (TP 202)

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 (TP 201 and TP 202) include components which are

necessary for mastering the predefined learning objectives and can be supplemented with other equipment

sets for the training system for automation technology as desired.

Equipment set for the advanced level (TP 202, order no. 540713)

Designation Order no. Quantity

Proximity switch, inductive 178574 1

Proximity switch, capacitive 178575 1

Emergency-stop button 183347 1

Relay, 3-way 162241 2

Non-return valve, piloted 540715 2

Signal input, electrical 162242 1

Valve terminal with 4 valve slices (MMJJ) 540696 1

Preset counter, electrical 162355 1

Time relay, 2-way 162243 1

© Festo Didactic GmbH & Co. KG 541091 XV

Equipment set symbols

Designation Symbol

Relay, 3-way

1412 2422 3432

32

4442

11 21 31 41

A1

A2

1412 2422 34 4442

11 21 41

A1

A231

1412 2422 3432 4442

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

XVI © Festo Didactic GmbH & Co. KG 541091

Designation Symbol

Time relay, 2-way

with switch-on delay

with switch-off delay

17

17

27

27

18

18

28

28

35

35

45

45

36

36

46

46

A1

A1

A2

A2

Preset counter, electrical

4 2

1A1 R1

A2 R2

Proximity switch, inductive

Proximity switch, capacitive

Emergency-stop button 13

14

21

22

Non-return valve, piloted 2

1 21

© Festo Didactic GmbH & Co. KG 541091 XVII

Allocation of components per exercise

TP 202 equipment set

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Component

Proximity switch, inductive 1

Proximity switch, capacitive 1

Emergency-stop button 1 1 1

Relay 2 6 6 6 6 6 4 5 6 6 6 6

Pushbutton, electrical, normally open 2 1 1 1 1 1 1 2 1 3 1

Pushbutton, electrical, normally closed 1

Non-return valve, piloted 2

Valve terminal with 4 valve slices (MMJJ) 1 1 1 1 1 1 1 1 1 1 1 1

Preset counter, electrical 1

Time relay, 2-way 1

XVIII © Festo Didactic GmbH & Co. KG 541091

Tools for the trainer

Learning objectives

The basic learning objectives for these exercises are the systematic drafting of circuit diagrams, as well as

the practical setup of the controller on the profile plate. This direct interaction involving both theory and

practice ensures faster progress and longer-lasting learning. Concrete, individual learning objectives are

assigned to each exercise. Important learning objectives are in parentheses in the revision sections.

Required time

The time required for working through the exercises depends on the student’s previous knowledge of the

subject matter. For a skilled labourer in the field of metalworking or electrical installation the time required

is approx. 2 weeks. For a technician or engineer it is approx. 1 week.

Equipment set elements

The exercise book and the equipment set match each other. For all 12 exercises, you’ll need the components

included in the equipment set for the TP 201 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 trainer’s manual includes the solutions for all 12 exercises.

© Festo Didactic GmbH & Co. KG 541091 XIX

Designations of the components

Pneumatic components are designated in circuit diagrams in accordance with 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 inputs: 1S1, 1S2 ...

Accessories: 0Z1, 0Z2, 1Z1 ...

Pressure lines: P1, P2 ...

CD-ROM contents

The CD-ROM supplied provides you with additional media. The contents of parts A (exercises) and C

(solutions) have been saved as PDF files.

The CD-ROM contains the following folders:

• 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 package are available. These

instructions are helpful when using and commissioning the equipment.

Data sheets

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

Demo

A demo version of the FluidSIM® pneumatics software package is included on the CD-ROM. This demo

version is also suitable for testing controllers developed by the user.

FluidSIM® circuit diagrams

The FluidSIM® circuit diagrams for all 12 exercises included in the technology package are contained in this

directory.

XX © Festo Didactic GmbH & Co. KG 541091

Industrial applications

Photos and graphics representing industrial applications are made available. These can be used to illustrate

individual tasks or to supplement project presentations.

Presentations

This directory contains short presentations for the components included in the technology package. These

can be used, for example, to create project presentations.

Product information

This directory contains product information and data sheets from Festo AG & Co. KG for the components

included in the technology package. This is intended to demonstrate which information and data is made

available for industrial components.

Videos

Several short videos of industrial applications in their actual environments round off the media provided

with the technology package.

© Festo Didactic GmbH & Co. KG 541091 XXI

Learning goals for the basic level (TP 201)

• Become familiar with the setup and mode of operation of a single-acting cylinder.

• Become familiar with the setup and mode of operation of a double-acting cylinder.

• Be able to calculate piston forces based on specified values.

• Become familiar with the setup and mode of operation of a 3/2-way solenoid valve.

• Become familiar with the setup 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 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 breaking signal.

• Be able to set up a pressure dependent controller.

• Become familiar with the setup 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 controllers.

XXII © Festo Didactic GmbH & Co. KG 541091

TP 201 equipment set

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

© Festo Didactic GmbH & Co. KG 541091 I

Contents

Solutions













II © Festo Didactic GmbH & Co. KG 541091

© Festo Didactic GmbH & Co. KG 541091 1

Exercise 1: Implementing a diverting device

Learning objectives

After completing this exercise:

• You’ll be familiar with the setup and function of valve terminals.

• You’ll be able to use valve terminals in accordance with specified requirements.

Presentation of the problem

Beverage bottles will be diverted from one conveyor to another by means of a diverting device. The diverting

panel is advanced when one of the pushbuttons is activated. The bottle is transferred and transported in the

opposite direction. The diverting panel is returned to its initial position when another pushbutton is

activated.

Layout

Diverting device for beverage bottles


2 © Festo Didactic GmbH & Co. KG 541091

Parameters

• A double-acting cylinder will be used.

• The cylinder will be controlled indirectly via pushbutton.

• In the event of a power failure, the cylinder’s piston rod should remain in its current position.

Project assignment

1. Answer the questions and complete the tasks relating to the learning content.

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.

Control sequence

1. Cylinder 1A1 is in the rear end-position.

2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the cylinder travels

to the front end-position.

3. After activating pushbutton S2, 5/2-way double solenoid valve 1V1 is reversed again and the cylinder

travels to the rear end-position.



Fundamentals: installation

The layout, tubing and wiring of the components of an electro-pneumatic controller should be selected so

that the total costs for the components, installation and maintenance are as low as possible. With regard to

wiring, selection is made between:

• Conventional wiring technology, e.g. terminal strips

• Modern installation concepts, e.g. wiring with multi-pin plug connection

With regard to layout and the number of drives, as well as tubing, a selection is made between:

• Individual mounting for solenoid operated directional control valves

• Block-type mounting (manifold block or valve terminal)

Comparison of required tubing connections

– Compare the concepts listed above using the controller for this exercise as an example with regard to

minimising tubing connections.

Note

Use the individual valves from TP 201 and the MPA valve terminal from TP 202, as well as the associated

technical descriptions.

Components Individual mounting of

directional control valves

Block-type mounting of


Savings with block-type

mounting

Tubing

Number of compressed air

distributors

1 0 1

Number of tubes for supplying

compressed air distributor

1 0 1

Number of tubes for compressed

air supply to the control loops

3 1 2

Number of tubes between

directional control valves and

cylinder

6 6 -

Silencers

Number of silencers for control

loops

6 1 5



Reducing required tube connections

– Which concept enables a reduction of the required tubing connections? Place an X next to your selection

and justify your decision.

Individual mounting of

directional control

valves

Block-type mounting

of directional control

valves

Reason

X

If the directional control valves in the control loops are mounted on a valve

terminal, one length of tubing is adequate for compressed air supply to all control

loops, and one silencer vents all of the exhaust air.

Compared with individual mounting, this solution eliminates numerous tubing

connections and silencers, as well as the need for a compressed air distributor.

The amount of work required for tubing is reduced correspondingly.

Note





Comparison of required wiring


minimising wiring.

Components Cables Number of

terminals/components with

conventional wiring

Number of


multi-pin plug

Control cabinet 1 1

Terminal strip 1 in the control

cabinet

Earth cable 1 2

Supply power (24 V) 1 2

PLC outputs (actuation of

solenoid coils)

6 6

PLC inputs (evaluation of

proximity switches)

6 6

Terminal strip 1 in the control cabinet, total 14 16

Cables from control cabinet to

terminal box

Cables between terminal

strips 1 and 2

Cable harness or single cable

with 14 cores

Cable harness or single cable

with 8 cores

Terminal strip 2

(in the control cabinet)

Proximity switch (3 cores

per proximity switch)

18 18

Solenoids

(2 cores per solenoid)

12 -

Terminal strip 2, total 30 18

Cables to directional control

valves and sensors

30 18

Connection of the solenoid

coils

6 cables with 2 cores each -

Wiring table

Note





Reducing required wiring

– Which concept enables you to reduce the wiring? Place an X next to your selection and justify your

decision.

Conventional wiring

technology

Multi-pin plug Reason

X

All valves included in the controller are arranged on the MPA valve terminal (with MP

connection).

As compared with conventional wiring, many of the terminals at terminal strip 2 and

the cables to the solenoid coils are eliminated when the valve terminal is connected

with a multi-pin plug.

Wiring is thus reduced, and maintenance and troubleshooting are simplified.

Note





Completing the pneumatic circuit diagram with individual valves

– Complete the pneumatic circuit diagram for the diverting device with individual valves.

1M1 1M2

1A1

1V1 2

1 1

2 2

4

35

1

1V2 1V3

Pneumatic circuit diagram with individual valves

Completing the pneumatic circuit diagram with valve terminal

– Complete the pneumatic circuit diagram for the diverting device with valve terminal.

14 14 14 1412 12

-M1 -M1 1M1 -M11M2 -M2

1A1

1V2 1V3

0V1

-V- -V- 1V1 -V-4 4 4 42 2 2 2

S M M J J

12/14 12/14 12/14 12/14 12/14

82/84 82/84 82/84 82/84 82/84 82/84

3/5 3/5 3/5 3/5 3/5 3/5

1 1 1 1 1 1

1

1 1

2 2

12/14

Pneumatic circuit diagram with valve terminal



Completing the electrical circuit diagram

– Complete the electrical circuit diagram for the diverting device.

K1 K2

14 1412 12

11 11

1M1 1M2

1 2

S1 S2

+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

13 13

14 14

1212

2222

3232

4242

.4.31414

2424

3434

4444

1111

2121

3131

4141

Electrical circuit diagram



Sequence description

– Describe the controller’s working sequence.

Initial position

In its initial position, cylinder 1A1 is in the rear end-position.

Step 1-2

When pushbutton S1 (NO contact) is activated, relay K1 is picked up and changeover contact K1 in

current path 3 is closed.

The electrical circuit of solenoid coil 1M1 is closed. 5/2-way double solenoid valve 1V1 is reversed as a

result.

The piston end of cylinder 1A1 is pressurised while the piston rod end is exhausted. The piston rod in

cylinder 1A1 advances.

As soon as pushbutton S1 (NO contact) is no longer activated, relay K1 is released and changeover

contact K1 in current path 3 is opened.

The electrical circuit of solenoid coil 1M1 is opened.

Step 2-3

When pushbutton S2 (NO contact) is activated, relay K2 is picked up and changeover contact K2 in

current path 4 is closed.

The electrical circuit of solenoid coil 1M2 is closed. As a result, 5/2-way double solenoid valve 1V1 is

returned to its initial position.

The piston rod end of cylinder 1A1 is pressurised while the piston end is exhausted. The piston rod in

cylinder 1A1 travels to the rear end-position.

As soon as pushbutton S2 (NO contact) is no longer activated, relay K2 is released and changeover

contact K2 opens.

The electrical circuit of solenoid coil 1M2 is opened.



Creating 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 devices to the table below.

Quantity Designation

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (slice J in the valve terminal)

2 Pushbutton (normally open)

2 Relay

1 Distributor block

1 On-off valve with filter regulator

1 Compressed air source

1 24 V DC power supply unit

Equipment list

© Festo Didactic GmbH & Co. KG 541091/570694 I

Contents

Exercises













II © Festo Didactic GmbH & Co. KG 541091/570694

© Festo Didactic GmbH & Co. KG 541091/570694 1


Learning objectives

After completing this exercise:

• You’ll be familiar with the setup and function of valve terminals.

• You’ll be able to use valve terminals in accordance with specified requirements.

Presentation of the problem

Beverage bottles will be diverted from one conveyor to another by means of a diverting device. The diverting

panel is advanced when one of the pushbuttons is activated. The bottle is transferred and transported in the

opposite direction. The diverting panel is returned to its initial position when another pushbutton is

activated.

Layout

Diverting device for beverage bottles


2 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 541091/570694

Parameters

• A double-acting cylinder will be used.

• The cylinder will be controlled indirectly via pushbutton.

• In the event of a power failure, the cylinder’s piston rod should remain in its current position.

Project assignment

1. Answer the questions and complete the tasks relating to the learning content.

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.

Control sequence

1. Cylinder 1A1 is in the rear end-position.

2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the cylinder travels

to the front end-position.

3. After activating pushbutton S2, 5/2-way double solenoid valve 1V1 is reversed again and the cylinder

travels to the rear end-position.


© Festo Didactic GmbH & Co. KG 541091/570694 Name: __________________________________ Date: ____________ 3

Fundamentals: installation

The layout, tubing and wiring of the components of an electro-pneumatic controller should be selected so

that the total costs for the components, installation and maintenance are as low as possible. With regard to

wiring, selection is made between:

• Conventional wiring technology, e.g. terminal strips

• Modern installation concepts, e.g. wiring with multi-pin plug connection

With regard to layout and the number of drives, as well as tubing, a selection is made between:

• Individual mounting for solenoid operated directional control valves

• Block-type mounting (manifold block or valve terminal)

Comparison of required tubing connections


minimising tubing connections.

Note



Components Individual mounting of


Block-type mounting of


Savings with block-type

mounting

Tubing

Number of compressed air

distributors

Number of tubes for supplying

compressed air distributor

Number of tubes for compressed

air supply to the control loops

Number of tubes between

directional control valves and

cylinder

Silencers

Number of silencers for control

loops



Reducing required tube connections

– Which concept enables a reduction of the required tubing connections? Place an X next to your selection

and justify your decision.

Individual mounting of

directional control

valves

Block-type mounting

of directional control

valves

Reason

Note





Comparison of required wiring


minimising wiring.

Components Cables Number of


conventional wiring

Number of


multi-pin plug

Control cabinet

Terminal strip 1 in the control

cabinet

Earth cable

Supply power (24 V)

PLC outputs (actuation of

solenoid coils)

PLC inputs (evaluation of

proximity switches)

Terminal strip 1 in the control cabinet, total

Cables from control cabinet to

terminal box

Cables between terminal

strips 1 and 2

Terminal strip 2

(in the control cabinet)

Proximity switch (3 cores

per proximity switch)

Solenoids

(2 cores per solenoid)

Terminal strip 2, total

Cables to directional control

valves and sensors

Connection of the solenoid

coils

Wiring table

Note





Reducing required wiring

– Which concept enables you to reduce the wiring? Place an X next to your selection and justify your

decision.

Conventional wiring

technology

Multi-pin plug Reason

Note





Completing the pneumatic circuit diagram with individual valves

– Complete the pneumatic circuit diagram for the diverting device with individual valves.

1M1 1M2

35

1

24

Pneumatic circuit diagram with individual valves

Completing the pneumatic circuit diagram with valve terminal

– Complete the pneumatic circuit diagram for the diverting device with valve terminal.

14 14 14 1412 12

-M1 -M1 1M1 -M11M2 -M2

0V1

-V- -V- 1V1 -V-4 4 4 42 2 2 2

S M M J J

12/14 12/14 12/14 12/14 12/14

82/84 82/84 82/84 82/84 82/84 82/84

3/5 3/5 3/5 3/5 3/5 3/5

1 1 1 1 1 1

1

12/14

Pneumatic circuit diagram with valve terminal



Completing the electrical circuit diagram

– Complete the electrical circuit diagram for the diverting device.

1M1 1M2

1 2+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141

Electrical circuit diagram



Sequence description

– Describe the controller’s working sequence.

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Creating 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 devices to the table below.

Quantity Designation

Equipment list

Documents

Electropneumatics Advanced level - Festo Didactic · Electropneumatics Advanced level K5 12 14 11 K1 12 14 11 ... The training package for electropneumatics may only be used: