Electropneumatics Basic Level - Festo Didactic · Workbook TP 201 With CD-ROM Festo ... 541090 EN Electropneumatics Basic Level Electropneumatics, Basic level Workbook TP 201 Festo

WorkbookTP 201

With CD-ROM

Festo Didactic

541090 EN

ElectropneumaticsBasic Level

Elec

trop

neum

atic

s, B

asic

leve

l

W

orkb

ook

TP 2

01

Festo worldwide

ArgentinaFesto S.A.Edison 2392(B1640 HRV) MartinezProv. Buenos AiresTel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82 E-mail: [email protected]

AustraliaFesto Pty. Ltd.Head Office (Melbourne)179-187 Browns Road, P.O. Box 261Noble Park Vic. 3174Call Toll Free 1300 88 96 96Fax Toll Free 1300 88 95 95Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87 E-mail: [email protected]

AustriaFesto Gesellschaft m.b.H.Linzer Straße 2271140 WienTel. ++43 (0)1/9 10 75-0, Fax 9 10 75-250 E-mail: [email protected]

BelarusIP FestoMinsk, 220035Mascherov Prospekt, 78BelarusTel. ++375 (0)17/204 85 58, Fax 204 85 59 E-mail: [email protected]

BelgiumFesto Belgium sa/nvRue Colonel Bourg 1011030 Bruxelles/BrusselTel. ++32 (0)2/702 32 11, Fax 702 32 09 E-mail: [email protected]

BrazilFesto Automação Ltda.Rua Guiseppe Crespi, 76KM 12,5 - Via Anchieta04183-080 São Paulo SP-BrazílTel. ++55 (0)11/50 13 16 00, Fax 50 13 18 68 E-mail: [email protected]

BulgariaFesto EOOD1592 Sofia9, Christophor Kolumb Blvd.Tel. ++359 (0)2/960 07 12, Fax 960 07 13 E-mail: [email protected]

CanadaFesto Inc.5300 Explorer DriveMississauga, Ontario L4W 5G4Tel. ++1 (0)905/624 90 00, Fax 624 90 01 E-mail: [email protected]

ChileFesto S.A.Mapocho 19016500151 Santiago de ChileTel. ++56 (0)2/690 28 00, Fax 695 75 90 E-mail: [email protected]

ChinaFesto (China) Ltd.1156 Yunqiao RoadJinqiao Export Processing ZonePudong,201206 Shanghai, PRCTel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00 E-mail: [email protected]

ColombiaFesto Ltda.Avenida El Dorado No. 98-43BogotáTel. ++57 (0)1/404 80 88, Fax 404 81 01 E-mail: [email protected]

CroatiaFesto d.o.o.Nova Cesta 18110000 ZagrebTel. ++385 (0)1/619 19 69, Fax 619 18 18 E-mail: [email protected]

Czech RepublicFesto, s.r.o.Modøanská 543/76147 00 Praha 4Tel. ++420 261 09 96 11, Fax 241 77 33 84 E-mail: [email protected]

DenmarkFesto A/SIslevdalvej 1802610 RødovreTel. ++45 70 21 10 90, Fax ++45 44 88 81 10 E-mail: [email protected]

EstoniaFesto OY AB Eesti FiliaalLaki 11B12915 TallinnTel. ++372 666 15 60, Fax ++372 666 15 61 E-mail: [email protected]

FinlandFesto OYMäkituvantie 9, P.O. Box 8601511 VantaaTel. ++358 (09)/87 06 51, Fax 87 06 52 00 E-mail: [email protected]

FranceFesto EurlNuméro Indigo Tel. 0820/204640, Fax 204641ZA des Maisons Rouges8 rue du Clos Sainte Catherine94367 Bry-sur-Marne cedexTel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01 E-mail: [email protected]

GermanyFesto Didactic GmbH & Co. KGPostfach 10 07 1073707 EsslingenRechbergstraße 373734 EsslingenTel. ++49 (0)711/3467-0Fax ++49 (0)711/347-54 88500E-mail: [email protected]

GreeceFesto Ltd.40 Hamosternas Ave.11853 AthensTel. ++30 210/341 29 00, Fax 341 29 05 E-mail: [email protected]

Hong KongFesto Ltd.Unit C&D, 7/F, Leroy Plaza15 Cheung Shun StreetCheung Sha Wan, KowloonHong KongTel. ++ 852/27 43 83 79, Fax 27 86 21 73 E-mail: [email protected]

HungaryFesto Kft.Csillaghegyi út 32-34.1037 BudapestTel. ++36 1/436 51 11, Fax 436 51 01E-mail: [email protected]

IndiaFesto Controls Private Ltd.237B,Bommasandra Industrial Area,Bangalore Hosur Highway,Bangalore 560 099Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58 E-mail: [email protected]

IndonesiaPT. FestoJL. Sultan Iskandar Muda No.68Arteri Pondok IndahJakarta 12240Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98 E-mail: [email protected]

IranFesto Pneumatic S.K.# 2, 6th street, 16th avenue,Tehran 1581975411Km 8, Special Karaj Road, P.O.Box 15815-1485Tehran 1389793761Tel. ++98 (0)21 44 52 24 09, Fax ++98 (0)21 44 52 24 08E-mail: [email protected]

IrelandFesto LimitedUnit 5 Sandyford ParkSandyford Industrial EstateDublin 18Tel. ++ 353(0)1/295 49 55, Fax 295 56 80 E-mail: [email protected]

IsraelFesto Pneumatic Israel Ltd.P.O. Box 1076, Ha'atzma'ut Road 48Yehud 56100Tel. ++972 (0)3/632 22 66, Fax 632 22 77 E-mail: [email protected]

ItalyFesto S.p.AVia Enrico Fermi 36/3820090 Assago (MI)Tel. ++39 02/45 78 81, Fax 488 06 20 E-mail: [email protected]

JapanFesto K.K.1-26-10 Hayabuchi, Tsuzuki-kuYokohama 224-0025Tel. ++81 (0)45/593 56 10, Fax 593 56 78 E-mail: [email protected]

Korea SouthFesto Korea Co., Ltd.470-1 Gasan-dong, Geumcheon-guSeoul #153-803Tel. ++82 (0)2/850 71 14, Fax 864 70 40 E-mail: [email protected]

LatviaFesto SIADeglava 601035 RigaTel. ++371 67/57 78 64, Fax 57 79 46 E-mail: [email protected]

LithuaniaFesto UABKaraliaus Mindago pr. 223000 KaunasTel. ++370 (8)7/32 13 14, Fax 32 13 15 E-mail: [email protected]

MalaysiaFesto Sdn.Berhad10 Persiaran IndustriBandar Sri Damansara, Wilayah Persekutuan52200 Kuala LumpurTel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11 E-mail: [email protected]

MexicoFesto Pneumatic, S.A.Av. Ceylán 3Col. Tequesquinahuac54020 Tlalnepantla, Edo. de MéxicoTel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55 E-mail: [email protected]

NetherlandsFesto B.V.Schieweg 622627 AN DelftTel. ++31 (0)15/251 88 99, Fax 261 10 20 E-mail: [email protected]

New ZealandFesto LimitedMT. WellingtonAuckland NZTel. ++64 (0)9/574 10 94, Fax 574 10 99 E-mail: [email protected]

NigeriaFesto Automation Ltd.Motorways Centre, First Floor, Block CAlausa, Ikeja,Lagos, NIGERIATel. ++234 (0)1/794 78 20, Fax 555 78 94 E-mail: [email protected]

NorwayFesto ASOle Deviks vei 20666 Oslo, NorwayTel. ++47 22 72 89 50, Fax ++47 22 72 89 51 E-mail: [email protected]

PeruFesto S.R.L.Calle Amador Merino Reyna #480, San IsidroLima, PerúTel. ++51 (0)1/222 15 84, Fax 222 15 95

PhilippinesFesto Inc.KM 18, West Service RoadSouth Superhighway1700 Paranaque City, Metro ManilaTel. ++63 (0)2/776 68 88, Fax 823 42 19 E-mail: [email protected]

PolandFesto Sp. z o.o.Janki k/Warszawy, ul. Mszczonowska 705090 RaszynTel. ++48 (0)22/711 41 00, Fax 711 41 02 E-mail: [email protected]

RomaniaFesto S.R.L.St. Constantin 17010217 BucurestiTel. ++40 (0)21/310 29 83, Fax 310 24 09 E-mail: [email protected]

RussiaFesto-RF OOOMichurinskiy prosp., 49119607 MoskowTel. ++7 495/737 34 00, Fax 737 34 01 E-mail: [email protected]

SingaporeFesto Pte. Ltd.6 Kian Teck WaySingapore 628754Tel. ++65/62 64 01 52, Fax 62 61 10 26 E-mail: [email protected]

SlovakiaFesto spol. s r.o.Gavlovicová ul. 183103 Bratislava 3Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11 E-mail: [email protected]

SloveniaFesto d.o.o. LjubljanaIC Trzin, Blatnica 81236 TrzinTel. ++386 (0)1/530 21 00, Fax 530 21 25 E-mail: [email protected]

South AfricaFesto (Pty) Ltd.22-26 Electron Avenue, P.O. Box 255Isando 1600Tel. ++27 (0)11/971 55 00, Fax 974 21 57 E-mail: [email protected]

SpainFesto Pneumatic, S.A.Tel. 901243660 Fax 902243660Avenida Granvia, 159Distrito económico Granvia L'HES-08908 Hospitalet de Llobregat, BarcelonaTel. ++ 3493/261 64 00, Fax 261 64 20 E-mail: [email protected]

SwedenFesto ABStillmansgatan 1, P.O. Box 2103820021 MalmöTel. ++46 (0)40/38 38 40, Fax 38 38 10 E-mail: [email protected]

SwitzerlandFesto AGMoosmattstrasse 248953 Dietikon ZHTel. ++41 (0)44/744 55 44, Fax 744 55 00 E-mail: [email protected]

TaiwanFesto Co., Ltd.Head Office24450, No. 9, Kung 8th RoadLinkou 2nd Industrial ZoneLinkou 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: [email protected]

ThailandFesto Ltd.67/1 Moo 6 Phaholyothin RoadKlong 1, Klong Luang,Pathumthani 12120Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33 E-mail: [email protected]

TurkeyFesto San. ve Tic. A.S.Tuzla Mermerciler OrganizeSanayi Bölgesi, 6/18 TR34956 Tuzla - Istanbul/TRTel. ++90 (0)216/585 00 85, Fax 585 00 50 E-mail: [email protected]

UkraineFesto UkrainaBorisoglebskaja 11Kiev 04070Tel. ++380 (0)44/239 24 33, Fax 463 70 96 E-mail: [email protected]

United KingdomFesto LimitedApplied Automation Centre, Caswell RoadBrackmills Trading EstateNorthampton NN4 7PYTel. ++44 (0)1604/66 70 00, Fax 66 70 01 E-mail: [email protected]

United StatesFesto Corporation (New York)Call Toll-free 800/993 3786Fax Toll-free 800/963 3786395 Moreland Road, P.O.Box 18023Hauppauge, N.Y. 11788Tel. ++ 1(0)314/770 01 12, Fax 770 16 84 E-mail: [email protected]

VenezuelaFesto C.A.Av. 23, Esquina calle 71, No. 22-62Maracaibo, Edo. ZuliaTel. ++58 (0)261/759 09 44, Fax 759 04 55 E-mail: [email protected]

1M1

1A1

1V1 24

351

1V2 1V31 1

2 2

1M1

1

S1

13

14

+24 V

0 V

K1

2

A1

A2

K1

1412

11

12

22

32

42

.214

24

34

44

11

21

31

41

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: [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. 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 Didactic’s 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. They’re 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 it’s 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.

You’ll 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

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

2

1M1

31

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 42

1

One-way flow control valve 21

XVI © Festo Didactic GmbH & Co. KG 541090

Designation Symbol

Single-acting cylinder

Double-acting cylinder

On-off valve with filter

regulator

2

31

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 trainee’s 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 you’ll 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 trainer’s 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:

• You’ll be familiar with the set-up and mode of operation of a single-acting cylinder.

• You’ll be familiar with the set-up and mode of operation of a 3/2-way solenoid valve.

• You’ll be able to recognise and sketch the various types of actuation for directional control valves.

• You’ll 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


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 cylinder’s 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

31

10

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

with manual override, spring return

2

1M1

31

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 valve’s 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 valve’s 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

valve’s 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 relay’s 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 valve’s 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.

42

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 Pilot line, function for pilot actuated or pneumatically actuated directional control valves when

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

31

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



Documents

Electropneumatics Basic Level - Festo Didactic · Workbook TP 201 With CD-ROM Festo ... 541090 EN Electropneumatics Basic Level Electropneumatics, Basic level Workbook TP 201 Festo