Workbook Pneumatics Basic Level

Equipment set for the basic level (TP101)
The equipment set has been put together for basic training in the field of pneumatic control technology. It
includes all the components that are necessary for mastering the specific learning objectives and can be
supplemented with any other equipment sets. A profile plate and a source of compressed air are also
required in order to set up functional control systems.
Equipment set for the basic level (TP101)
Quantity Designation Order no.
2 3/2-way roller lever valve, normally closed 152866
1 3/2-way valve with pushbutton, normally open 152861
2 3/2-way valve with pushbutton, normally closed 152860
1 3/2-way valve with selector switch, normally closed 152863
1 3/2-way valve, pneumatically actuated at one end 576302
3 5/2-way double pilot valve, pneumatically actuated at both ends 576303
1 5/2-way valve with selector switch 152862
1 Double-acting cylinder 152888
2 One-way flow control valve 193967
2 Pressure gauge 152865
1 Pressure regulator with pressure gauge 539756
1 Pressure sequence valve 152884
1 Single-acting cylinder 152887
1 On-off valve with filter regulator 540691
2 Plastic tubing, 4 x 0.75, silver, 10 m 151496
2 Pneumatic proximity switch with cylinder mounting 539775
1 Pneumatic timer, normally closed 540694
1 Quick exhaust valve 539772
10 Push-in sleeve 153251
10 Push-in T-connector 153128
1 Distributor block 152896
1 Shuttle valve (OR) 539771
2 Dual-pressure valve (AND) 539770
XIV © Festo Didactic GmbH & Co. KG 541088

Equipment set symbols
Designation Symbol
3/2-way valve with pushbutton, normally closed 2
1 3
3/2-way valve with pushbutton, normally open
5/2-way valve with selector switch 4 2
5 3
1
3/2-way valve with selector switch
Pressure gauge
3/2-way roller lever valve, normally closed 2
1 3
Pneumatic proximity switch 2
1 3
3/2-way valve, pneumatically actuated at one end 2
12
1 3
5/2-way valve, pneumatically actuated at one end 4 2
14
5 1 3
5/2-way double pilot valve, pneumatically actuated at both

ends
© Festo Didactic GmbH & Co. KG 541088 XV

Designation Symbol
Shuttle valve
1 1
Dual-pressure valve
2
1 1
Pneumatic timer, normally closed

2
1 3
Quick exhaust valve
1
3
One-way flow control valve

1 2
Pressure sequence valve

2
12 1 3
Single-acting cylinder
Double-acting cylinder
XVI © Festo Didactic GmbH & Co. KG 541088

Designation Symbol
On-off valve with filter regulator
2
3
Pressure regulator with pressure gauge
1 3
Distributor block
Connectors
© Festo Didactic GmbH & Co. KG 541088 XVII

Allocation of equipment per exercise
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Equipment
Cylinder, single-acting 1 1 1 1 1 1
Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1 1 1 1 1
One-way flow control valve 2 2 1 2 2 2 2 2 2 2 1 2 2
Quick exhaust valve 1 1
Pressure gauge 2 2 1 2 1
3/2-way valve, pushbutton, 1 2 2 1 2 1 2 2 1 1 1 1

normally closed
3/2-way valve, pushbutton, 1 1

normally open
3/2-way valve, selector 1 1 2 1

switch, normally closed
3/2-way roller lever valve, 1 1 1

normally closed
Pneumatic proximity switch 2 2 2 1 2 2 2 2
3/2-way pneumatic valve 1 1
3/2-way pneumatic double 1 1

pilot valve
5/2-way valve, selector 1 1 1

switch
5/2-way pneumatic valve 1 1 1 1
5/2-way pneumatic double 1 1 1 1 1 1 1 1

pilot valve
Shuttle valve 1 1 1 1 1
Dual-pressure valve 1 2 2 1 1 2 1 1
Pressure sequence valve 1 1 1
Pressure regulator with 1 2 1 1

pressure gauge
Time delay valve, normally 1 1

closed
Distributor block 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
On-off valve with filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

regulator
XVIII © Festo Didactic GmbH & Co. KG 541088

Equipment set for the advanced level (TP102)
The equipment set for the advanced level has been put together for further training in the field of pneumatic
control technology. The two equipment sets (TP101 and TP102) 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 (TP102)
Quantity Designation Order no.
1 3/2-way roller lever valve with idle return, normally closed 152867
2 3/2-way valve with pushbutton, normally closed 152860
1 3/2-way valve with mushroom actuator (red), normally open 152864
2 5/2-way double pilot valve, pneumatically actuated at both ends 576303
2 Double-acting cylinder 152888
2 One-way flow control valve 193967
2 Plastic tubing, 4 x 0.75, silver, 10 m 151496
1 Pneumatic timer, normally open 539759
2 Non-return valve, piloted non-return function 540715
1 Back pressure limit valve 152868
10 Push-in sleeve 153251
1 Stepper module 152886
20 Push-in T-connector 153128
1 Pneumatic preset counter 152877
1 Shuttle valve (OR) 539771
1 Shuttle valve, 3-way (OR) 152882
1 Dual-pressure valve, 3-way (AND) 152883
XXII © Festo Didactic GmbH & Co. KG 541088

Exercise 1: Pressing cheeses
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 able to calculate the piston force of a single-acting cylinder.
 Be familiar with the set-up and mode of operation of a normally closed 3/2-way valve.
 Be able to recognise and sketch the various types of actuation for directional control valves.
 Be able to explain and set up direct actuation.
Presentation of the problem

Presses are used to press cheeses into moulds during the production process. Develop a control system
with which this process can be executed
Layout
Cheese production
© Festo Didactic GmbH & Co. KG 541088 1

Parameters
 Use a double-acting cylinder.
 Pneumatically control the cylinder using a manually actuated valve.
Project assignment
1. Describe the mode of operation of a single-acting cylinder.
2. Describe the mode of operation of a normally closed 3/2-way valve.
3. Complete the pneumatic circuit diagram for the pressing tool.
4. Set up the control system.
5. Double-check the control system configuration.
6. Describe the mode of operation of the control system.
7. Create an equipment list.
Procedure
1. The cheeses are placed into the tool manually.
2. When the pushbutton is activated, the cylinder advances and presses the cover onto the tool.
3. The pushbutton is pressed and held until the pressing operation has been completed.
4. When the pushbutton is released, the cylinder is retracted and the tool can be accessed.
5. The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately
deactivate compressed air supply if the tubing slips off.
2 © Festo Didactic GmbH & Co. KG 541088

Set-up and mode of operation of a single-acting cylinder
1 2 3 4 5
8 7 6
Circuit symbol and schematic diagram of a single-acting cylinder
– Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two representations coincide with each other.
The two representations coincide with each other.
– Describe the set-up and mode of operation of a single-acting cylinder.
The compressed air flows into the cylinder’s piston chamber. Pressure is built up in the chamber and
force is applied to the surface of the piston as a result. If this force exceeds static friction, the piston is
advanced. Pressure is not built up to full operating pressure until the piston is fully advanced.
When this pressure drops, the integrated return spring forces the piston back into its initial position.
Spring force is not great enough to move heavy loads attached to the piston rod. Hence single-acting
cylinders only perform work in a single direction.
– Match up each component with the corresponding number from the above drawing.
Component Designation
3 Cylinder barrel
1 End cap
6 Bearing cap
5 Piston rod
8 Piston
7 Spring return
2 Supply port
4 Exhaust port
Table of component designations

Calculate the piston force of a single-acting cylinder

Theoretical piston force is calculated using the following formula:
Fth = Ap
Fth = theoretical piston force (N)
A = effective piston surface (sq. metres)
D2  
= ( )
4
p = working pressure (Pa)
D = cylinder diameter (m)
Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when
calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa),
it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.
The following applies to the effective piston force of single-acting cylinders:
Feff = A  p – (FR + FF)

Feff = effective piston force (N)
FR = friction force (approx. 10% of Fth ) (N)
FF = return spring force (N)
– Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure
of 6 bar (600 kPa).
0.022  3.14
A= ( ) = 0.000314
4
Feff = 0.9  A  p – FF
Feff = 0.9  (0.000314)  600,000 – 13.6
Feff = 169.56 – 13.6 = 155.96 N
Note
TThe piston diameter of the used cylinder is 20 mm and spring return force is 13.6 N.

Mode of operation of a normally closed 3/2-way valve
– Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.
3
2
1
1 3
Circuit symbol and schematic representation of a normally closed 3/2-way valve
– Describe the mode of operation of the 3/2-way valve.
A 3/2-way valve has 3 ports and 2 switching positions. It’s represented in the normal position.
Normally closed means that compressed air cannot flow through the valve. When the pushbutton is
actuated the valve is opened, thus allowing air to flow and the piston of a connected cylinder is
advanced.

Complete the pneumatic circuit diagram
– Complete the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1 2
1 3
0Z2
0Z1
1
2
3
Pneumatic circuit diagram

Sequence description
– Set up the control system and describe its working sequence.
Initial position
Valve 1S1 is closed in its initial position. The piston rod of cylinder 1A1 is retracted.
Step 1-2
When the pushbutton on 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber of
cylinder 1A1 and the piston rod is advanced.
Step 2-3
When the pushbutton is released, valve 1S1 is exhausted and cylinder 1A1 returns to its initial position
due to force applied by the return spring.

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 and their quantities in the table below.
Quantity Designation
1 Cylinder, single-acting
1 3/2-way valve with pushbutton, normally open
1 Distributor block
1 On-off valve with filter regulator
1 Compressed air source
Equipment list

Exercise 2: Opening a fodder silo
Learning objectives
 Be familiar with the set-up and mode of operation of a normally open 3/2-way valve.

The slide of a fodder silo is to be opened by pressing a pushbutton. When the pushbutton is released, the
slide is once again closed.
Layout
Fodder silo

Parameters
 A single-acting cylinder is to be used.
 The cylinder will be pneumatically controlled using a pushbutton.
Project assignment
1. Answer the questions on the normally open 3/2-way valve.
2. Create the pneumatic circuit diagram for controlling the slide.
6. Create the equipment list.
Procedure
1. When the pushbutton is activated, the cylinder is retracted to the retracted end position.
2. The pushbutton is pressed and held for as long as the slide is to remain open.
3. When the pushbutton is released, the cylinder is advanced and the slide closes the opening in the silo.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.

Mode of operation of a 3/2 way valve
– Complete the circuit symbol of the 3/2-way valve. It needs to include the following functions: manual
actuation, spring return, normally open.
1 3
Circuit symbol, 3/2-way valve, normally open
Schematic representation of a 3/2-way valve, normally open
– Explain the mode of operation of a 3/2-way valve, normally open.
A normally open 3/2-way valve has 3 controlled ports and 2 switching positions. It’s represented in the
normal position.
This is a normally open variant of the valve. This means that compressed air flows through the valve to
the cylinder and holds the cylinder’s piston in the advanced end position. When the pushbutton is
activated, the valve stops the flow of compressed air, the cylinder is exhausted via the valve and the
piston is retracted.

Change the pneumatic circuit diagram
– Change the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1 2
1 3
0Z2
0Z1
1
2
3
Circuit diagram
Note
Please note that control systems must be represented in their initial positions.

Initial position
The 3/2-way valve is open in the free-flow direction and the piston chamber is pressurised. The piston at
cylinder 1A1 is advanced.
Step 1-2
If pushbutton 1S1 is activated, the piston is exhausted via the 3/2-way valve and cylinder 1A1 is
retracted.
Step 2-3
When the pushbutton is released, the spring forces the 3/2-way valve into its initial position, the piston
chamber is once again pressurised and cylinder 1A1 advances again.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).

Change the equipment list
– Change the equipment list shown below such that it corresponds with the requirements for this control
system.
1 Distributor block
Tubing material
1 Single-acting cylinder
1 3/2-way valve, manually actuated, normally closed
Equipment list
1 Distributor block
Tubing material
1 Single-acting cylinder
1 3/2-way valve, manually actuated, normally open
Equipment list

Exercise 3: Clamping boards to a saw bench
Learning objectives
 Be able to analyse and optimise control systems.

Boards are manually laid on the saw bench where they are cut to length with a circular saw. The sawing
operation is controlled from a separate control panel and thus the boards are pneumatically clamped to the
saw bench. The control system is implemented with only one cylinder for the test set-up.
Layout
Sawing fixture

Parameters
 Use one of the control systems from the previous exercises and modify it for this task.
 Use, by way of example, only one single-acting cylinder to design the control system.
Project assignment
1. Complete the pneumatic circuit diagram for the clamping tool.
5. Change the equipment list.
Procedure
1. A board is manually laid on the saw bench.
2. After activating a switch, the cylinder advances and clamps the board.
3. The cylinder remains in the advanced position, even when the switch has been released.
4. After turning the switch back to its initial position, the cylinder is retracted to the retracted end position,
where it remains until the switch is activated again.
Safety note

– Complete the circuit diagrams shown below by entering the required type of actuation.
a) b)
Circuit diagram
– Select the best control system and justify your answer.
The correct solution is a).
Reason:
The cylinder has to be in its retracted end position when the switch is deactivated.

Initial position
The valve’s free-flow direction is closed. The cylinder’s piston rod is retracted.
Step 1-2
When selector switch 1S1 is activated, compressed air flows into the piston chamber and the cylinder is
advanced.
Step 2-3
When the selector switch is reset, the valve is exhausted and the cylinder returns to its initial position
due to force applied by the return spring.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).

Change the equipment list

– Change the equipment list by entering the required components in the table below.
1 3/2-way valve with switch, normally closed
1 Distributor block
Changed equipment list

Exercise 4: Sorting packages
Learning objectives
 Be familiar with the set-up and mode of operation of a double-acting cylinder.
 Be able to calculate the piston force of a double-acting cylinder for both the advance and the return
strokes.
 Be familiar with the set-up and mode of operation of a 5/2-way valve.

Packages are sorted manually from a roller conveyor into large containers at a sorting station. When the
containers are full, they’re removed and new containers are provided. At this point the material flow should be
interrupted, but the roller conveyor continues to run. The material flow is interrupted by mechanical blocking
(slide). The slide has to be operated at the sorting station.
Layout
Sorting station

Parameters
 A double-acting cylinder will be used, because work is carried out during both the advance and the
return strokes.
Project assignment
1. Describe the set-up of a double-acting cylinder.
2. Describe the mode of operation of a 5/2-way valve.
3. Create a pneumatic circuit diagram for the package blocking slide.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material.
2. The cylinder remains in this position after releasing the selector switch and the material flow remains
interrupted.
3. After turning the selector switch to its initial position, the cylinder moves to its retracted end position
and the material flow is resumed. The cylinder remains in this position until the selector switch is
activated again.
Safety note

Set-up of a double-acting cylinder
1 2 3 4 5
7 6
Circuit symbol and schematic diagram of a double-acting cylinder
– Compare the circuit symbol shown above with the schematic diagram of the double-acting cylinder.
Determine whether or not the two illustrations are the same.
The two illustrations are the same.
– Make a note of the characteristics of a single-acting and a double-acting cylinder designs that are the
same as well as those that are different.
Both cylinder designs include cylinder barrel, piston and piston rod.
The double-acting cylinder doesn’t have a return spring.
The double-acting cylinder has 2 supply ports.
– Match the numbers from the schematic drawing with the individual components of the double-acting
cylinder.
Component Designation
1 Supply port, piston chamber
2 Piston
3 Cylinder barrel
4 Supply port, piston rod chamber
5 Piston rod
6 Bearing cap
7 End cap

Mode of operation of a double-acting cylinder
– Describe the mode of operation of a double-acting cylinder.
As opposed to a single-acting cylinder, more air is consumed. As the piston surfaces differ in size, the
forces vary with identical pressure.
Forward stroke
Compressed air flows into the cylinder through the piston chamber supply port. Pressure is built up in the
chamber and force is applied to the surface of the piston as a result. If this force exceeds static friction,
the piston is advanced. Air in the piston rod chamber escapes through the port at the piston rod end.
Pressure is not built up to full force until the piston is fully advanced.
Return stroke
After reversing, air flows through the supply port at the piston rod chamber where it builds up pressure
until the piston rod is retracted. Air escapes from the piston chamber through the piston chamber port.

Calculate the piston force for the advance and return strokes
Theoretical piston force is calculated using the following formula:
Fth = Ap
The following applies to double-acting cylinders:

Advance stroke Feff = (A  p) – FR
Return stroke Feff = (A'  p) – FR
Feff = effective piston force (N)

A = effective piston surface (m2)
D2  
= ( )
4
A' = effective piston ring surface (m2)

(D 2  d 2 )
= 4
p = working pressure (Pa)
FR = friction force (approx. 10% of Fth ) (N)
D = cylinder diameter (m)
d = piston rod diameter (m)
– Calculate the effective piston force for the advance and return strokes of the cylinder with a working
pressure of 6 bar (600 kPa).
Forward stroke
Feff = (A  p) – FR
Feff = 0.9  A  p
Feff = 0.9  0.000314  600,000
Feff = 169.66 N
Return stroke
Feff = (A'  p) – FR
Feff = 0.9  (0.000314 – 0.00005024)  600,000
Feff = 0.9  0.00026376  600,000
Feff = 142.4 N
Note
The piston diameter of the cylinder is 20 mm and the piston rod diameter is 8 mm.

Determine the requirements for the directional control valve
– Write down the requirements for the directional control valve.
Compressed air must be available in both switching positions, because the double-acting cylinder cannot
be retracted without compressed air. Venting of the other cylinder chamber must be ensured in each
case.
– Indicate why the directional control valve has to be actuated with a switch.
A switch has to be used because a pushbutton cannot be held in the activated position for as long as it
takes to replace the containers.

Mode of operation of a 5/2 way valve
– Complete the circuit symbol of a manually actuated, 5/2-way valve with spring return and locking
function, and enter the port designations.
4 2
5 3
1 5 4 1 2 3
Circuit symbol and schematic representation of a 5/2-way valve
– Describe the mode of operation of a 5/2-way valve when valve port 2 is connected to the piston rod end
of a double-acting cylinder.
Mode of operation of a 5/2 way valve, unactuated

When the 5/2-way valve is not actuated, the return spring holds the valve in its initial position. The piston
rod end of the cylinder is pressurised and the piston rod is retracted.
Mode of operation of a 5/2 way valve, actuated

When the 5/2-way valve is actuated, the force of the valve return spring is overcome and the valve is
reversed. In this state, the supply port is connected to the piston end of the cylinder via the valve while
the piston rod end is exhausted via the valve. Pressure which is built up at the piston end causes the
piston rod to advance. As soon as the piston rod has reached its advanced end position, maximum
operating pressure is built up at the piston end of the cylinder.
Actuation with a switch

If the valve is actuated with a switch, the valve remains in either of its positions until the switch is
reversed again.

Complete the circuit diagram
– Complete the circuit diagram shown below.
1A1
1S1 4 2
5 3
1
0Z2
0Z1
1
2
3


– Create an equipment list by entering the required components in the table below.
1 Cylinder, double-acting
1 5/2-way valve with selector switch
1 Distributor block

Exercise 5: Stopping milk bottles
Learning objectives
 Be able to explain and set up indirect actuation.
 Be familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.
 Be familiar with the difference between a signalling element and a control element.

A filling system fills bottles with milk. The bottles are fed to the system on a conveyor belt and are stopped
underneath the filler using a pneumatic cylinder. The positioning accuracy of the stopping operation will be
checked during a test set-up. The stopping operation will be activated at the system’s control panel.
Layout
Milk bottle filling system

Parameters
 Stopping of the material flow will be carried out at a central control panel.
 As compressed air is available at the control panel, a pneumatic solution will be used.
 The control valve for the cylinder will be pneumatically actuated.
Project assignment
1. Determine the requirements for the control system with regard to actuating components and the control
element.
2. Complete the pneumatic circuit diagram for stopping the material flow.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material, thus stopping the bottles.
2. After setting the selector switch back to its initial position, the cylinder is in its retracted end position
and once again enables material flow.
3. The cylinder remains in this position until the selector switch is activated again.
Additional task
Explain the term “indirect control”.

– Complete the circuit diagram shown below and enter the missing connection and component
designations.
1A1
1V1 2
4
14
5 1 3
1S1 2
0Z2
1 3
0Z1
1
2
3
Note
The on-off valve with filter regulator and the distributor block are not shown. These components are
required in order to set up the control system.

– Explain the mode of operation of the control system by describing its operating sequence.
Initial position
The signalling element and the control element are in the position generated by the return spring.
Step 1-2
When the selector switch at the 3/2-way valve 1S1 is actuated, pneumatic control port 14 at 5/2-way
valve 1V1 is pressurised with compressed air. The 5/2-way valve is reversed as a result. The left-hand
port (piston end) of the double-acting cylinder is pressurised with compressed air, and the right-hand
port (piston rod end) is exhausted. The cylinder advances.
Step 2-3
When the selector switch is returned to its initial position, the compressed air supply to the 3/2-way
valve is blocked, the 5/2-way valve looses pressure at control port 14 and the valve piston is returned to
its initial position by the return spring. The piston end of the cylinder is thus exhausted and the piston
rod end is pressurised with compressed air. The cylinder travels to its retracted end position.


1 Pneumatic 5/2-way valve with spring return
1 Normally closed 3/2-way valve with selector switch
1 Distributor block

Additional task
– Explain the term “indirect control”.
Indirect control
Cylinders with large piston diameters have high air consumption rates. Control elements with high
nominal flow rates must be used to actuate them. If the force is too great for manual actuation of the
valve, indirect actuation must be set up. In doing so, a signal is generated by a second, smaller valve,
which then provides the force required in order to switch the control element.

Exercise 6: Opening and closing a pipeline
Learning objectives
 Be able to measure pressure in pneumatic control systems.
 Be able to differentiate between the various types of flow control and use them in accordance with
specifications.

The gate in a pipeline needs to be opened and closed. Actuation is via a valve with selector switch. A
double-acting cylinder will be used as an actuator.
Layout
Wastewater treatment

Parameters
 The gate must be opened and closed slowly because the pipeline would otherwise be overloaded (the
forming of waves should be avoided).
 The speed of the opening and closing strokes should be steady.
Project assignment
1. Create a pneumatic circuit.
6. Observe pressure conditions upstream and downstream of the flow control and document them.
Procedure
1. When the selector switch is activated, the cylinder is advanced and opens the gate.
2. When the selector switch is returned to its initial position, the cylinder is retracted to its initial position
and the gate is closed.
Additional tasks
 At which pressure level do you observe jerking motion?
 Explain how jerking motion occurs.
Safety note

Mode of operation of a one-way flow control valve
1 2
2
Circuit symbol and schematic diagram of a one-way flow control valve
– Describe the mode of operation of a one-way flow control valve.
Air is restricted in one direction only with a one-way flow control valve. The non-return valve inhibits the
flow of air in one direction and air can only flow through the selected cross-section. Air flows freely in the
other direction through the open non-return valve. These valves are used primarily for controlling the
speed of the pneumatic cylinders. The speed of the piston rod can be controlled with one-way flow
control valves by adjusting the volumetric flow rate.
– Describe two types of flow control used with double-acting cylinders.
Supply air flow control

In the case of supply air flow control, the one-way flow control valves are installed such that air being fed
to the cylinder is restricted. Exhaust air can escape freely on the downstream side via the non-return
valve. Feed speed irregularities occur as the result of even the smallest load fluctuations at the piston
rod, for example in the case of limit switch overtravel. A load in the direction of cylinder motion
accelerates the cylinder beyond the selected value.
Exhaust air flow control

In the case of exhaust air flow control, supply air flows freely to the cylinder and the flow control in the
exhaust line resists the escaping air. The piston is held between two air cushions, which are generated as
a result of supply air pressure and resistance caused by the flow control. This one-way flow control valve
arrangement contributes significantly to improved feed characteristics. Exhaust air flow control should be
used with double-acting cylinders.
– Explain how a one-way flow control valve is tested for correct functioning.
A one-way flow control valve is tested for correct functioning by means of two pressure gauges. The
pressure gauges are connected directly upstream and downstream from the valve under test.

Create the pneumatic circuit diagram
– Complete the circuit diagram shown below. Complete the symbols for the one-way flow control valves..
Observe the specified basic conditions when doing so.
1A1
1Z2
1V1 1 1 1V2
1Z1 2 2
1S1 4 2
5 3
1


2 One-way flow control valve
2 Pressure gauge
1 Distributor block

– Set up the control system and describe its operating sequence.
Initial position
In the initial position, the piston is in the retracted end position. The piston chamber is exhausted via
5/2-way valve 1S1.
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised via the one-way
flow control valve. The cylinder travels to its advanced end position.
Step 2-3
After resetting the switch, the cylinder’s piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve. The cylinder travels to its retracted end position.
The required retraction time is adjusted with the one-way flow control valve. Use a stopwatch to this end.

Additional tasks
– At which pressure level do you observe jerking motion?
Jerking motion occurs in the case of very low operating pressure or excessive restriction.
– Explain how jerking motion occurs.
It’s caused by pressure building up and working against static friction and sliding friction. Pressure builds
up at the stationary piston and works against static friction. If force due to pressure exceeds the friction
coefficient, the piston is advanced and minimal sliding friction comes into play. But then the air increases
again and pressure drops, because it can’t be built back up quickly enough; the piston stops. This
sequence is repeated. The piston “stammers”.

Exercise 7: Shutting off a pipeline
Learning objectives
 Be able to adjust cylinder advancing and retracting speeds.
 Be able to differentiate between the various types of flow control and use them appropriately.

A filling system fills bottles with milk. The pipes through which the milk flows are opened and closed using a
gate. The gate should be opened slowly in order to prevent any spillage at the beginning of the filling
process. Closing, on the other hand, should take place as quickly as possible.
Layout
Milk bottle filling

Basic condition
 Speed control should enable a smooth opening process.
Project assignment
1. Select the appropriate type of flow control.
2. Create a pneumatic circuit diagram for the shut-off mechanism.
Procedure
1. A gate valve is opened slowly after activating a selector switch.
2. The gate valve is closed quickly when the selector switch is returned to its initial position.
Safety note

Select the type of flow control

Determine whether supply air or exhaust air flow control is required for the application.
– Justify your selection and write your reasons down.
Exhaust air flow control is the right selection for the application. Load-independent, uniform feed speed
is ensured by means of exhaust air flow control.

Create the pneumatic circuit diagram
– Complete the circuit diagram shown below. Observe the specific constraints when doing so.
1A1
1 1V1
1S1 4 2
5 3
1

1 Distributor block

– Set up the control system and describe its operating sequence.
Initial position
The piston’s initial position is the retracted rear end position. The piston chamber is exhausted via 5/2-
way valve 1S1.
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised with compressed
air. The piston rod chamber is exhausted via 5/2-way valve 1S1. The cylinder travels slowly to its
advanced end position. The required advancing time is adjusted with the one-way flow control valve.
Step 2-3
After resetting the switch, the cylinder’s piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve is pressurised without flow control. The piston chamber is exhausted via
5/2-way valve 1S1. The cylinder travels to its retracted end position.
Note
This control system works with exhaust air flow control. Use a stopwatch in order to set the required time
value. The setting can be secured with a lock nut.

Exercise 8: Actuating a shut-off device
Learning objectives
After completing this exercise:
 You’ll be familiar with one type of signal storage in pneumatic control systems.
 You’ll be able to adjust cylinder advancing and retracting speeds.

The gate in a filling system for plastic pellets needs to be closed quickly. However, it should be opened slowly.
Layout
Plastic pellet filling system

Parameters
 A double-acting cylinder will be used.
 The closing operation should be executed by the cylinder’s forward stroke.
Project assignment
1. Describe the mode of operation of a quick exhaust valve.
2. Describe the mode of operation of a 5/2-way double pilot valve.
3. Draw a pneumatic circuit diagram for the shut-off mechanism.
Procedure
1. A shut-off mechanism (ball valve) is opened slowly after activating a pushbutton.
2. The shut-off mechanism is closed quickly after activating a second pushbutton.
Safety note

Mode of operation of a quick exhaust valve
1
3 1
Circuit symbol and schematic diagram of a quick exhaust valve
– Describe the mode of operation of a quick exhaust valve.
Increased piston speeds during the return stroke can be achieved with single and double-acting cylinders
using quick exhaust valves, because flow resistance is thus reduced for the exhaust air.
Compressed air flows from the pilot valve to the cylinder via the quick exhaust valve. Exhaust port 3 is
closed at this time.
When pressure at port 1 drops, exhaust flow occurs from 2 to 3. In order to implement optimised quick
exhaust, the valve must be connected directly to the cylinder’s supply port.

Mode of operation of a 5/2-way double pilot valve
14 5 4 1 2 3 12
Schematic diagram of a 5/2-way double pilot valve
– Explain the mode of operation of the 5/2-way double pilot valve.
A 5/2-way double pilot valve has 5 working ports and 2 switching positions. The valve is equipped with a
latching function; a short signal (pulse) suffices for reversal.
The valve piston is moved to the opposite switching position by means of a compressed air pulse at one
of the two pilot ports (12/14). The valve piston is held in this position by the compressed air at the
working port until a compressed air pulse at the other side of the valve reverses the valve back to its
previous position. If signals are present at both pilot ports, the first signal to arrive is dominant.
A pneumatic signal at pilot port 12 causes flow from port 1 to port 2. A pneumatic signal at pilot port 14
causes flow from port 1 to port 4.
– Describe the performance of the valve depicted above when port 14 is briefly pressurised with
compressed air.
When port 14 is pressurised, the valve piston is moved to the right and directs compressed air from port
1 to port 4. Port 2 is exhausted via port 3. When port 14 is once again unpressurised, the valve position
remains in this position by compressed air from port 1.

1A1
1Z1
1V3 2
1V2 1
1
3
2 2
1V1 4 2
14 12
5 1 3
1S1 2 1S2 2
1 3 1 3

Initial position
The piston’s initial position should be the retracted end position. The piston chamber is exhausted via
5/2-way double pilot valve 1V1 and the piston rod chamber is pressurised. If the piston is in the
advanced end position, it has to be moved to the retracted end position by actuating 1S2.
Step 1-2
After actuating 3/2-way valve 1S1, the 5/2-way double pilot valve is reversed and the cylinder’s piston
chamber is pressurised via the one-way flow control valve. The double-acting cylinder travels to its
advanced end position. The piston rod chamber is vented via the quick exhaust valve. The piston remains
in this end position, even when 1S1 is released again.
Step 2-3
The 5/2-way double pilot valve is reversed by actuating 3/2-way valve 1S2. The cylinder’s piston rod
chamber is pressurised via the quick exhaust valve. The cylinder’s piston chamber is exhausted via the
one-way flow control valve and the 5/2-way double pilot valve. The cylinder travels to its retracted end
position.
Retracting time
The required retraction time is adjusted using the one-way flow control valve. Use a stopwatch to this
end. This setting can be secured with the lock nut.


– Create an equipment list by entering the required components to the table below.
1 Quick exhaust valve
1 Pressure gauge
1 5/2-way double pilot valve
2 3/2-way valve with pushbutton, normally closed
1 Distributor block

Exercise 9: Expanding the control system for pressing cheeses
Learning objectives
 Be able to expand existing control systems.
 Be able to analyse a proposed solution.
 Be able to implement an OR operation.

Presses are used to press cheeses into moulds during a cheese production process. The cheese presses are
operated by using one of two pushbuttons, so that pressing can be done at the loading or unloading end.
There is a possible solution which, however, does not achieve the piston force required to press a cheese.
Layout
Cheese production

Parameters
 Design pneumatic control of the cylinder using an additional manually actuated valve.
 Operation should be possible using either of the valves.
Project assignment
1. Analyse the proposed solution.
2. Complete the pneumatic circuit diagram for the pressing device.
4. Update the equipment list.
Procedure
1. The cheeses are placed into the press manually.
2. After actuating a pushbutton at the loading or unloading end of the system, the cylinder advances and
presses the lid onto the press.
3. The pushbutton is pressed and held until the pressing operation has been completed.
4. When the pushbutton is released, the cylinder is retracted and the press can be accessed.
5. The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of 3.5 bar (350 kPa).

Analyse the pneumatic circuit diagram

The required functional expansion has been achieved with the help of the control system shown below.
However, it has been noticed that the piston force required to press the cheese is not reached. Piston force
is only adequate when both pushbuttons are activated simultaneously.
1A1
2 2
1 3 1 3
Circuit diagram for proposed solution
– Analyse the control system depicted above and explain why the required piston force is not achieved.
The required piston force is not reached because part of the operating pressure escapes via the exhaust
port of the unactuated valve.

Mode of operation of a shuttle valve
1 1 1 1
Circuit symbol and schematic diagram of a shuttle valve
– Describe the mode of operation of the required components.
The shuttle valve is used for the OR operation. Pneumatic signals at one or both of the inputs 1 cause a
signal at the signal output 2.
If there’s no input signal, there’s no output signal.
If a signal is present at both inputs, the earlier signal arrives at the output.

– Complete the circuit diagram below.
1A1
1V1 2
1 1
1S1 2 1S2 2
1 3 1 3

Update the equipment list

The equipment list for the original control system must be changed in order to document the current control
system.
1 Distributor block
Existing equipment list
– Fill in the table below.
1 Shuttle valve
1 Distributor block
Updated equipment list

Exercise 10: Clamping a workpiece
Learning objectives
 Be able to implement an AND operation.
 Be familiar with one option for end-position sensing in cylinders.

A rotary indexing machine is used for feeding workpieces in production process. The workpieces have to be
clamped in the individual workpiece holders for machining. A clamping tool is to be developed and tested by
means of a test set-up.
Layout
Rotary indexing machine

Parameters
 The clamping process can only be started when the cylinder is in the retracted end position.
 After activating a second pushbutton, the cylinder returns to the retracted end position and releases the
workpiece.
 Pressure gauges will be installed between the one-way flow control valve and each of the cylinder’s two
working ports in order to indicate pressure.
Project assignment
1. Describe the mode of operation of a dual-pressure valve.
2. Describe the mode of operation of a 3/2-way roller lever valve.
3. Complete the pneumatic circuit.
Procedure
1. A double-acting cylinder can only be advanced when a pushbutton is activated and the cylinder is in the
retracted end position; otherwise it’s not possible to insert a workpiece for machining.
2. The clamping cylinder should be held in the advanced end position until the workpiece has been
machined. Machining time may vary.
3. The workpiece is released by pressing a second pushbutton.
Safety note
Additional task
What happens if the 3/2-way roller lever valve is readjusted?

Mode of operation of a dual-pressure valve
2
1 1
1 1
Circuit symbol and schematic diagram of a dual-pressure valve
– Describe the mode of operation of a dual-pressure valve.
The dual-pressure valve is used for the AND operation. Pneumatic signals at both inputs 1 cause a signal
at output 2. If there’s only one input signal or none at all, there’s no output signal.
If the input signals are generated at different times, the later signal arrives at the output. If the input
signals have different pressure values, the signal with the lower pressure value arrives at the output.

Mode of operation of a 3/2-way roller lever valve
1 3
Circuit symbol for a 3/2-way roller lever valve
– Describe the mode of operation of a 3/2-way roller lever valve.
A 3/2-way roller lever valve has 3 working ports and 2 switching positions. The roller lever is actuated by,
for example, a trip cam on a cylinder. Reduced actuation force is achieved by means of pilot control.
– Explain how the roller lever valve has to be mounted in order to ensure correct functioning of the control
system.
The roller lever valve must be mounted so that it’s actuated when the cylinder piston is in the retracted
end position. If the valve is mounted in front of or underneath the cylinder cam, the roller lever is not
actuated and the AND operation cannot be fulfilled. The control system is not started.

1A1
1B1
1Z1 1Z2
1V3 1 1 1V4
2 2
1V2 4 2
14 12
5 1 3
1V1 2
1 1
1S1 2 1B1 2 1S2 2
1 3 1 3 1 3

Initial position
Pressure is present. The piston chamber of the double-acting cylinder is exhausted and the piston rod
chamber is pressurised. 3/2-way roller lever valve 1B1 is actuated. The cylinder is in its retracted end
position.
Step 1-2
When 3/2-way valve 1S1 is actuated, compressed air is applied to both inputs at dual-pressure valve
1V1. Compressed air is now also present at the output of the dual-pressure valve. 5/2-way double pilot
valve 1V2 is reversed by the signal at pilot port 14. The cylinder is thus also reversed and the piston
advances. 3/2-way roller lever valve 1B1 is switched to its normal position and the output signal at the
dual-pressure valve is deactivated. The cylinder is held in the advanced end position by the self-locking
loop.
Step 2-3
After activating the pushbutton at 3/2-way valve 1S2, 5/2-way double pilot valve 1V3 is reversed again
(signal at pilot port 12). The cylinder’s piston rod chamber is pressurised. The cylinder travels to its
retracted end position. 3/2-way roller lever valve 1B1 is actuated again.


2 Pressure gauge
1 5/2-way valve, double piloted
1 Dual-pressure valve (AND)
1 3/2-way roller lever valve, normally closed
1 Distributor block

Exercise 11: Loading wire baskets
Learning objectives
 Be able to implement a latching circuit with OR operation.

Wire baskets are loaded with packages at a loading station. They are positioned at two supply points along
the conveyor belt so that the continuous flow of packages doesn’t have to be interrupted. When one wire
basket is full, the flow of packages is diverted to the other supply point by means of a deflector, so that the
full wire basket can be removed and an empty one moved into place.
Layout
Loading cage boxes

Parameters
Material flow will be controlled by two valves with pushbutton, one for disabling and one for enabling. Due to
the fact that the pushbutton signals are of short duration, a control system must be set up which stores the
signal.
Project assignment
1. Describe the mode of operation of a shuttle valve.
Procedure
1. When the pushbutton is activated, the cylinder advances and pushes the deflector into the flow of
material.
2. The cylinder remains in this position after the pushbutton has been released and the material flow is
diverted.
3. After activating the second pushbutton, the cylinder is retracted to the retracted end position and the
material flow reverts to the original supply point.
4. The cylinder remains in this position until the pushbutton is activated again.

– Develop the required latching circuit and complete the circuit diagram shown below.
1A1
1V4 1 1 1V5
2 2
1V3 4 2
14
5 1 3
1V2 2
12
1 3
1S2 2
1 3
1V1 2
1 1
1S1 2
1 3

Mode of operation of a latching circuit
– Describe the mode of operation of a latching circuit.
A latching circuit is used to convert a brief signal into a continuous signal. The valve group consisting of
1S1, 1S2, 1V1 and 1V2 is such a latching circuit. Activating pushbutton 1S1 causes a continuous signal at
the output of valve 1V2.
If the pushbutton at valve 1S1 is activated, shuttle valve 1V1 allows compressed air to flow. As valve 1S2
is normally open, the compressed air actuates input 12 at 3/2-way valve 1V2. As a result, input 14 at 5/2-
way valve 1V3 is also actuated. Directional control valve 1V3 is reversed, and the cylinder’s piston
advances. However, valve 1V2 is held in the actuated state at the same time by the return line to shuttle
valve 1V1.
When 3/2-way valve 1S2 is actuated, the self-latching loop is interrupted. There’s no longer a signal at
input 12 at valve 1V2, and the valve is switched to its normal position. Input 14 at 5/2-way valve 1V3 and
the return line to the shuttle valve are exhausted. Valve 1V3 is switched to its normal position and the
cylinder piston returns to its initial position.
In the event that pushbuttons 1S1 and 1S2 are both activated at the same time, there’s no signal at the
output either. This type of control system is called an RS flip-flop.

– Create an equipment list by entering the required components in the table below. Take all components
into consideration that are required for the set-up.
1 5/2-way valve, pneumatic, with spring return
1 3/2-way valve with pushbutton, normally open
1 3-2 way valve, pneumatic, normally closed
1 Shuttle valve (OR)
1 Distributor block
1 On-off valve with filter -regulator

Exercise 12: Actuating a sliding door
Learning objectives
 You’ll be able to combine logic operations.
 You’ll be familiar with the set-up and mode of operation of a pneumatic proximity switch.
 You’ll be able to differentiate between 5/2-way valves and select and use them in accordance with
specifications.

A sliding door between two rooms needs to be opened and closed using a pushbutton. Only one pushbutton
should be located at each side of the door in order to prevent operator error in case of an emergency.
Layout
Sliding door
© Festo Didactic GmbH & Co. KG 79

Parameters
 Either process can only be started when the door is in one of its end positions.
 Pressure must be limited to 3 bar (300 kPa) for safety reasons (danger of pinching).
Project assignment
1. Create a pneumatic circuit diagram for the sliding door’s control system.
Procedure
When the sliding door is in one of its defined end positions, it can be moved to the other end position by
pressing the pushbutton. The door can thus be opened and closed.
The opening and closing processes cannot be started as long as the door is not in one of its end positions.
Safety note
Limit pressure at the service unit to a maximum of 3 bar (300 kPa) for this exercise.
Additional tasks
 What happens if compressed air supply fails during advance or return motion?
 How can the control system be put back into operation, what must be done?

Mode of operation of a pneumatic proximity switch
S
N
N
2 S
1 3
Circuit symbol and schematic diagram of a pneumatic proximity switch
– Describe the mode of operation of the pneumatic proximity switch.
A pneumatic proximity switch is a 3/2-way valve which is actuated by a permanent magnet mounted on
the piston of a cylinder. If the permanent magnet is in close proximity to the proximity switch, the 3/2-
way valve is actuated and generates a pneumatic signal. Proximity switches are mounted directly on the
cylinder barrel.

1A1
1B1 1B2
1V5 1 1 1V6
2 2
1V4 4 2
14 12
5 1 3
1V2 2 1V3 2
1 1 1 1
1V1 2
1 1
1B1 2 1S1 2 1S2 2 1B2 2
1 3 1 3 1 3 1 3

Create a sequence description
Initial position
The cylinder is in the retracted end position. Pneumatic proximity switch 1B1 is actuated. A pneumatic
signal is applied to one input of dual-pressure valve 1V2.
Step 1-2
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 14 at the 5/2-way double pilot valve and the valve is switched. The cylinder
advances.
When the cylinder reaches the advanced end position, pneumatic proximity switch 1B2 is attenuated.
Step 2-3
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 12 at the 5/2-way double pilot valve and the valve is switched. The cylinder is
retracted. When the cylinder reaches the retracted end position, pneumatic proximity switch 1B1 is
attenuated.


1 5/2-way double pilot valve, pneumatic
2 Proximity sensor, pneumatic
1 Distributor block

Additional task: malfunction due to pressure failure

Compressed air supply to the control system fails during forward or reverse motion of the sliding door. What
happens, and how can the control system be placed back into service?
– Describe the consequences of a pressure failure and explain how the control system can be placed back
into service.
The door remains in its current position. It must be manually pushed into one of its end-positions in order
to restart the control system, because otherwise the start condition is not fulfilled (door is in one of its
two end-positions).

Exercise 13: Feeding wooden boards
Learning objectives
 Be familiar with the NOT operation.
 Be able to combine logic operations.
 Be able to further develop existing control systems.

Wooden boards need to be fed from a magazine to a machining process. Workpieces should not be pushed
out of the magazine if the picking area is occupied.
Layout
Stacking magazine

Parameters
 A roller lever valve is used to mechanically determine whether or not a board is located in the picking
area. The cylinder is throttled while advancing and retracting.
Project assignment
Procedure
1. The ejecting process is started by means of a pushbutton when the cylinder is in its retracted end
position. The ejecting cylinder only pushes a workpiece out of the magazine when the roller lever valve
in the picking area indicates that the picking area is NOT occupied.
2. If the picking area is empty, the cylinder advances to the advanced end position with restricted exhaust
air, pushes the workpiece out and immediately returns to its retracted end position with restricted
exhaust air.
Additional task
How would you have to change the control system if the ejecting process could only start when a workpiece
is in the magazine AND the picking area is empty?

1A1
1B1 1B2
1V4 1 1 1V5
2 2
1V3 4 2
14 12
5 1 3
1V2 2
1 1
1V1 2
1 1
1S1 2 1B1 2 1S2 2 1B2 2
1 3 1 3 1 3 1 3
Note
You can use a 3/2-way valve with selector switch in the control system instead of a 3/2-way roller lever
valve, if you want to simulate whether the picking area is empty or occupied.

Initial position
Compressed air is present. The cylinder is in the retracted end position. Pneumatic proximity switch 1B1
is attenuated and switched to the free-flow direction. The piston rod chamber is pressurised.
Step 1-2
If the picking area is occupied, 3/2-way roller lever valve 1S2 is not actuated. Dual-pressure valve 1V1
does not generate an output signal and the 5/2-way double pilot valve cannot be reversed.
If the picking area is empty, 3/2-way roller lever valve 1S2 is actuated. Dual-pressure valve 1V1
generates an output signal. If the pushbutton at 3/2-way valve 1S1 is activated, dual-pressure valve 1V2
generates an output signal. A signal is applied to pilot port 14 at 5/2-way double pilot valve 1V3. The
5/2-way double pilot valve is reversed and the cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the free-flow direction. A signal is applied
to pilot port 12 at the 5/2-way double pilot valve. 5/2-way double pilot valve 1V3 is switched and the
cylinder travels to its retracted end position. Pneumatic limit switch 1B1 is attenuated and switches to
the free-flow direction.
Step 3-1
Same as step 1


1 Distributor block

Adapt the control system

The control system must be changed so that the ejecting process can only be started when a workpiece is in
the magazine AND the picking area is empty.
– Explain how the control system has to be changed in order to meet this requirement.
An additional sensor will have to be connected for workpiece sensing. A suitable sensor is therefore
required (roller lever valve) as well as a dual-pressure valve (AND). An AND operation will be added for
the two sensors instead of using 3/2-way valve 1S2.

Exercise 14: Compacting beverage cans
Learning objectives
 You’ll be familiar with the set-up and mode of operation of a pressure sequence valve.
 You’ll be able to set up pressure-dependent control systems.

Beverage cans are pressed into bales so that they take up minimal storage space at a recycling plant. The
compacting process is started using a pushbutton. The return stroke can be triggered with another
pushbutton. The compacting process should only be started when enough pressure is available.
Layout
Can press

Parameters
 The initial position of the compacting cylinder is the retracted end position.
 The compacting process should only be started when system pressure is greater than 6 bar (600 kPa).
 The return stroke can be triggered manually if the compacting cylinder does not fully reach the
advanced end position due to the quantity of cans to be compacted.
Project assignment
1. Complete the pneumatic circuit diagram for the can press.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system. The control system should not be operable at a pressure of less
than 4.5 bar (450 kPa).
2. It should only be possible to start the compacting process using a start button when the compacting
cylinder is in the retracted end position. The compacting cylinder moves to the advanced end position or
as far as it can depending on the amount of material to be compacted.
3. The return stroke is triggered either by a limit switch or a pushbutton.
Note
The required protective guard is not shown.

Mode of operation of a pressure sequence valve
12 1 3 3 2 1 12
Circuit symbol for a pressure sequence valve Schematic diagram of a pressure sequence valve
– Describe the mode of operation of a pressure sequence valve.
If pressure at pilot port 12 exceeds a certain adjustable value, the actuated 3/2-way valve is switched
and compressed air is applied to working port 2.
The 3/2-way valve switches back to its initial position when pressure at the pilot port drops back below
the selected value.

1A1
1B1 1B2
1V6 1 1 1V7
2 2
1V5 4 2
14 12
5 1 3
1V3 2 1V4 2
1 1 1 1
1B1 2 1S1 2 1S2 2 1B2 2
1 3 1 3 1 3 1 3
1V2 2
12 1 3
1V1
1 3


1 Pressure sequence valve
1 Pressure regulator valve with gauge
1 Distributor block

Set up the control system and put it into operation.
– Describe the control system’s working sequence.
Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is actuated
and switched to the free-flow direction. Compressed air is present. The required pressure level has been
pre-selected at the pressure regulator in the service unit. The desired pressure value has been set at the
pressure sequence valve.
Step 1-2
The pushbutton at valve 1S1 is activated. The condition at dual-pressure valve 1V3 (AND) is changed to
TRUE as a result. 5/2-way double pilot valve 1V5 is switched to the operating position. The double-acting
cylinder advances.
Step 2-3
Pneumatic limit switch 1B2 is actuated and switches to the operating position. 5/2-way double pilot
valve 1V5 is reset by shuttle valve 1V4 (OR).
Alternatively, this process can be started using the pushbutton at valve 1S2. The 5/2-way double pilot
valve is reset by shuttle valve 1V4 (OR).
The double-acting cylinder returns to its initial position. The process is finished when pneumatic limit
switch 1B1 is actuated.

Exercise 15: Packaging of brochures
Learning objectives
 You’ll be familiar with the set-up and mode of operation of a pressure regulator.
 You’ll be able to set up pressure-dependent control systems.

Sets of 10 brochures each are to be wrapped in plastic film. The brochures have to be clamped in order for
the film to seal properly. An operating pressure of at least 4 bar (400 kPa) is required in order to be able to
clamp the brochures securely. However, the maximum operating pressure of 6 bar (600 kPa) should not be
exceeded as otherwise the brochures risk being damaged.
The advance and reverse strokes are triggered using a pushbutton. The retracted end position of the
clamping cylinder is sensed via a pneumatic proximity switch.
Layout
Brochure production

Parameters
 The process can only be started when the clamping cylinder is in the retracted end position.
 The operating pressure has to be greater than 6 bar (600 kPa) before the control system can be started up.
 The return stroke is triggered manually, because the duration of the packaging process varies.
Project assignment
1. Complete the pneumatic circuit diagram for the packaging unit.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system.
2. The tensioning process starts when the clamping cylinder is in the retracted end position and a
pushbutton is activated. The cylinder is advanced and remains in the advanced position.
3. The process ends when a second pushbutton is activated and the cylinder returns to the retracted end
position.

Mode of operation of a pressure regulator
2
p1 p2
1 3
Circuit symbol for a pressure regulator Schematic diagram of a pressure regulator
– Describe the mode of operation of a pressure regulator.
Input pressure (primary pressure) at the pressure regulator must always be higher than output pressure
(secondary pressure). Pressure regulation itself takes place via a diaphragm. Output pressure acts on
one side of the diaphragm and the force of a spring on the other. Spring force can be adjusted with an
adjusting screw.
If pressure at the secondary side is increased, for example due to a load change at the cylinder, the
diaphragm is pressed against the spring and the outlet cross-section of the valve seat is reduced or
closed. The valve seat of the diaphragm is opened and compressed air is able to escape into the
atmosphere through the relief ports in the housing.
If pressure drops at the secondary side, the valve is opened by the force of the spring. Thus regulating air
pressure to the pre-selected operating pressure means that the valve seat is continuously opened and
closed, which is triggered by the volume of air that flows through. Operating pressure is indicated by a
measuring instrument.

1A1
1B1
1 1V7
2
1V6
1V5 1
2 1 3
1V4 4 2
14 12
5 1 3
1V3 2
1 1
1B1 2 1S1 2 1S2 2
1 3 1 3 1 3
1V2 2
12 1 3
1V1
1 3


2 Pressure regulator (on-off valve with filter regulator).
1 Distributor block

Mode of operation of the one-way flow control valve
– Describe the function of the one-way flow control valve which is connected in parallel to the pressure
regulator.
One-way flow control valve 1V5 functions as a bypass for the pressure regulator. The flow control is fully
closed. Compressed air can escape via the non-return valve when the cylinder is retracted, because it’s
unable to escape via the pressure regulator.

Exercise 16: Mounting locking pins
Learning objectives
 Be able to set up pressure-dependent control systems.
 Be able to analyse and optimise existing control systems.

Locking pins are to be mounted on plug connector housings at an automated assembly machine. So far,
pressure has been set using a pressure regulator at the assembly machine. This has led to repeated
malfunctions in the assembly process.
The assembly process will now be examined using a test set-up. Each assembly step is triggered manually.
The control system will be changed so that it only functions when pressure does not exceed a certain value.
Layout
Automated assembly machine for plug connector housings

Parameters
 Pressure at the working port of the assembly cylinder must have a value of at least 3.5 bar (350 kPa), in
order to ensure that the locking pins are securely mounted.
 It should not be possible to start the process if pressure is greater than 3.8 bar (380 kPa).
 The return stroke of the assembly cylinder is started automatically when it reaches the advanced end
position.
Project assignment
1. Complete the pneumatic circuit diagram for the automated assembly machine.
Procedure
1. The process will be started with a pushbutton when the assembly cylinder is in the retracted end
position.
2. The cylinder should move to the advanced end position with minimal force.
3. It actuates a limit switch in this position.
4. It should then quickly return to the retracted end position.
Analyse the pneumatic circuit diagram
– Analyse the circuit diagram shown below and determine whether or not it’s suitable for the required task.
The circuit diagram is suitable.
– What are the advantages or disadvantages of the characteristics of the required control system?
There is a danger that pressure can be incorrectly set at the pressure regulator in the supply line to the
cylinder which would result in the pins being damaged.

1A1
1B1
1 1V7
2
1V6
1V5 1
2 1 3
1V4 4 2
14 12
5 1 3
1V3 2
1 1
1B1 2 1S1 2 1S2 2
1 3 1 3 1 3
1V2 2
12 1 3
1V1
1 3

– Complete the pneumatic circuit diagram shown below, taking all required conditions into consideration.
1A1
1B1 1B2
1V7 1 1 1V8
2 2
1V6 4 2
14 12
5 1 3
1V5 2
1 1
1V3 2 1V4 2
1 1
12
1 3
1V2 2
12 1 3
1V1
2
1B1 2 1S1 2 1B2 2
1 3
1 3 1 3 1 3


1 3-2 way valve, pneumatic, normally open
1 Pressure regulator
1 Distributor block
Equipment list

– Describe the control system’s working sequence.
Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is attenuated.
Compressed air is present. The desired pressure value has been set at the regulator and at the pressure
sequence valve.
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V3 (AND), thus becomes TRUE. After the pressure sequence valve has been
switched with sufficient pressure, the 3/2-way valve is switched to the operating position. The condition
at the second 2-way valve, 1V5 (AND), thus becomes TRUE and the 5/2-way double pilot valve is
switched to the operating position. The double-acting cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. The 5/2-way
double pilot valve is switched. The double-acting cylinder returns to its initial position. The process is
finished when pneumatic proximity switch 1B1 is attenuated.

Exercise 17: Labelling paint pots
Learning objectives
 Be able to set up time-dependent control systems.
 Be familiar with the set-up and mode of operation of a time delay valve.

Paint pots are labelled at a gluing machine. The gluing process is triggered using a pushbutton at the machine.
A drying time of approximately 10 seconds is required for the adhesive to become effective. The system is
not ready to start until the piston of the pressing cylinder is in the retracted end position.
Layout
Farbe rau
lichtg 35
0
RAL 7
Farbe au
lichtgr 35
RAL 70
Labelling fixture

Parameters
 As the label has to be glued to the paint pot with minimal pressure, working pressure must be
adjustable.
 The cylinder should be retracted as quickly as possible.
 Working pressure must be adjustable within a range of 3 to 7 bar (300 and 700 kPa).
 Pressure should be indicated by a pressure gauge upstream of the cylinder.
Project assignment
Procedure
1. The process will be started using a pushbutton when the cylinder is in the retracted end position.
2. The cylinder should advance to the advanced end position with minimal force and speed and remain in
this position for an adjustable period of time.
3. It should then quickly return to the retracted end position.
4. Pressure during the forward stroke should be indicated at a pressure gauge.

Mode of operation of a time delay valve
1 3
Circuit symbol for a time delay valve
– Describe the mode of operation of a time delay valve and enter the most important technical data in the
table.
The time delay valves switches input pressure applied to port 1 to port 2 after the preset delay time has
expired. If the supply of compressed air is interrupted at port 1, working port 2 is once again switched to
the unpressurised state. The time delay valve is automatically reset within 200 ms. Delay time is infinitely
adjustable via an adjusting knob.
Technical data
Pressure range 2 to 6 bar (200 to 600 kPa)
Switch-on pressure > 1.6 bar (160 kPa)
Standard nominal flow rate 50 l/min.
Delay time 2 to 30 sec. (adjustable)
Setting accuracy ±0.6 sec.
Pause period for reset > 200 ms

1A1
1B1 1B2
1Z1
1V6 2
1
3
1V5 2
1V4 4 2
14 12
5 1 3
1V2 2 1V3 2
1 1
t
1V1 1 3
2
1B1 2 1S1 2 1B2 2
1 3
1 3 1 3 1 3


1 Quick exhaust valve
1 Time delay valve
1 Pressure regulator with pressure gauge
1 Pressure gauge
1 Distributor block
Equipment list

Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is attenuated.
Compressed air is present. The required pressure value has been set at the pressure regulator.
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V2 (AND), thus becomes TRUE and 5/2-way double pilot valve 1V4 is switched to
the operating position. The double-acting cylinder is advanced with minimal pressure and with flow
control.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. Compressed air is
fed to time delay valve 1V3 as a result, which then switches through after a preset period of time. The
5/2-way double pilot valve is reset. The double-acting cylinder returns to its initial position with minimal
pressure. The piston chamber is vented via the quick exhaust valve. The process is finished when
pneumatic proximity switch 1B1 is attenuated.

Exercise 18: Cleaning workpieces
Learning objectives
 Be able to set up control systems with oscillating motion.
 Be able to use time delay valves in accordance with specific constraints.

A wire basket with workpieces needs to be moved up and down in a cleaning bath. The process is started
using a pushbutton.
Layout
Automatic cleaning system

Parameters
 A roller lever valve will be used in order to detect the retracted end position.
 The cleaning process should be limited to a period of 20 seconds.
Project assignment
1. Convert a 5/2-way double pilot valve to a 3/2-way double pilot valve.
2. Complete the pneumatic circuit diagram for the automatic cleaning system.
Procedure
1. The process is started using a pushbutton when the lifting cylinder is in its retracted end position.
2. The cylinder for the lifting device moves to the advanced end position. It then goes back to the mid-
position and returns to the advanced end position. This motion sequence is repeated until the process
is stopped by the time delay valve.
3. The cylinder then returns to its retracted end position.

Convert a 5/2-way double pilot valve
4 2
14 12
5 1 3
Circuit symbol for a 5/2-way double pilot valve
– Convert a 5/2-way double pilot valve to a 3/2-way double pilot valve.

– Describe what has to be done.
Output 4 is closed using a blanking plug.

1B1 1B3 1B2

1A1
1 1V6
2
1V5 1
1V4 4 2
14 12
5 1 3
1V3 2
1 1
1B1 2 1B3 2 1B2 2
1 3 1 3 1 3
1V2 2
10 12
1 3
1V1 2 1S1 2
t
1 3
1 3
Pneumatic circuit diagram (solution)

Initial position
In the initial position, the cylinder is in its retracted end position and it actuates 3/2-way roller lever valve
1B1. Final control element 1V4 (5/2-way double pilot valve) is advanced to the right switching position.
Signal latch 1V2 (3/2-way double pilot valve) is also in the right switching position. The required pressure
value has been set at the pressure regulator.
Step 1-2
After activating start button 1S1, signal latch 1V2 is switched. Compressed air is fed to the input at time
delay valve 1V1. The 5/2-way double pilot valve 1V4 is switched by 3/2-way roller lever valve 1B1 and
shuttle valve 1V3 (OR) and the cylinder is advanced. Travel beyond pneumatic proximity switch 1B3 at
the mid-position has no effect, because the same control port of the final control element is actuated.
Step 2-3
Pneumatic proximity switch 1B2 is actuated in the advanced end position. The final control element (5/2-
way double pilot valve) is switched. The cylinder is retracted and actuates pneumatic proximity switch
1B3 at the mid-position.
Step 3-4
The cylinder is once again reversed when pneumatic proximity switch 1B3 at the mid-position is actuated.
Reversing only takes a few milliseconds, and thus the trip cam does not travel beyond pneumatic
proximity switch 1B3.
Step 4-5 See step 2-3.
Oscillating motion
The cylinder moves back and forth between pneumatic proximity switches 1B3 and 1B2 until time
specified at time delay valve 1V1 has elapsed.
Steps n-2 through n

After the time delay valve has switched through, signal latch 1V2 (3/2-way double pilot valve) is
reversed. Pneumatic proximity switch 1B3 and 3/2-way roller lever valve 1B1 are no longer supplied with
compressed air. The cylinder travels to its initial position (retracted end position). The process is finished
when 3/2-way roller lever valve 1B1 is actuated.


1 Time delay valve
1 Distributor block
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.

Exercise 19: Pressing labels into place
Learning objectives
 Be able to analyse and set up control systems with two cylinders.

Rating plates are pressed into valve housings at a workstation. First of all, the labels are inserted into
recesses in the valve housings. Then they’re pressed into place with a pressing cylinder.
The valve housings are clamped by pressing a pushbutton. The pressing process is started once the valve
housing has been clamped. Both cylinders should be retracted after the pressing cylinder has reached its
advanced end-position.
Layout
Labelling fixture

Parameters
 A single-acting cylinder will be used to clamp the valve housings.
 A roller lever valve will be used to detect whether or not the clamping cylinder has reached its advanced
end position.
 A double-acting cylinder will be used as a pressing cylinder.
 The feed speeds of both the clamping and the pressing cylinders should be adjustable.
Project assignment
1. Analyse the pneumatic circuit diagram for the pressing fixture.
Procedure
1. The pressing process is started using a pushbutton.
2. A limit switch will be used to detect whether or not the clamping cylinder has reached its position.
3. The pressing cylinder should not advance until the clamping cylinder has reached its advanced end
position.
4. After the plastic cap has been pressed into place, both cylinders are retracted.
Note
Necessary protective guards are not taken into consideration.

2A1
2B1 2B2
1A1
1B2
1V3 2 2V2 1
1 2
1V2 2 2V1 4 2
12 10 14 12
1 3 5 1 3
1V1 2
1 1
1S1 2 2B1 2 1B2 2 2B2 2
1 3 1 3 1 3 1 3


1 Distributor block
Equipment list
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.

Initial position
Pressure is present. In the initial position, both cylinders are in the retracted end position. The piston in
the double-acting cylinder attenuates pneumatic proximity switch 2B1, which is switched to the free-flow
direction. Final control elements 1V2 and 2V1 (5/2-way double pilot valve and 3/2-way double pilot
valve) travel to the right switching position.
Step 1-2
When pushbutton 1S1 is activated, the condition at dual-pressure valve 1V1 (AND) becomes TRUE. The
3/2-way double pilot valve 1V2 is reversed. The single-acting cylinder advances with restricted supply air.
Step 2-3
When the single-acting cylinder reaches its advanced end position, roller lever valve 1B2 is actuated and
reverses 5/2-way double pilot valve 2V1. The double-acting cylinder moves to its advanced end position
where it attenuates pneumatic proximity switch 2B2, which is switched to the free-flow direction.
Step 3-4
5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 are reversed. Both cylinders are
retracted. The process is finished when the piston in the double-acting cylinder attenuates pneumatic
proximity switch 2B1, which then switches to the free-flow direction.
Note
Single-acting cylinder 1A1 is retracted slightly earlier than double-acting cylinder 2A1. This is due to
overlapping of the control signals at pilot ports 14 and 12 at 5/2-way double pilot valve 2V1. The 5/2-way
double pilot valve 2V1 can only reverse when single-acting cylinder 1A1 has left its advanced end
position and 3/2-way roller lever valve 1B2 is no longer actuated.

Proximity switch failure

What happens if the position of pneumatic proximity switch 1B2 is shifted along the cylinder?
– Make a note of the resulting consequences.
Pneumatic proximity switch 1B2 is not attenuated and the 5/2-way double pilot valve and the 3/2-way
double pilot valve are thus no longer reset. The cylinder no longer returns to the retracted end position.
As a result, proximity switch 1B1 is not attenuated and the control system can no longer be started.

Workbook Pneumatics Basic Level

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Equipment set for the basic level (TP101)

Equipment set for the basic level (TP101)

Quantity Designation Order no.

2 3/2-way roller lever valve, normally closed 152866

1 3/2-way valve with pushbutton, normally open 152861

2 3/2-way valve with pushbutton, normally closed 152860

1 3/2-way valve with selector switch, normally closed 152863

1 3/2-way valve, pneumatically actuated at one end 576302

3 5/2-way double pilot valve, pneumatically actuated at both ends 576303

1 5/2-way valve with selector switch 152862

1 5/2-way valve, pneumatically actuated at one end 576307

1 Double-acting cylinder 152888

2 One-way flow control valve 193967

2 Pressure gauge 152865

1 Pressure regulator with pressure gauge 539756

1 Pressure sequence valve 152884

1 Single-acting cylinder 152887

1 On-off valve with filter regulator 540691

2 Plastic tubing, 4 x 0.75, silver, 10 m 151496

2 Pneumatic proximity switch with cylinder mounting 539775

1 Pneumatic timer, normally closed 540694

1 Quick exhaust valve 539772

10 Push-in sleeve 153251

10 Push-in T-connector 153128

1 Distributor block 152896

1 Shuttle valve (OR) 539771

2 Dual-pressure valve (AND) 539770

XIV © Festo Didactic GmbH & Co. KG 541088

3/2-way valve with pushbutton, normally closed 2

3/2-way valve with pushbutton, normally open

5/2-way valve with selector switch 4 2

3/2-way valve with selector switch

3/2-way roller lever valve, normally closed 2

Pneumatic proximity switch 2

3/2-way valve, pneumatically actuated at one end 2

5/2-way valve, pneumatically actuated at one end 4 2

5/2-way double pilot valve, pneumatically actuated at both

© Festo Didactic GmbH & Co. KG 541088 XV

Pneumatic timer, normally closed

Quick exhaust valve

One-way flow control valve

Pressure sequence valve

XVI © Festo Didactic GmbH & Co. KG 541088

On-off valve with filter regulator

© Festo Didactic GmbH & Co. KG 541088 XVII

One-way flow control valve 2 2 1 2 2 2 2 2 2 2 1 2 2

Quick exhaust valve 1 1

3/2-way valve, pushbutton, 1 2 2 1 2 1 2 2 1 1 1 1

3/2-way valve, pushbutton, 1 1

3/2-way valve, selector 1 1 2 1

3/2-way roller lever valve, 1 1 1

Pneumatic proximity switch 2 2 2 1 2 2 2 2

3/2-way pneumatic valve 1 1

3/2-way pneumatic double 1 1

5/2-way valve, selector 1 1 1

5/2-way pneumatic valve 1 1 1 1

5/2-way pneumatic double 1 1 1 1 1 1 1 1

Pressure sequence valve 1 1 1

Pressure regulator with 1 2 1 1

Time delay valve, normally 1 1

On-off valve with filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

XVIII © Festo Didactic GmbH & Co. KG 541088

Equipment set for the advanced level (TP102)

Quantity Designation Order no.