Elektropneumatika Seminari PDF

541090 EN
04/05
Intended use
The Festo Didactic Learning System has been developed and produced solely for
vocational and further training in the field of automation and technology. The
training company and/or instructor needs to ensure that trainees observe the safety
precautions specified in this workbook..
Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,
the training company and/or other parties, which may occur during the
use/application of this equipment set other than in a training situation and unless
such damages are caused by intention or gross negligence on the part of Festo
Didactic.
Order No.: 541090

Status: 04/2005
Authors: M. Pany, S. Scharf
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 09/2005
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005
Internet: www.festo-didactic.com
e-mail: did@festo.com
The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Parts of this documentation may be copied by the authorised user exclusively for
training purposes.
2 © Festo Didactic GmbH & Co. KG • 541090

Contents
Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology package for electropneumatics (TP200) ________________________ 11
Training aims of Basic Level (TP201) _____________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Basic Level (TP201) _____________________________________ 17
Allocation of equipment and exercises ___________________________________ 21
Methodological help for the trainer ______________________________________ 23
Methodological structure of the exercises_________________________________ 25
Designation of equipment _____________________________________________ 26
Contents of the CD-ROM _______________________________________________ 27
Equipment set – Advanced Level (TP202) _________________________________ 29
Training aims – Advanced Level (TP202) __________________________________ 30
Part A – Exercises
Exercise 1: Realising a sorting device ____________________________________A-3

Exercise 2: Realising a shut-off device___________________________________A-15
Exercise 3: Realising a lid press ________________________________________A-25
Exercise 4: Realising the operation of a hinged lid _________________________A-35
Exercise 5: Realising a diverting device __________________________________A-43
Exercise 6: Actuation of a stacking magazine _____________________________A-53
Exercise 7: Sorting of packages ________________________________________A-65
Exercise 8: Actuation of a sliding platform _______________________________A-73
Exercise 9: Expanding a diverting device _________________________________A-81
Exercise 10: Designing a stamping device________________________________A-91
Exercise 11: Realising a pallet loading station __________________________ A-101
Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
© Festo Didactic GmbH & Co. KG • 541090 3

Contents
Part B – Fundamentals
Part C – Solutions
Exercise 1: Realising of a sorting device __________________________________C-3

Exercise 2: Realising a shut-off device___________________________________C-15
Exercise 3: Realising a lid press ________________________________________C-23
Exercise 4: Realising the operation of a hinged lid _________________________C-33
Exercise 5: Realising a diverting device __________________________________C-41
Exercise 6: Actuation of a stacking magazine _____________________________C-49
Exercise 7: Sorting of packages ________________________________________C-59
Exercise 8: Actuation of a sliding platform _______________________________C-67
Exercise 9: Expanding a diverting device _________________________________C-75
Exercise 10: Designing a stamping device________________________________C-85
Exercise 11: Realising a pallet loading station ____________________________C-95
Exercise 12: Eliminating a fault on the pallet loading station _______________C-101
Part D – Appendix
Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets

Preface
Festo Didactic’s Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured
into the following training packages:
• Basic packages to provide technology-spanning basic knowledge
• Technology packages to address the major subjects of open and closed-loop
technology
• Function packages to explain the basic functions of automated systems
• Application packages to facilitate vocational and further training based on actual
industrial applications
The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal
computer, hydraulics, electrohydraulics, proportional hydraulics and handling
technology.

Preface
The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.
All the training packages are of identical structure:

• Hardware
• Teachware
• Software
• Seminars
The hardware consists of didactically designed industrial components and systems.

The didactic, methodological design of the Teachware is harmonised with the
training hardware and comprises:
• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, additional information, solutions and data
sheets)
• Overhead transparencies and videos (to create an interesting and lively training
environment)
Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.

Introduction
This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package TP200 is
comprised exclusively of electropneumatic control systems.
Basic Level TP201 is suitable for basic training in electropneumatic control

technology and provides knowledge regarding the physical fundamentals of
electropneumatics and the function and use of electropneumatic equipment. The
equipment set enables you to construct simple electropneumatic control systems.
Advanced Level TP202 focuses on further training in electropneumatic control

technology. The two equipment sets enable you to construct complex combinational
circuits with logic operations of input and output signals and program controls.
Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-
circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is
used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar =
800 kPa) can be used for compressed air supply.
Working pressure must not exceed a maximum of p = 6 bar = 600 kPa.
Optimum operational reliability is achieved if the control system is operated

unlubricated at a working pressure of p = 5 bar = 500 kPa.
The equipment set of Basic Level TP201 is used to construct all of the complete
control systems of the 12 problem definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook
• Electropneumatics
Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices, etc.).

Introduction

Notes on safety and operation
The following advice should be observed in the interest of your own safety:
• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately.
• Do not switch on compressed air until tubing is securely connected.
• Caution!
Cylinders may advance automatically as soon as the compressed air is switched
on.
• Do not operate an electrical limit switch manually during fault finding (use a
tool).
• Observe general safety regulations.
• With electrical limit switches you need to distinguish between two designs
– Actuation from the left
– Actuation from the right.
• At high piston speeds, limit switches must be approached only in the designated
direction of the trip cam of the cylinder. Limit switches must not be actuated from
the front.
• Do not exceed the permissible working pressure (see data sheets).
• Only use extra-low voltage ≤ 24 V DC.
• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use
cables with jack plugs for the electrical connections.
• Pneumatic circuit assembly:
Connect devices using the silver-metallic plastic tubing of 4mm outer diameter,
plugging the tubing into the push-in fitting up to the stop; no need for securing!
• Releasing of push-in fitting:
The tubing can be released by pressing down the releasing ring (disconnection
under pressure is not possible!)
• Switch off compressed air supply and power supply prior to dismantling the
circuit.

Notes on safety and operation
• The mounting plates of the devices are equipped with mounting variants A to D:
Variant A, latching system
For lightweight non loadable devices (e.g. directional control valves). Simply clip
the device into the slot in the profile plate. Devices can be released by pressing
the blue lever.
Variant B, rotary system
Medium weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head bolts. Clamping and releasing is
effected by means of the blue knurled nut.
Variant C, screw system
For heavy loadable devices rarely removed from the profile plate (e.g. Start-up
valve with filter control valve). These devices are mounted by means of socket
head screws and T-head bolts.
Variant D, plug-in system
Lightweight non loadable devices with locking pins (e.g. indicating devices).
These devices are attached by means of plug-in adapters.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.

Technology package for electropneumatics (TP200)
The technology package TP200 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively electropneumatic
control systems. Individual components from the technology package TP200 may
also form a component part of other packages.
Important elements of • Fixed workstation with Festo Didactic profile plate

TP200 • Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa )
• Equipment sets or individual components
• Optional training aids
• Practical training models
• Complete laboratory setups
Training documentation
Textbooks Basic Level TP201

Fundamentals of pneumatic control technology
Maintenance of pneumatic devices and systems
Workbooks Basic Lvel TP201

Advanced Level TP202
Optional Teachware Sets of overhead transparencies and overhead projector

Magnetic symbols, drawing template
WBT Fluid Studio Electropneumatics
Cutaway model sets 1 + 2 with storage case
®
Simulation software FluidSIM Pneumatic

Technology package for electropneumatics (TP200)
Seminars
P111 Fundamentals of pneumatics and electropneumatics
P121 Maintenance of and fault finding on pneumatic and electropneumatic systems
IW-PEP Maintenance and servicing in control technology– pneumatic and electropneumatic

control systems
EP-AL Electropneumatics for vocational training
Details of venues, dates and prices can be found in the current seminar planner.
Information regarding further training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually
updated and expanded. The sets of overhead transparencies, films, CD-ROMs and
DVDs as well as technical books are available in several languages.

Training aims of Basic Level (TP201)
• To familiarise yourself with the design and mode of operation of a

single-acting cylinder.
• To familiarise yourself with the design and mode of operation of a
double-acting cylinder.
• To be able to calculate piston forces according to specified values.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To familiarise yourself with the design and mode of operation of a double
solenoid valve.
• To be able to select solenoid valves according to requirements.
• To be able to identify and draw the various types of actuation of directional
control valves.
• To be able to convert solenoid valves.
• To be able to explain and design an example of direct actuation.
• To be able to explain and design an example of indirect actuation.
• To familiarise yourself with logic functions and to design these.
• To familiarise yourself with different types of end position control and to be able
to select a suitable type.
• To be able to calculate electrical characteristic values.
• To familiarise yourself with latching circuits with different characteristics.
• To be able to explain and design an electrical latching circuit with dominant
switch-off signal.
• To be able to design a pressure-dependent control system.
• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
• To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
• To be able to realise a sequence control using two cylinders.
• To be able to identify and eliminate errors in simple electropneumatic control
systems.

Training aims of Basic Level (TP201)

Allocation of training aims and exercises
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aims
To familiarise yourself with the design •

and mode of operation of a single-
acting cylinder.
To familiarise yourself with the design • • •

and mode of operation of a double-
acting cylinder.
To be able to calculate piston forces •

according to specified values.
To familiarise yourself with the design •

and mode of operation of a 3/2-way
solenoid valve.
To familiarise yourself with the design • •

and mode of operation of a double
solenoid valve.
To be able to select a solenoid valve •

according to requirements.
To be able to identifiy and draw the •

various types of actuation of
directional control valves.
To be able to convert solenoid valves. •
To be able to explain and design an • •

example of direct actuation.
To be able to explain and design an • • •

example of indirect actuation.
To familiarise yourself with different • •

types of end position control and to be
able to select a suitable type.
To familiarise yourself with logic • •

functions and to be able to design
these.
To be able to calculate electrical •

characteristic values

Allocation of training aims and exercises
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aims
To familiarise yourself with latching • •

circuits with different characteristics.
To be able to explain and design an •

electrical latching circuit with
dominant switch-off signal.
To be able to design a pressure- •

dependent control system.
To familiarise yourself with the mode •

of operation of magnetic proximity
sensors.
To familiarise yourself with •

displacement step diagrams and to be
able to create these for specified
problem definitions.
To be able to realise a sequence •

control using two cylinders.
To be able to detect and eliminate •

errors in simple electropneumatic
control systems.

Equipment set – Basic Level (TP201)
This equipment set has been compiled for basic training in electropneumatic control
technology. It contains all the components required to meet the specifed training
aims and can be expanded in any way with other equipment sets. The profile plate
and a compressed air supply are required in addition.
Equipment set – Basic Level Description Order No. Quantity

(TP201
2 x 3/2-way solenoid valve, normally closed 539776 1
Order No.: 540712)
5/2-way double solenoid valve 539778 2
5/2-way solenoid valve 539777 1
Blanking plug 153267 10
Double-acting cylinder 152888 2
Limit switch, electrical, actuated from the left 183322 1
Limit switch, electrical, actuated from the right 183322 1
Manifold 152896 1
One-way flow control valve 539773 4
Plastic tubing 4 x 0.75, 10 m 151496 2
Pressure sensor 539757 1
Proximity sensor, electronic 540695 2
Proximity sensor, optical 178577 1
Push-in sleeve 153251 10
Push-in T-connector 153128 20
Relay, 3-off 162241 2
Signal input, electrical 162242 1
Single-acting cylinder 152887 1
Start-up valve with filter control valve 540691 1

Equipment set symbols Description Symbol
Relay, 3-off
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
Signal input, electrical

13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
3/2-way solenoid valve, 2

normally closed
1M1
1 3
1M1

Description Symbol
5/2-way solenoid valve 4 2
1M1
5 1 3
1M1
5/2-way double solenoid valve 4 2
1M1 1M2
5 1 3
1M1 1M2
Proximity sensor, electronic
Pressure sensor
Proximity sensor, optical
Limit switch, electrical

2 4
One-way flow control valve 1 2

Description Symbol
Single-acting cylinder
Double-acting cylinder
Start-up valve with filter control valve
2
3
Manifold
Connection elements

Allocation of equipment and exercises
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Equipment
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 double solenoid valve, 1 (1) 1 1

normally closed
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 sensor, normally open 2 2 2 2

conact
Pushbutton, electrical, normally open 1 1 1 2 2 1 1 1 1 1 1 1

contact
Pushbutton, electrical, normally 1 1

closed button
Relay 1 1 2 2 3 1 3 3 3 3
Manifold 1 1 1 1 1 1 1 1 1 1 1 1
Start-up valve with filter control valve 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

Allocation of equipment and exercises

Methodological help for the trainer
• Training aims
The overall aim of this collection of exercises is the systematic design of circuit
diagrams and practical assembly of a control system on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
The detailed training aims are documented in the table. Actual individual training
aims are allocated to each problem and major training aims are shown in
brackets.
• Time required
The time required to work through a problem depends on the trainee’s prior
knowledge. Skilled workers in the engineering and electrical fields require
approximately 2 weeks. Technicians or engineers require approximately 1 week.
• Components of the equipment set
The book of exercises and equipment set are harmonised. For all 18 exercises
you only require the components of the equipment set of Basic Level TP201.
Each of the Basic Level exercises can be assembled on a profile plate.
• Representation
Abbreviated notation and motion diagrams are used for the representation of
motion sequences and switching statuses.

Methodological help for the trainer

Methodological structure of the exercises
All 12 exercises in Part A are of identical methodological structure.
The exercises are divided into:

• Title
• Training aims
• Problem definition
• Parameters
as well as
• Project task
• Positional sketch
• Worksheets
The proposed solutions in Part C are divided into:

• Circuit diagram
• Solution description
as well as
• Circuit assembly
• Equipment list

Designation of equipment
The designation of components in the circuit diagrams is effected in accordance with

the DIN-ISO 1219-2 standard. All components of a circuit have the same main code
number. Letters are assigned depending on components. Several components
within a circuit are numbered consecutively. The designation of pressure ports is P
and these are separately consecutively numbered.
Drives: 1A1, 2A1, 2A2, ...

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

Contents of the CD-ROM
The CD-ROM supplied provides you with additional media. The contents of Part A –
Exercises and Part C – Solutions are stored in the form of pdf files.
The structure of the CD-ROM is as follows:

• Operating instructions
• Data sheets
• Demo
• Festo catalogue
• FluidSIM® circuit diagrams
• Industrial applications
• Presentations
• Product information
• Videos
Operating instructions Operating instructions are available for the various pieces of equipment of the
technology package to assist you in the use and commissioning of the equipment.
Data sheets The data sheets for the equipment of the technology package are available in the
form of pdf files.
Demo A demo version of the software package FluidSIM® Pneumatic is stored on the CD-
ROM. This version is suitable for the testing of the control systems developed.
Festo catalogue Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of
equipment. The representation and description of equipment in this form is intended
to illustrate how such equipment is represented in an industrial catalogue. You will
also find additional information here regarding the equipment.
FluidSIM® circuit diagrams FluidSIM® circuit diagrams are stored in this directory for all of the 12 exercises in
the technology package.

Contents of the CD-ROM
Industrial applications Photos and pictures are provided of industrial applications to enable you to
illustrate your own problem definitions. These can also be added to project
presentations.
Presentations Brief presentations are stored in this directory regarding the equipment of this
technology package. These presentations can for instance be used to create project
presentations.
Product information This directory provides you with the product information and data sheets of Festo
AG & Co. KG regarding the equipment of the technology package and is intended to
explain what information and data are provided for an industrial component.
Videos A number of videos of industrial applications complete the media for the training
package. Short sequences are shown of practice-related applications.

Equipment set – Advanced Level (TP202)
This Advanced Level equipment set has been compiled for further training in
pneumatic control technology. The two equipment sets (TP201 and TP202) comprise
the components required for the specified training aims and can expanded in any
way with other equipments sets of the Learning System for Automation and
Technology.
Equipment set – Advanced Description Order No. Quantity

Level (TP202
Relay, 3 off 162241 2
Order No.: 540713)
Signal input, electrical 162242 1
Time relay, 2 off 162243 1
Predetermining counter 162355 1
Proximity sensor, inductive 178574 1
Proximity sensor, capacitive 178575 1
EMERGENCY-STOP button 183347 1
Valve terminal with 4 valve slices (MMJJ) 540696 1
Non-return valve, piloted 540715 2

Training aims of Advanced Level (TP202)
• To describe the design and use of valve terminals

• To solve sequence controls with signal overlap – solution according to group
method
• To solve sequence controls with signal overlap – solution with sequence chain
using spring-return valves
• To solve sequence control with signal overlap – solution with sequence chain
using double solenoid valves (with control step)
• To be able to describe and configure modes of operation (single cycle,
continuous cycle, , ...)
• To describe the function and use of a predetermining counter
• To explain and realise an EMERGENCY-STOP FUNCTION using spring-return
valves
• To realise special EMERGENCY-STOP conditions: Actuators must stop during
EMERGENCY-STOP
• To explain the function and use of a 5/3-way solenoid valve
• To describe and configure the Reset mode of operation
• To carry out fault finding in complex electropneumatic circuits

Contents
Part A – Exercises
Exercise 1: Realising a sorting device ____________________________________A-3

Exercise 2: Realising a shut-off device___________________________________A-15
Exercise 3: Realising a lid press ________________________________________A-25
Exercise 4: Realising the operation of a hinged lid _________________________A-35
Exercise 5: Realising a diverting device __________________________________A-43
Exercise 6: Actuation of a stacking magazine _____________________________A-53
Exercise 7: Sorting of packages ________________________________________A-65
Exercise 8: Actuation of a sliding platform _______________________________A-73
Exercise 9: Expanding a diverting device _________________________________A-81
Exercise 10: Designing a stamping device________________________________A-91
Exercise 11: Realising a pallet loading station __________________________ A-101
Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
© Festo Didactic GmbH & Co. KG • 541090 A-1

Contents
A-2 © Festo Didactic GmbH & Co. KG • 541090

Exercise 1: Realising a sorting device
Training aims • To familiarise yourself with the design and mode of operation of a single-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To be able to identify and draw various types of actuation of directional control
valves.
Problem definition A sorting device is to be used to sort water samples according to the size of the
sample bottle. Design a control system whereby this process can be carried out.
Parameters • A single-acting cylinder is to be used.

• The control of the cylinder is to be effected by means of a pushbutton.
• In the event of a power failure the cylinder piston rod is to return into the
retracted end position.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Positional sketch
Sorting device
1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to

push the sample bottle off the conveyor.
2. When the pushbutton is released, the piston rod is to return into the retracted
end position.

Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Function of pneumatic working components Sheet 1 of 7
Pneumatic working components can be divided into two groups:

• Working components using linear movement
• Working components using rotary movement
– Describe the function of the working components shown.
Symbol 1 Symbol 2 Symbol 3
Description of function
Symbol 1:
Symbol 2:
Symbol 3:

Name: Date:
Fundamentals: Completing solenoid valve symbols Sheet 2 of 7
– Complete the individual symbols with the help of the corresponding component
descriptions.
Description Symbol
Directly actuated 3/2-way

2
solenoid valve, normally open,
with manual override, with
spring return 1 3
Pilot actuated 3/2-way solenoid
2
valve, normally closed, with
manual override, with spring
return 1 3

Name: Date:
Fundamentals: Normal positions of directional control valves Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated) or in the switching position (actuated). In the
normal position the valve can be open or closed.
– Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions. The single-acting cylinder shown is
controlled by an electrically actuated 3/2-way solenoid valve.
2 2
1M1 1M1
1 3 1 3
Description: Normal position closed Description: Normal position open

Name: Date:
Fundamentals: Direct and indirect actuation Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly.
– Describe the difference with the help of the following application: Electrical
actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.
Description: Direct actuation Description: Indirect actuation

Name: Date:
Design and function of an electrical switch Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally open or normally closed contact or changeover
switch.
– Describe the design and function of the switches shown.
3 1 2 4
4 2 1
Description: Design/Function

Name: Date:
Fundamentals: Mode of operation of different valve types Sheet 6 of 7
Electrically actuated directional control valves are switches with the help of
solenoids. Basically, these can be divided into two groups:
• Spring-return solenoid valves
• Double solenoid valves
– Describe the differences between the two groups with regard to function and
behaviour in the event of power failure.
Valve type Mode of operation
Spring-return valve
Double solenoid valve

Name: Date:
Fundamentals: Port designations of valves Sheet 7 of 7
In order to prevent incorrect tubing up of directional control valves, the valve ports
(working and pilot lines) are identified in accordance with ISO 5599, both on the
valve itself and in the circuit diagram.
– Describe the meaning and function of the designations below.
Designation Meaning, function
12
10

Name: Date:
Completing the pneumatic and electrical circuit diagram Sheet 1 of 1
– Complete the pneumatic and electrical circuit diagram for the sorting device.
1 3
Pneumatic circuit diagram
+24 V 1
0V
Electrical circuit diagram

Name: Date:
Compiling the equipment list Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list


Exercise 2: Realising a shut-off device
Training aims • To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
Problem definition In a water treatment system numerous pipes need to be opened or and closed by
means of shut-off devices. A test setup is to be used to find a possible means of
actuating the shut-off valve.
Parameters • A double-acting cylinder is to be used.

• The cylinder control is to be effected by means of a pushbutton.
• In the event of power failure the cylinder piston rod is to return into the retracted
end position.
2. Design the pneumatic and electrical circuit diagrams.

Positional sketch
Shut-off device
1. Pressing of a pushbutton is to cause the valve to open the slide

2. Releasing of the pushbutton is to cause the slide to close.

Name: Date:
Fundamentals: Comparison of directly actuated and pilot actuated valves Sheet 1 of 5
Differentiation is made between directly actuated and pilot actuated solenoid valves
with regard to the type of actuation of the valve piston.
– Compare these two valve types and describe the respective advantages and
disadvantages.
Directly actuated valve Pilot actuated valve

Name: Date:
Port designations of valves Sheet 2 of 5
In order to prevent incorrect tubing up of directional control valves, valve ports

(working and pilot lines) are identified in accordance with ISO 5599-3, both on the
– Describe the meaning and function of the designations below.
14
82/84

Name: Date:
Fundamentals: Mode of operation of a solenoid valve Sheet 3 of 5
A valve symbol provides information regarding the function of the valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.
– Describe the mode of operation of the directional control valve shown.
4 2
1M1
5 3
1
Description: Mode of operation of a directional control valve

Name: Date:
Fundamentals: IP classification Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is

protected by means of a housing or cover. The required protection class against
dust, humidity and foreign objects is to be identified.
The classification IP 65 is shown on a valve
– Describe the meaning of this classification.
Description of IP 65 classification

Name: Date:
Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5
Piston rod cylinders with linear action can be divided into two groups:
• Single-acting cylinders
• Double-acting cylinders
– Describe the meaning of the cylinder symbol shown.
Symbol 1 Symbol 2
Description of symbolic representation

Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 1
– Complete the pneumatic and electrical circuit diagrams for the sorting device.
4 2
5 3
1
+24 V 1
0V

Name: Date:
an equipment list.
below.
Equipment list


Exercise 3: Realising a lid press
cylinder.
• To be able to explain and design an example of indirect actuation.
Problem definition In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids
are to be pressed onto the plastic pots.

• The cylinder control is to be effected indirectly and by means of a pushbutton. In
the event of power failure the cylinder piston rod is to return into the retracted
end position.

Positional sketch
Filling of pots of paint
1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid
to be pressed on.
2. Once the pushbutton is released, the pressing ram is to be returned into the
initial position.

Exercise 3: Realising of a lid press
Name: Date:
Fundamentals: Mode of operation of relays Sheet 1 of 4
A relay is a remotely controlled electromagnetically actuated switch with several

contacts.
The main components are:

• Coil with core
• Winding of coil
• Contact set
• Return spring
• Armature
• Terminal lugs
The following illustration shows a sectional representation of a relay.
– Allocate the component designations.
2 3
A1 A2 4 2 1
7 6

Name: Date:
Fundamentals: Design and mode of operation of relays Sheet 2 of 4
– Describe the mode of operation of a relay.
Description of mode of operation of a relay

Name: Date:
One or several contacts can be switched by a relay coil. Relays with normally closed,
normally open or changeover contact(s) are used depending on the function
required.
Additional designs of electromagnetically actuated switches are for instance a

remanence relay, the time relay with switch-on delay, the time relay with switch-off
delay and the contactor.
– Describe the design and contact alignment of the relays shown.
Description of design/contact alignment Symbol
13 23 31 41
A1
A2 14 24 32 42
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41

Name: Date:
– List the possible applications of relays in electrical or electropneumatic control

systems.
Description: Possible applications

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the lid press.

Name: Date:
+24 V 1 2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Name: Date:
an equipment list.
below.
Equipment list


Exercise 4: Realising the operation of a hinged lid
Training aims • To be able to design an example of indirect actuation

• To familiarise yourself with logic operations
• To be able to select solenoid valve according to requirements
Problem definition Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed
using a hinged lid. The process is to be effected from two points.
Parameters • A single-acting cylinder is to be used.

• The cylinder control is to be indirect and via hand levers.
In the event of power failure, the cylinder piston rod is to advance into the
forward end position.

Positional sketch
Filling of plastic granulate
1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and
to empty the bulk material from the container.
2. Once the pusbutton is released, the hinged lid closes.

Name: Date:
Fundamentals: Converting solenoid valves Sheet 1 of 3
In industrial practice, there are numerous different requirements with regard to a

valve. If a valve with all the required features is not available, it is often possible to
use a valve with a different number of ports. The table below lists a selection of
directional control valves frequently in use in industrial applications.
– Describe the valve types shown.

– Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of
the type shown..
– If measures are required to convert the valve, describe these.
Note
By „conversion measures“ we understand the simplest of conversions such as the
sealing of working ports 2 or 4 using a blanking plug.
4 2
14
1M1
5 3
1
Symbol Description of valve type Replacement Description of necessary conversions

possible
12
1M1
1
12
1M1
1 3
10
1M1
1 3
4 2
14
1M1
1 3

Name: Date:
Fundamentals: Selecting solenoid valves Sheet 2 of 3
Valves are selected according to the following criteria:

• Exercise definition,
• Required behaviour in the event of power failure,
• Minimum possible overall costs
The following valves are available for selection for the actuation of a single-acting
cylinder:
• A pilot actuated, spring return 3/2way solenoid valve with manual override,
• A pilot actuated, spring-return 5/2-way solenoid valve with manual override
– Select a valve and explain the reasons for your decision.
Note
Apart from the cost of the valve, the above overall costs also include the cost of
installation, maintenance and storage for replacement parts.
Valve type Reason

Name: Date:
Fundamentals: Logic operations: The OR function Sheet 3 of 3
Triggering the advancing of a cylinder piston rod is to be possible using two

pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve
coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position
and the piston rod advances. If both pushbuttons are released, the valve switches
into the initial position and the piston rod retracts.
– Create the appropriate function table and the logic symbol.
Note
0 means: Pushbutton not actuated, i.e. piston rod does not advance
1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
Logic symbol

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the operation of the
hinged lid.

Name: Date:
+24 V 1 2 3
12 14
K1
11
A1
K1 1M1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Name: Date:
an equipment list.
below.
Equipment list

Exercise 5: Realising a diverting device
cylinder.
solenoid valve.
Problem definition Packages are to be pushed from one conveyor to another via a diverting device.

• The cylinder control is to be effected indirectly and via a pushbutton. In the event
of power failure the cylinder piston rod is to remain in the current position.
Project task 1. Answer the questions and carry out the exercises regarding the training contents
listed.

Positional sketch
Diverting device
1. Pressing of a pushbutton is to cause the frame of the diverting device to be

advanced. The package is transferred and transported away.
2. Pressing of another pushbutton causes the frame to be moved into the initial
position.

Name: Date:
Fundamentals: Use of solenoid valves Sheet 1 of 4
Two factors are to be considered regarding the question as to which valve type is to
be used for a particular application:
• Duration, i.e. time frame,
• Quantity or frequency
of required switching operations.
In order to utilise a directional control valve as efficiently as possible, you will need
to decide in each case whether the use
• of a double solenoid valve or
• a spring-return directional control valve
is more cost effective for the required application.
– Decide whether a double solenoid or a spring-return solenoid valve seems more

cost effective for the applications listed and explain the reasons for your choice.
Application 1
The clamping cylinder of a milling device is to firmly hold in position a workpiece for
the duration of a milling operation (duration of approx. 10 min, 60 clamping
operations per day).
Valve type Reason
Application 2
The ejecting cylinder of a sorting device is to push defective workpieces from a
conveyor (duration of approx.1s, 600 ejecting operations per day).
Valve type Reason

Name: Date:
4 2
1M1 1M2
5 3
1
Description of mode of operation of a directional control valve

Name: Date:
Fundamentals: Calculating the current consumption of a valve coil Sheet 3 of 4
A spring-return solenoid valve is to be switched via pushbutton S1.
– Calculate the current consumption of the valve coil 1M1 at a voltage supply of
24 V DC and a coil resistance of 48 Ω (Ohm).
+24 V 1
13
S1
14
1M1
0V
Current consumption in 1M1 Power rating of 1M1

Name: Date:
Fundamentals: Calculate the current consumption of a valve coil Sheet 4 of 4
– Would the current consumption in 1M1 be the same, higher or lower if the above
valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Identical Higher Lower Reason

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the diverting device.

Name: Date:
+24 V 1 2 3 4
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44

Name: Date:
an equipment list.
below.
Equipment list


Exercise 6: Actuation of a stacking magazine
Training aims • To be able to use a double-acting cylinder.

solenoid valve.
• To familiarise yourself with the option of sensing the end positions of cylinders.
Problem definition Wooden boards are to be pushed from a stacking magazine into an assembly device.
Parameters • The forward end position of the cylinder is to be sensed.

Positional sketch
Stacking magazine
1. Pressing of a pushbutton causes a wooden board to be pushed out of the

stacking magazine.
2. Once the forward end position is reached, the slide is moved into the initial
position.

Name: Date:
Fundamentals: Components of an electropneumatic system Sheet 1 of 6
The components of an electropneumatic system are represented in a pneumatic

circuit diagram and/or in an electrical circuit diagram.
– Determine where the components below are to be represented.
Component Pneumatic circuit Electrical circuit

diagram diagram
Manually operated pushbutton
Cylinder
Valves
Valve coils
Relay
Electromechanical limit switch
Electronic proximity sensor
Indicating devices

Name: Date:
The function of sensors in electropneumatic control systems is to acquire

information and to transmit this for signal processing.
– What function(s) can an electromechanical limit switch fulfill in an

electropneumatic control system?
Description: Function(s) of electromechanical limit switches

Name: Date:
Fundamentals: Representation of limit switches Sheet 3 of 6
Limit switches can be actuated in different ways, via the function of a normally
closed or normally open contact or changeover switch and, in the normal position of
the system, can be either actuated or unactuated.
– Describe the appropriate design or function of the symbols shown.
Description: Design/function Symbol

Name: Date:
Fundamentals: Creating a logic element table Sheet 4 of 6
One possibility of recording the allocated contacts of a relay is by means of listing

these in a logic element table.
– Create the logic element tables for relays K6 and K9.
+24 V 10 11 12 13 14 15 16 17 18 19
...
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
11 11 11 11 11 11 11 11 31 31
12 14
K1
11
22 24 22 24 22 24 22 24 32 34 32 34
K9 K6 K7 K8 K9 K8
21 21 21 21 31 31
A1 A1 A1 A1
K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2
...
0V
Logic element Description: Logic element table

table
K6
K9

Name: Date:
Another method of recording the allocated contact sets of a relay can be seen in the
electrical circuit diagram below.
+24 V 1 2 3 4 5 6 7 8 9 10 11 25 27
21 12 14 22 24 32 34
NA K11 K11 K11
EMERGENCY 22 11 21 31
STOP 12 13 16 17 18 19 20 21 22 23 24 26
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34 22 24
1B1 1B2 2B1 2B2 13
K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
S1
11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
Start 14
12 14
K1
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
21 21 21 21 21 41 41 41 31
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 1M1 2M1 2M2 1M2

K11 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 .11 11 14 .12 11 14 .14 11 14 .18 11 14 .16 11 14 .12 11 14 .13 11 14 .15 11 14 .17 11 14 .19 11 14 .21
22 22 22 22 22 22 22 22 22 22 22
21 24 .25 21 24 .20 21 24 21 24 .27 21 24 21 24 21 24 .14 21 24 .16 21 24 .18 21 24 .20 21 24 .12
32 32 32 32 32 32 32 32 32 32 32
31 34 .27 31 34 31 34 31 34 31 34 31 34 31 34 .22 31 34 .23 31 34 .24 31 34 .26 31 34 .26
42 42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 .22 41 44 .23 41 44 .24 41 44

Name: Date:
– Complete the information regarding the relays shown by:

Indicating the current path in which the respective contact is used and
specifying the function fulfilled by the contact set (normally open or normally
closed contact).
Relay Current path Function: Function:

Normally Normally
open contact closed
contact
Relay K9
Relay K10

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the stacking magazine.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
5 3
1

Name: Date:
+24 V 1 2 3 4
12 14 12 14
K1 K2
11 11
A1 A1
K1 K2
A2 A2
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44

Name: Date:
an equipment list.
below.
Equipment list


Exercise 7: Sorting of packages
Training aims • To be able to calculate piston forces according to specific values

• To be able to calculate electrical characteristic values
• To be able to explain and design an example of indirect actuation
• To familiarise yourself with logic functions and to be able to design these
Problem definition Packages are to be transported on a conveyor past workstations. The packages can
be diverted by means of deflectors.

• The cylinder control is to be effected indirectly via pushbuttons and
electromechanical limit switches.
• Triggering of the advancing movement is to be possible only if the piston rod is in
the retracted end position.

Positional sketch
Conveyor belt for packages
1. The piston rod of a cylinder is to advance automatically as soon as pushbutton

S1 is actuated.
2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted
end position.

Name: Date:
Fundamentals: Calculation of piston force Sheet 1 of 3
The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a
diameter of 8 mm. The frictional losses within the cylinder are 10 %.
The following applies for double-acting cylinders:
Advance stroke Feff = (A • p) – FF

Return stroke Feff = (A' • p) – FF
Feff = Effective piston force (N)
A = Effective piston surface (m2)
D2 • π
= ( )
4
A' = Effective annular surface (m2)
π
= (D 2 − d 2 )
4
p = Working pressure (Pa)
FF = Friction force (approx. 10% of Fth ) (N)
D = Cylinder diameter (m)
d = Piston rod diameter (m)
– Calculate the effective piston force in the advance and return stroke at an
operating pressure of 6 bar (600 kPa).
To be calculated Solution approach
Advance stroke
Return stroke

Name: Date:
Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3
A relay in an electropneumatic circuit is designated as follows: 580 Ω, 1 W.
– Calculate the permissible operating voltage which ensures that no overload

occurs on the relay.
Max. Operating
voltage

Name: Date:
Fundamentals: Sheet 3 of 3
Triggering of the advancing movement of the piston rod of a cylinder is to be

achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if
both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches
into the actuated position causing the piston rod to advance. If at least one of the
two pushbuttons is released, the valve switches into the initial position and the
piston rod retracts.
– Create an appropriate function table and the logic symbol.
Note
0 means: Pushbutton not actuated, i.e. piston rod not advancing
S1 S2 1M1 1V1
Function table
Logic symbol

Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 vof 2
– Configure the pneumatic circuit diagram and design the electrical circuit diagram
for the feeding device.
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

Name: Date:
+24 V 1 2 3 4 5
A1 A1
K1 K2 K3 1M1 1M2
A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Name: Date:
an equipment list.
below.
Equipment list

Exercise 8: Actuation of a sliding platform
Training aims • To familiarise yourself with logic functions and to be able to design these
• To be able to explain and design electrical latching circuits with dominant switch-
off signal
Problem definition Wooden boards are to be manually placed onto a sliding platform. The boards are to
be pushed under a belt sanding machine by means of a pneumatic drive.

• The cylinder control is to be effected indirectly.
4. Compile the equipment list.

Positional sketch
Sliding platform
1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated.

2. Actuation of pushbutton S2 is to cause the piston rod to retract.

Name: Date:
Fundamentals: Signal storage Sheet 1 of 3
The actuation of the pushbutton must be stored if the piston rod of a cylinder is to
also advance if the pushbutton is only briefly actuated. This signal storage can be
effected either in the power section or in the signal control section of a circuit.
– Describe how signal storage is devised in the power section or in the signal
control section respectively.
Place of signal storage Description: Signal storage
Signal storage in the

power section
Signal storage in the

signal control section

Name: Date:
Fundamentals: Analysing circuits Sheet 2 of 3
– Describe the behaviour of the circuit specified (pilot actuated, spring-return

5/2-way solenoid valve with manual override, double-acting cylinder) in the
event of
– Power failure
– Pressure failure.
Power failure Pressure failure

Name: Date:
Fundamentals: Logic functions Sheet 3 of 3
The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated.
– Draw up the appropriate function table and the logic symbol(s).

0 means: Pushbutton S1 not actuated, i.e. lamp P1 off
1 means: Pushbutton S1 actuated, i.e. P1 illuminated
S1 P1
Function table
Logic symbol

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the sliding platform.
4 2
5 3
1

Name: Date:
+24 V 1 2 3
A1
K1 1M1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Exercise 8: Actuation of a diverting device
Name: Date:
an equipment list.
below.
Equipment list

Exercise 9: Expanding a diverting device
Training aims • To familiarise yourself with different types of end position control and to be able
to select a suitable type.
• To familiarise yourself with latching circuits of different characteristics.
Problem definition Packages are to be transferred from one conveyor belt to another via a diverting
device using reciprocating strokes. Once switched on, the device is to run
continuously and only be switched off via a stop signal.
Parameters • The latching circuit used is to exhibit a dominant „Off“ behaviour.
2. Design the pneumatic and electrical circuit diagram.
4. Compile the equipment list.

Positional sketch
Diverting device for packages
1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder

piston rod to drive the diverting device via a latching drive.
2. The packages are to be deflected and transported in the opposite direction.
3. Pressing of a second pushbutton is to switch off the drive.

Name: Date:
Fundamentals: Latching circuits Sheet 1 of 4
A latching relay circuit is required in order to store a signal in the signal control
section.
– The relay K1 is energised by actuating pushbutton S1. Complete the electrical

circuit diagram below so that the relay latches after the pushbutton S1 is
released.
+24 V 1
13
S1
14
A1
K1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Name: Date:
An additional normally closed contact is required in order to cancel a set self-

latching loop.
Differentiation is made between two groups depending on the configuration of this
normally closed contact:
• Dominant setting self-latching loop
• Dominant resetting self-latching loop
– Complete the electrical circuit diagram below so that the self-latching loop is
reliably cancelled via the actuation of a pushbutton S2.
+24 V 1
13
S1
14
A1
K1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Name: Date:
The various circuits for signal storage exhibit different behaviour:

• with simultaneously applicable set and reset conditions
• in the event of power failure or cable fracture
– Complete the table and enter the behaviour of the respective valve.
Valve position unchanged/valve is actuated/valve switches to normal position
Signal storage via Signal storage via electrical latching circuit

double solenoid combined with spring-return valve
valve
Dominant setting Dominant resetting
Set and reset signal shared
Power failure

Name: Date:
Fundamentals: Limit switches and proximity sensors Sheet 4 of 4
The function of limit switches and proximity sensors is to acquire information and to
transmit this for signal processing.
These include:
Mechanical position switches (limit switches), magnetic proximity sensors (reed
switches), optical proximity sensors, capacitive proximity sensors, inductive
proximity sensors
– Allocate the designations to the corresponding symbols in the table.
Designation Symbol
BN
BK
BU
BN
BK
BU
BN
BK
BU
2 4
BN
BK
BU

Name: Date:
– Design the pneumatic and electrical circuit diagram for the diverting device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

Name: Date:
+24 V 1 2 3 4 5 6 7 8
13 12 14
S1 K1
14 11
31
S2
32
A1
K1 1M1 1M2
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44

Name: Date:
an equipment list.
below.
Equipment list


Exercise 10: Designing a stamping device
Training aims • To be able to design a pressure-dependent reversal control.

• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
Problem definition Small mounting blocks are to be stamped during the production of door frames.
These blocks are to be stamped by means of a stamping device.
Parameters • The stamping pressure is to be 5.5 bar (550 kPa).

Positional sketch
Stamping device
1. The pressing of a pushbutton is to cause the stamping device to advance and the
workpiece to be stamped.
2. The stamping tool is to return into the initial position once the stamping pressure
is obtained.

Name: Date:
Fundamentals: Magnetic proximity sensor Sheet 1 of 5
In contrast with limit switches proximity sensors are switched contactlessly and
without an external mechanical actuating force.
– Describe the design and function of a magnetic proximity sensor (reed switch).
Description: Design and function Symbol Schematic representation
BN
BK
BU

Name: Date:
Fundamentals: Magnetic proximity sensors Sheet 2 of 5
As regards polarity there are two different designs of electronic proximity sensors,
i.e. PNP or NPN.
– Describe the differences between these two types.
PNP NPN

Name: Date:
Fundamentals: Pressure switches Sheet 3 of 5
Pressure sensitive sensors, so-called PE converters, are used to monitor the

pressure in a system.
– Describe the mode of operation of PE converter.
Description of mode of operation

Name: Date:
Fundamentals: Pressure sensors Sheet 4 of 5
Pressure sensors can be divided into two groups whereby differentiation is made
between:
• Pressure sensors with mechanical contact (mechanical principle of action)
• Pressure sensors with electronic switching
(electronic principle of action)
– Describe the purpose and function of the pressure sensor shown below.
Description: Purpose and function Symbol Schematic representation

Name: Date:
Fundamentals: Choice of proximity sensors Sheet 5 of 5
The end positions of a drive cylinder are to be sensed by means of proximity

sensors. The following requirements apply regarding the proximity sensors:
• The end positions of the piston rod are to be sensed contactlessly
• The proximity sensors are to be insensitive to dust
• The piston rod and trip cam of the cylinder are made of metal
– Choose which proximity sensors meet the specified requirements and explain
your reasons for this.
Proximity sensor Reason

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the stamping device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B1 1B2 1B3
A1 A1 A1
K1 K2 K3 1M1 1M2
A2 A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Name: Date:
an equipment list.
below.
Equipment list

Exercise 11: Realising a pallet loading station
Training aims • To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
• To be able to realise a sequence control using two cylinders.
Problem definition Stacks of roof tiles are to be strapped with a band and then transported to a pallet
loading station, where they are to be transferred onto Euro pallets.
Parameters • Adjust the one-way flow control valve so that both cylinders retract at identical
speed.
Project task 1. Design the displacement-step diagram.

2. Draw up the corresponding function diagram and function chart.

Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single

package arrives at the loading point and sensor 1B2 is actuated.
2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the
pallet.
3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no
longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is:
1A1+ 2A1+ 1A1–

2A1–

Name: Date:
Fundamentals: Designing the displacement-step diagram Sheet 1 of 3
If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches

its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates
sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1
unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1
retracts. Consequently the overall sequence is:
1A1+ 2A1+ 1A1–

2A1–
– Design the displacement-step diagram for the problem definition described.
1 2 3 4=1
1A1
0
1
2A1
0
Displacement-step diagram

Name: Date:
– Design the pneumatic and electrical circuit diagrams for the pallet loading
station.
1A1 2A1
1V2 1 1 1V3 2V2 2
2 2 1
1V1 4 2 2V1 2
5 3 1 3
1

Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
BK BK
BU BU
A1 A1 A1
1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Name: Date:
an equipment list.
below.
Equipment list

Exercise 12: Eliminating a fault on the pallet loading station
Training aims • To be able to identify and eliminate faults in simple electropneumatic control
systems.
Problem definition The pallet loading station stops during continuous operation. A fault has occurred
and must be eliminated. Thereafter the pallet loading station is to be re-started.
Parameters • Only one fault has occurred.
Project task 1. Describe the behaviour of the control system. Compare this with the correct
control system behaviour. Use the displacement-step diagram to assist you.
2. Localise potential causes of the fault with the help of the pneumatic and
electrical circuit diagrams.
3. Find the fault in the control system and eliminate it.
4. Re-start the control system.

Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single

package to reach its loading point thereby actuating sensor 1B2.
2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the
pallet.
3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer
actuated and cylinder 2A1 retracts. Consequently the overall sequence is:
1A1+ 2A1+ 1A1–

2A1–

Name: Date:
Fault finding in simple electropneumatic circuits Sheet 1 of 4
The following fault occurs in the circuit shown below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and
remain in the forward end position.
– Describe what the potential causes of the fault could be.
1A1 2A1
1B2 2B2
1V2 1 1 1V3 2V2 2
2 2 1
1V1 4 2 2V1 2
1M1 1M2 2M1

5 3 1 3
1

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

Name: Date:
A cable break occurs at the areas marked in the circuit shown below.
– Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Name: Date:
Fault Effect of fault
Break in earthing wire of

relay K1 (current path 2)
Break in signal line of

sensor 2B2 (current path 4)
Break in supply line of relay

K3 (current path 5)
Break in supply line of relay

contact 14 at K2 (current
path 7)
Break in earthing wire 2M1

(current path 8)

Name: Date:
Fault finding: Determining the required status Sheet 1 of 9
– Create the displacement-step diagram with the help of the documentation given
out.
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal

Exercise 12: Eliminating a fault in the pallet loading station
Name: Date:
Fault finding: Setpoint/actual comparison Sheet 2 of 9
Determine the ACTUAL status of the system with the help of the following
documentation:
• Positional sketch with problem description
• Graphic representation
– If the correct function is not given (REFERENCE/ACTUAL comparison), clearly

mark the area in the diagram where the fault occurs.
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal

Name: Date:
Fault finding: Description of faults Sheet 3 of 9
You have marked the area where a fault occurs in the diagram of the worksheet
‘REFERENCE/ACTUAL comparison.
– Describe the process up the point where the station or system stops.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Fault finding: Definition of faults - pneumatics Sheet 4 of 9
Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.
In which pneumatic tubing connections could the fault occur?
– Enter all the possibilities and indicate components at the start and end of the
tubing connection in order to ensure clear identification.
Potential fault Tubing connection

No. Start End
Potential faults

Name: Date:
Fault finding: Definition of faults – electrics Sheet 5 of 9
Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.
• In which current paths could the fault be located?

• What is the function of the current path?
– Enter all the possibilities.
Potential fault Current path No. Function of current path

No.
Potential faults

Name: Date:
Fault finding: Localisation of faults - pneumatics Sheet 6 of 9
Investigate the potential causes of errors you have found in the pneumatics.
• Use the same fault numbering that you have used for the worksheet ‘Definition
of faults – pneumatic.
• Document the procedure used to investigate the tubing connections.
– Enter the results of your investigation.
Measuring and test protocol
Potential fault Tubing connection Inspection Result

No. Start End

Name: Date:
Fault finding: Localisation of faults Sheet 7 of 9
Investigate the potential error causes you have found.
• Use the same fault numbering that you have used in the worksheet ‘Definition of
faults - electrics’.
• Document the procedure you have used to check the line connection.
– Enter the result of the investigation.
Potential fault Current path Measuring points Inspection Result

No. No.

Name: Date:
Fault finding: Elimination of fault Sheet 8 of 9
Once you have localised the failure location, your procedure for the elimination of
the fault must be documented on this worksheet.
– Describe each of the steps carried out in detail.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Note
In the event of the system not fulfilling the intended function return to the first
worksheet and repeat the fault finding.
Ask for new worksheet s to do so.

Name: Date:
Fault finding: Re-starting Sheet 9 of 9
Once you have identified, localised and eliminated the fault, re-start the system in
accordance with the required status.
Reset the specified required times.
– Briefly document the procedure followed in note form.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Part B – Fundamentals
The theoretical fundamentals for the electropneumatics training package are

summarised in the textbook:
Electropneumatics, Basic Level

This textbook represents an impressive synthesis of years of experience gained in
Festo Didactic courses and the requirements of company and college training. It
explains basic equipment and modern installation-saving components that require
little maintenance. A comprehensive description of methods of representation
showing motion sequences and operating states makes complex circuits easy to
understand. A detailed example provides students with the necessary knowledge for
the planning and implementation of an electropneumatic circuit.
G. Prede, D. Scholz, 2001 edition,

296 pages, bound
Order No.: 091181
© Festo Didactic GmbH & Co. KG • 541090 B-1

B-2 © Festo Didactic GmbH & Co. KG • 541090
Contents
Part C – Solutions
Exercise 1: Realising a sorting device ____________________________________C-3

Exercise 2: Realising a shut-off device___________________________________C-15
Exercise 3: Realising a lid press ________________________________________C-23
Exercise 4: Realising the operation of a hinged lid _________________________C-33
Exercise 5: Realising a diverting device __________________________________C-41
Exercise 6: Actuation of a stacking magazine _____________________________C-49
Exercise 7: Sorting of packages ________________________________________C-59
Exercise 8: Actuation of a sliding platform _______________________________C-67
Exercise 9: Expanding a diverting device ________________________________C-75
Exercise 10: Designing a stamping device________________________________C-85
Exercise 11: Realising a pallet loading station ____________________________C-95
Exercise 12: Eliminating a fault on the pallet loading station________________C-101
© Festo Didactic GmbH & Co. KG • 541090 C-1

Contents
C-2 © Festo Didactic GmbH & Co. KG • 541090

Solutions
Name: Date:
Fundamentals: Function of pneumatic working components Sheet 1 of 7
Pneumatic working components can be divided into two groups:

• Working components using linear movement
• Working components using rotary movement
– Describe the function of the working components shown.
Description: Function
Symbol 1
Single-acting cylinder, return spring in piston chamber, return stroke via compressed air, forward
stroke via return spring.
Function
The piston rod of this single-acting cylinder is moved into the retracted end position by means of
switching on the compressed air. Once the compressed air is switched off the piston reverses into the
forward end position via a return spring in the piston chamber (2 operating positions).
Symbol 2
Single-acting cylinder, return spring in piston chamber, forward stroke via compressed air, return
stroke via return spring
Function
The piston rod of the single-acting cylinder is moved into the forward end position by means of
switching on the compressed air. Once the compressed air is switched off the piston reverses into the
retracted end position (2 operating positions).
Symbol 3
Pneumatic semi-rotary drive (swivelling drive), with limited swivel range
Function
This semi-rotary drive is double-acting and is reversed by means of alternating connection of
compressed air (2 operating positions).

Solutions
Name: Date:
Fundamentals: Completing solenoid valve symbols Sheet 2 of 7
– Complete the individual symbols with the help of the corresponding component
descriptions.
Description Symbol
Pilot actuated 3/2-way solenoid 2

valve, normally open, with 10
manual override, with spring 1M1
1 3
return
Pilot actuated 3/2-way solenoid 2

valve, normally closed, with 12
manual override, with spring 1M1
1 3
return

Solutions
Name: Date:
Fundamentals: Normal positions of directional control valves Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated), or in the switching position (actuated). In the
normal position the valve can be closed or open.
– Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions: The single-acting cylinder shown is
controlled by one of the represented 3/2-way solenoid valves respectively.
2 2
12 10
1M1 1M1
1 3 1 3
Description: Description:
3/2-way solenoid valve, normally closed 3/2-way solenoid valve, normally open
The solenoid valve used is reversed via the The solenoid valve used is reversed by applying
application of voltage at the solenoid coil; flow is voltage at the solenoid coil; port 1 (and
released from pressure port 1 to working port 2. consequently flow) is closed. If the signal is
When the signal is cancelled, the valve is cancelled the valve is returned to the initial
returned to the initial position via a return spring; position via a return spring and flow is released
pressure port 1 (and consequently flow) is from pressure port 1 to working port 2. If the
closed. If the solenoid coil of the directional solenoid coil of the directional control valve is
control valve is de-energised, the cylinder de-energised, the cylinder chamber is
chamber is exhausted via the directional control pressurised via the directional control valve and
valve (exhaust port 3), and the piston rod is the piston rod is advanced. If the solenoid coil is
retracted. If the solenoid coil is energised, the energised the directional control valve switches
directional control valve switches. The cylinder and the cylinder chamber is exhausted via the
chamber is pressurised and the piston is directional control valve (exhaust port 3),
advanced. If the solenoid coil is de-energised, causing the piston rod to retract. The valve
the valve reverses. The cylinder chamber is reverses if the solenoid coil is de-energised. The
exhausted and the piston rod retracts. cylinder chamber is pressurised and the piston
Consequently the motion sequence is: 1A1+ 1A1- rod advances.
Consequently the motion sequence is: 1A1- 1A1+

Solutions
Name: Date:
Fundamentals: Direct and indirect actuation Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly.
– Describe the difference with the help of the following application:

Electrical actuation of a spring returned 3/2-way solenoid valve using a
pushbutton.
Description: Direct actuation Description: Indirect actuation
Current flows through the solenoid coil of the In the case of indirect control, current flows
valve if the pushbutton is actuated. The solenoid through a relay coil if a pushbutton is actuated.
is energised and the valve switches into the The relay contact closes and the valve switches.
actuated position. The switching position is retained for as long as
The current flow is interrupted if the pushbutton current flows through the solenoid or relay coil
is released. The solenoid is de-energised and the (in the case of self-latching loops also after the
directional control valve returns to the initial pushbutton is released). The relay is de-
position. energised if the current flow is interrupted via
the relay coil and the valve switches into the
initial position.
More complex, indirect actuation is always used
if the control circuit and primary circuit operate
using different voltages, the current through the
coil of the directional control valve exceeds the
permissible current for the pushbutton, if several
valves are switched using one pushbutton or
extensive logic functions are required between
the signals of various pushbuttons.

Solutions
Name: Date:
Design and function of an electrical switch Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally closed contact, normally open contact or
changeover switch.
– Describe the design and function of the switches shown.
3 1 2 4
4 2 1
Description: Design/function
Symbol
Pushbutton with normally open function
Function
With a pushbutton, the selected switching position is only retained for as long as it is actuated. The
pushbutton shown performs the function of a normally open contact. In the case of a normally open
contact, the circuit is interrupted in the normal position of the pushbutton, i.e. in the unactuated state.
Actuation of the switching stem causes the circuit to be closed and current to flow to the consuming
device. Once the switching stem is released, the pushbutton returns to the normal position as a result
of the spring force, thereby interrupting the circuit.
Symbol
Detent switch with normally closed contact
Function
In the case of a detent switch both switching positions are mechanically locked. A switching position is
therefore always retained until the switch is re-actuated. The detent switch shown performs the
function of a normally closed contact. With a normally closed contact the circuit is closed in the normal
position of the detent switch due to the spring force. Actuation of the detent switch causes the circuit
to be interrupted and renewed actuation closes the circuit again.
Symbol
Pushbutton with changeover function
Function
In the case of this pushbutton, the selected switching position is retained only for as long as this is
actuated. The pushbutton shown performs the function of a changeover switch, where the functions of
a normally closed and normally open contact are combined in one device. A switching action causes
one circuit to be closed and another circuit to be opened. Both circuits are briefly interrupted during
switching.

Solutions
Name: Date:
Fundamentals: Mode of operation of different valve types Sheet 6 of 7
Electrically actuated directional control valves are switched with the help of
solenoids and can basically be divided into two groups:
• Spring return valves
• Double solenoid valves
– Describe how these two groups differ with regard to function and behaviour in
the event of a power failure.
Valve type Mode of operation
Spring return valve The actuated switching position is maintained only for as long as
current flows through the solenoid coil. The normal position is
clearly defined by the return spring. In the event of a power failure
the valve switches to the normal position via the spring and this
may trigger dangerous machine movements,
e.g. causes the piston rod of a pneumatic cylinder to move into
the initial position and release the clamping of a workpiece.
Double-solenoid valve Switching of the valve merely requires a brief signal; due to the
static friction, the last assumed switching position is retained
even in the de-energised state. All solenoid coils are de-energised
in the normal position and the normal position cannot be clearly
defined. In the event of a power failure, the valve retains its last
switching position; no dangerous movements are triggered,
e.g. the piston rod of a pneumatic cylinder maintains its operating
position and retains a workpiece.

Solutions
Name: Date:
Fundamentals: Port designations of valves Sheet 7 of 7
In order to prevent incorrect tubing of directional control valves, valve ports

(working and pilot lines) are identified to ISO 5599 3, both on the valve itself and in
the circuit diagram.
– Describe the meaning or function of the designations below.
Designation Meaning or function
3 Working line, exhaust port
Pilot line, with pilot actuated or pneumatically actuated directional control valves;
12
Function on actuation: Connection of supply port 1 and working port 2
Pilot line, with pilot actuated or pneumatically actuated directional control valves;
10
Function on actuation: Closing of supply port 1

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the sorting device.
1A1
1V2 2
1
1V1 2
1M1
1 3
0Z2
0Z1
1
2
3

Solutions
Name: Date:
+24 V 1
13
S1
14
1M1
0V

Solutions
Name: Date:
Process description Sheet 1 of 1
Initial position
The cylinder is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact), causes the solenoid coil 1M1 of
the 3/2-way solenoid valve 1V1 to be energised. The valve 1V1 reverses and cylinder
1A1 advances.
Steps 2-3
As soon as pushbutton S1(normally open contact) is no longer actuated, the coil
1M1 is de-energised, the valve 1V1 is returned into the initial position via the return
spring, the cylinder 1A1 is exhausted and the spring returns the cylinder into the

Solutions
Name: Date:
an equipment list.
below.
1 Cylinder, single-acting
1 One-way flow control valve
1 3/2-way solenoid valve, normally closed
1 Pushbutton (normally open contact)
1 Manifold
1 Start-up valve with filter control valve
1 Compressed air supply
1 Power supply unit 24 V DC
Equipment list

Solutions

Solutions
Name: Date:
Differentiation is made between directly actuated and pilot actuated directional

control valves with regard to the type of actuation.
– Compare these two valve types and describe the respective advantages and
disadvantages.
Directly actuated valve Pilot actuated valve
Flow is releases to the consuming device via Flow to the consuming device is switched via the
the armature of the solenoid. In order to obtain main stage. The valve piston is moved via an air
a sufficient cross section of opening, a duct from pressure port 1.
comparably large armature is required. This This only requires a low flow so that a
consequently requires a powerful return spring comparatively small armature with minimal
and the solenoid to generate a high force. It is actuating force can be used. A minimum supply
therefore of a large design with high power pressure is required in order to actuate the piston
consumption. against the spring force.
Compared to a directly actuated valve, the solenoid
can be configured in a small design and the power
consumption and heat emission is thus reduced.

Solutions
Name: Date:
In order to prevent incorrect tubing up of directional control valves, valve ports

(working and pilot lines) are identified in accordance with ISO 5599-3, both on the
– Describe the meaning and function of the designations below
4 Working line, working port
Power line, with pilot actuated or pneumatically actuated directional control valves
14
Function on actuation: Connection of supply port 1 and working port 4
Pilot line, with pilot actuated or pneumatically actuated directional control valves
82/84
Function on actuation: Auxiliary pilot air exhausting

Solutions
Name: Date:
A valve symbol provides information regarding the function of the valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.
4 2
1M1
5 3
1
Description: Mode of operation of directional control valve
Pilot actuated 5/2-way solenoid valve, with manual override, with spring return
Mode of operation:
In the normal position, the piston is positioned at the lefthand stop, the ports 1 (supply port) and 2
(working port), as well as the ports 4 (working port) and 5 (exhaust port) are connected. If the
solenoid coil is energised, the valve piston moves up to the righthand stop. In this position, ports 1
and 4 as well as 2 and 3 (exhaust port) are connected (the designation of the internal line of the pilot
control is 14; function on actuation: Connection of supply port 1 and working port 4).
If the solenoid is de-energised, the valve piston switches back into the normal position due to the
spring force and the pilot air is exhausted. In the de-energised state the valve can be switched by
means of a manual override.

Solutions
Name: Date:
Fundamentals: IP classification Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is

protected by means of a housing or cover. The required protection class against
dust, humidity and foreign objects is to be identified.
Protection class IP 65 is shown on a valve.
– Describe the meaning of this classification.
Description: IP 65 classification
In accordance with DIN-VDE 470-1, the protection classification code is composed of the two letters IP
(for “International Protection”) and two digits.
The first digit indicates the scope of protection against the ingress of dust or foreign objects and the
second digit the scope of protection against the penetration of humidity or water.
Protection class IP 65 therefore means protection against the ingress of dust .
(i.e. complete protection against contact with energised or internally moving parts, protection against
the ingress of dust) and hose-water (i.e. strong jets of water aimed from any direction against the
housing/enclosure must not have any harmful effect).

Solutions
Name: Date:
Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5
Piston rod cylinder with linear action can be divided into two groups:
• Single-acting cylinders
• Double-acting cylinders
– Describe the meaning of the cylinder symbols shown.
Symbol 1 Symbol 2
Description: Symbolic representation
Symbol 1
Double-acting multi-position cylinder; reversal via alternating supply of compressed air. By series
connecting two cylinders of identical piston diameter and different stroke length, it is possible to
approach three positions. The third position can be approached directly or via the second
intermediate position from the first position. However, to do so the subsequent cylinder stroke must
always be greater than the previous stroke. With the return stroke, an intermediate position is only
possible with the appropriate actuation (3 working positions). The shorter stroke length is half of the
longer one.
Symbol 2
Double-acting cylinder, reversal via alternating supply of compressed air, adjustable end position
cushioning (2 working positions)
Cushioning is used in the end position if large loads are to be moved by a cylinder. Prior to reaching
the end position, a cushioning piston interrupts the direct exhaust path of air to atmosphere. The
restricted exhaust air causes the piston speed to be reduced during the last part of the stroke travel.

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the shut-off device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1
+24 V 1
13
S1
14
1M1
0V

Solutions
Name: Date:
Initial position
The cylinder is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1(normally open contact) causes the solenoid coil 1M1 of
the 5/2-way solenoid valve 1V1 to be energised and the valve 1V1 to reverse. The
piston side of cylinder 1A1 is now filled with compressed air whilst the piston rod
side is exhausted. Cylinder 1A1 advances.
Steps 2-3
As soon as pushbutton S1 (normally open contact) is no longer actuated, the coil
1M1 is de-energised and the valve 1V1 is returned to the initial position again via
the return spring. The piston side of cylinder 1A1 is exhausted whilst the piston rod
side is filled with compressed air. The cylinder returns into the retracted end
position.

Solutions
Name: Date:
an equipment list.
below.
1 Cylinder, double-acting
1 5/2-way solenoid valve
1 Manifold
Equipment list

Solutions
Name: Date:
Fundamentals: Mode of operation of relays Sheet 1 of 4
Relays form part of the components of the electrical signal control section. The main
components are:
• Coil with core
• Coil winding
• Contact set
• Return spring
• Armature
• Terminal lugs
The illustration below represents a sectional view of a relay.
– Allocate the component designations.
2 3
A1 A2 4 2 1
7 6
The relay consists of
(1) Coil with core

(2) Return spring
(3) Coil winding
(4) Armature
(5) Contact set
(6) Terminal lugs
(7) Terminal lugs

Solutions
Name: Date:
– Describe the mode of operation of a relay.
Description: Mode of operation of a relay
A relay is an electromagnetically operated switch. An electromagnetic field is created if voltage is

applied at the coil of the solenoid, which causes the movable armature to be attracted to the coil core.
The armature acts on the relay contacts which, depending on configuration either open or close. If the
current flow through the coil is interrupted, a spring causes the armature to return into the initial
position.

Solutions
Name: Date:
One or several contacts can be switched by a relay coil. Depending on the required
function, a relay with normally open, normally closed or changeover contact(s) is
used.
Additional designs of electromagnetically operated switches are

for instance the remanence relay, time relay with switch-on delay and the contactor.
– Describe the design and contact line-up of the relays shown.
Description: Design/contact line-up Symbol
Design: Relay with two normally closed contacts 13 23 31 41

A1
and two normally open contacts
Function: If the relay coil is energised, two of the
four contacts are opened and two contacts are
A2 14 24 32 42
closed.
Design: Relay with four changeover contacts

12 14 22 24 32 34 42 44
Function: If the relay coil is energised, up to four A1
current paths are opened or closed via the four
relay contacts.
High flexibility, wide range of different contact A2 11 21 31 41
combinations possible.

Solutions
Exercise 3: Realising a list press
Name: Date:
– Name possible applications of relays in electrical or electropneumatic control

systems.
Description: Possible applications
• Signal multiplication
• Voltage or current amplification
• Delaying or converting of signals
• Logic operations of information
• Isolation of control and primary circuits
• Isolation of DC and AC circuits in purely electrical control systems

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the lid press.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1

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

Solutions
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised, the changeover contact K1 (connected in the form of a normally open
contact) also closed and the solenoid coil 1M1 of the 5/2-way valve 1V1 is
energised. The valve 1V1 reverses and causes the rear chamber of cylinder 1A1 to be
filled with compressed air whilst the front chamber if exhausted. Cylinder 1A1
advances.
Steps 2-3
As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K1 is
de-energised and the changeover contact K1(connected in the form of a normally
open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1
to be returned into the initial position via the return spring. The rear chamber of
cylinder 1A1 is exhausted whilst the front chamber is filled with compressed air. the
cylinder returns into the retracted end position.

Solutions
Name: Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 1 of 2
Indirect actuation does of course function equally with a 3/2-way solenoid valve and
single-acting cylinder.
1A1
1V2 2
1V1 2
1M1
1 3

Solutions
Name: Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 2 of 2
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44

Solutions
Name: Date:
an equipment list.
– Create the equipment list by entering the required equipment in the table below.
Quantity Designation
1 Pushbutton (normally open)
1 Relay
1 Manifold
Equipment list

Solutions
Name: Date:
Fundamentals: Converting solenoid valves Sheet 1 of 3
In industrial practice there are numerous different requirements placed on a valve. If

a valve with the desired characteristics is not available, it is often possible to use a
valve with a different number of ports to obtain the required function. The table
below lists a selection of directional control valves frequently in use in industrial
applications.
– Describe the valve types shown.

– Designate all the solenoid valves that can be replaced by using a 5/2-way
solenoid valve of the type shown.
– If conversion measures need to be taken in order to obtain the desired function,
then please describe thee.
Note
By the term „conversion measures“ we understand the simplest of conversions,
such as the closing of working ports 2 or 4 using a blanking plug.
4 2
14
1M1
5 3
1
Symbol Description: Valve type Replacement Description: Necessary conversions

possible
2 Pilot actuated, spring return Replacement possible, no conversion required?

12 2/2-way solenoid valve, with manual X
1M1
1 override
2 Pilot actuated, spring return Replacement possible, conversion by closing

12 3/2-way solenoid valve, normally closed, X working port 2 using a blanking plug
1M1
1 3 with manual override
2 Pilot actuated, spring return Replacement possible, conversion by closing

10 3/2-way solenoid valve, normally open, X working port 4 using a blanking plug
1M1
1 3 with manual override
4 2 Pilot-actuated, spring return Replacement possible, no conversion required

14 4/2-way solenoid valve, with manual X
1M1
1 3 override

Solutions
Exercise 4: Realising the operation of hinged lid
Name: Date:
Fundamentals: Selecting solenoid valves Sheet 2 of 3
The choice of a valve is made according to the following criteria:

• Problem definition,
• Required behaviour in the event of a power failure,
• Lowest possible overall costs
The following choice of valves is available for the actuation of a single-acting

cylinder:
• A pilot actuated, spring return 3/2-way solenoid valve with manual override
• A pilot actuated, spring return 5/2-way solenoid valve with manual override
– Make your choice and explain your reasons for this.
Note
Apart from the costs of the actual valve, the above mentioned overall costs of a
valve also include the costs for installation, maintenance and storage of
replacement parts.
Valve type Reason
Pilot actuated, spring As can be seen from question 1, the 5/2-way solenoid valve has a broad
return 5/2-way spectrum of possible applications. In practice this means that only one valve
solenoid valve with type is required for different requirements or applications. This in turn
manual override means a considerable cost reduction thanks to more alternatives when it
comes to the procurement of the valve and storage of replacement parts.
The maintenance of different valves entails considerable higher expenditure
compared to maintaining a single valve type. A 3/2-way valve can only
actuate single-acting cylinders whereas a 5/2-way valve can actuate single-
acting and double-acting cylinders. This is why the choice should be a 5/2-
way solenoid valve. The fact that the costs of a 3/2-way solenoid valve are
usually 5 % below that of a 5/2-way double solenoid valve is immaterial in
view of the above mentioned advantages.

Solutions
Name: Date:
Fundamentals Sheet 3 of 3
Triggering the advance of the cylinder piston rod is to be possible using two
pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve
coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position
and the piston rod advances. If both pushbuttons are released, the valve switches
into the initial position and the piston rod retracts.
– Create the appropriate function table and the logic symbol.
Note
0 means: Pushbutton not actuated, i.e. piston rod does not advance
S1 S2 1M1 1V1
0 (not actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)
0 (not actuated) 1 (actuated) 1 (actuated) 1 (actuated)
1 (actuated) 0 (not actuated) 1 (actuated) 1 (actuated)
1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)
Function table
S1 <=1 1M1
S2
Logic symbol

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the hinged lid.
1A1
1V2 2
1V1 4 2
1M1
5 3
1

Solutions
Name: Date:
Complete the pneumatic and electrical circuit diagrams Sheet 2 of 2
+24 V 1 2 3
13 13 12 14
S1 S2 K1
14 14 11
A1
K1 1M1
A2
0V 12
11 14 .3
22
21 24
32
31 34
42
41 44

Solutions
Name: Date:
Initial position
In the initial position cylinder 1A1 is in the forward end position and the rear cylinder
chamber is filled with compressed air.
Steps 1-2
Actuation of pushbutton S1 or pushbutton S2 (both in the form of normally open
contacts), causes the relay K1 to be energised, the changeover contact K1
(connected in the form of a normally open contact) closes and the solenoid coil 1M1
of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and the rear chamber
of cylinder 1A1 is exhausted; the spring presses the cylinder into the retracted end
position.
Steps 2-3
As soon as the pushbutton S1 or S2 (both in the form of normally open contacts), are
no longer pressed, the relay K1 is de-energised, the changeover switch K1
(connected in the form of a normally open contact) opens. This causes the coil 1M1
to be de-energised and the valve 1V1 to be returned into the initial position via the
return spring. The rear chamber of cylinder 1A1 is filled with compressed air and the
cylinder returns into the forward end position.

Solutions
Name: Date:
Compiling the equipment Sheet 1 of 1
an equipment list.
– Create the equipment list by entering the required equipment in the table below.
1 Relay
1 Manifold
Equipment list

Solutions

Exercise 5: Realising the operation of a diverting device
Solutions
Name: Date:
Fundamentals: Use of solenoid valves Sheet 1 of 4
Two factors are to be taken into consideration with regard to the question as to
which valve type is to be used for a particular application:
• Duration, i.e. time frame,
• Quantity or frequency
of required switching operations.
In order to utilise a directional control valve as efficiently as possible, you will need
to decide in each case whether
• a double-solenoid valve or
• a spring-return directional control valve
is more cost effective for the required application.
– Decide whether a double soleoid or a spring-return valve seems more cost

effective for the applications listed and explain the reasons for your choice.
Application 1
The clamping cylinder of a milling device is to firmly hold in position a workpiece for
the duration of a milling operation (duration of approx. 10 min, 60 clamping
operations per day).
Valve type Reason
Double solenoid An applied signal needs to be stored for lengthy switching operations. In the
valve case of double solenoid valve this occurs via static friction and with spring
return directional control valves via continuously energising the solenoid
coil. Clamped workpieces must not be released in the event of EMERGENCY-
STOP, hence the use of spring-return solenoid valves is not permissible in
this case.
Application 2
The ejecting cylinder of a sorting device is to push defective workpieces from a
conveyor (duration of approx. 1s, 600 ejecting operations per day).
Valve type Reason
Spring-returned For short switching operations an applied signal does not need to be stored.
solenoid valve Spring-return solenoid valves have the advantage: Only one valve coil needs
to be actuated, i.e. energised to switch the valve.

Solutions
Name: Date:
4 2
1M1 1M2
5 3
1
Description: Mode of operation of a directional control valve
Pilot actuated 5/2-way double solenoid valve, with manual override

Mode of operation:
If the piston is at the lefthand stop, ports 1 (compressed air supply) and 2 (working port), as well as
port 4 (working port) and port 5 (exhaust port)are connected. If the lefthand solenoid coil is energised,
the piston moves to the righthand stop and ports 1 and 4 as well as port 2 and port 3 (exhaust port)
are connected (power line, 14 and 12, function during actuation: Connection of compressed air supply
1 and working port 4, i.e. 2). If the valve is to return into the initial position, it is not sufficient to
interrupt the current to the lefthand solenoid coil since the righthand solenoid coil also needs to be
energised. If neither of the two solenoids is actuated the piston, owing to friction, remains in its last
assumed position (signal control in the power section). This also applies if both solenoids are
simultaneously energised since they then act against one another with identical force.
The valve can be switched via a manual override in the de-energised state .

Solutions
Name: Date:
A spring-return solenoid valve is to be switched via pushbutton S1.
– Calculate the current consumption of the valve coil 1M1 at a voltage supply of
24 V DC and a coil resistance of 48 Ω (Ohm).
+24 V 1
13
S1
14
1M1
0V
Current consumption in 1M1 Capacity of 1M1
According to Ohm’s law According to

R=U•I
P = U • I = 24 V • 0.5 A = 12 W
A current consumption of 0.5 A (ampere) is
calculated via a power consumption of 12 W (Watt) is calculated
U 24V
I= = = 0.5 A
R 48Ω

Solutions
Name: Date:
– Would the current consumption in S1 be the same, higher or lower if the above
valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Identical Higher Lower Reason
The magnetic fields of the AC voltage create an induction

voltage in the coil windings which acts against the
voltage applied and which increases the coil resistance.
X
This resistance of the AC coil (impedance) is made up of
the ohmic resistance and the so-called inductive
reactance, thereby reducing the effective current.

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the diverting device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

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

Solutions
Name: Date:
Initial position
In the initial position, cylinder 1A1 is in the retracted end position.
Steps 1-2
energised, the changeover contact K1 (connected in the form of a normally open
contact) to close and the solenoid coil 1M1 of the 5/2-way double solenoid valve
1V1 to be energised. The valve 1V1 reverses and the rear chamber of cylinder 1A1 is
filled with compressed air whilst the front chamber is exhausted. Cylinder 1A1
advances.
As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay

K1 is de-energised and the changeover contact K1 (connected in the form of a
normally open contact) opens, thereby causing the coil 1M1 to be de-energised.
Steps 2-3
energised and the changeover contact K2 (connected in the form of a normally open
contact) to be closed. This causes the coil 1M2 to be energised and the valve 1V1 to
return into the initial position. The front chamber of the cylinder 1A1 is filled with
compressed air whilst the rear chamber is exhausted. The cylinder 1A1 returns into
the retracted end position.
As soon as pushbutton S2 (normally open contact) is no longer actuated, relay K2 is

de-energised and changeover contact K2 (connected in the form of a normally open
contact) opens. This causes the coil 1M2 to be de-energised.

Solutions
Name: Date:
an equipment list.
below.
1 5/2-way double solenoid valve
2 Relay
1 Manifold
Equipment list

Solutions
Name: Date:
The components of an electropneumatic system are represented in a pneumatic

circuit diagram and/or in an electrical circuit diagram.
– Determine where the components below are to be represented.
Component Pneumatic circuit Electrical circuit

diagram diagram
Manually operated pushbutton X
Cylinder X
Valves X
Valve coils X X
Relay X
Electromechanical limit switch X X
Electronic proximity sensor X X
Indicating devices X

Solutions
Name: Date:
The function of sensors in electropneumatic control systems is to acquire

information and transmit this for signal processing.
– What function(s) can an electromechanical limit switch fulfill in an

electropneumatic control system?
Description: Function (s) of electromechanical limit switches
To detect the forward and retracted end positions of the piston rod of drive cylinders
To establish the availability and position of a workpiece

Solutions
Name: Date:
Fundamentals: Representation of limit switches Sheet 3 of 6
Limit switches can be actuated in different ways, via the function of a normally
closed or normally open contact or changeover switch and, in the normal position of
the system, can be either actuated or unactuated.
– Describe the appropriate design or function of the symbols shown.
Description: Design/ function Symbol
Roller actuated limit switch with normally closed function,

2
unactuated
Roller actuated limit switch with normally open function, unactuated

4

Solutions
Name: Date:
One possibility of recording the allocated contacts of a relay is by means of listing

these in a logic element table.
– Create the logic element table for the relays K6 and K9.
+24 V 10 11 12 13 14 15 16 17 18 19
...
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
11 11 11 11 11 11 11 11 31 31
12 14
K1
11
22 24 22 24 22 24 22 24 32 34 32 34
K9 K6 K7 K8 K9 K8
21 21 21 21 31 31
A1 A1 A1 A1
K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2
...
0V
Logic element- Description: Logic element table

table
K6 1 Normally open contact in current path 11

1 Normally open contact in current path 12
1 Normally open contact in current path 18
11
12
18
K9 1 Normally open contact in current path 17

1 Normally closed contact in current path 10
1 Normally closed contact in current path 18
10 17
18

Solutions
Name: Date:
Another method of recording the allocated contact sets of a relay can be seen in the
electrical circuit diagram below.
+24 V 1 2 3 4 5 6 7 8 9 10 11 25 27
21 12 14 22 24 32 34
NA K11 K11 K11
EMERGENCY 22 11 21 31
STOP 12 13 16 17 18 19 20 21 22 23 24 26
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34 22 24
1B1 1B2 2B1 2B2 13
K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
S1
11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
Start 14
12 14
K1
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
21 21 21 21 21 41 41 41 31
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 1M1 2M1 2M2 1M2

K11 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 .11 11 14 .12 11 14 .14 11 14 .18 11 14 .16 11 14 .12 11 14 .13 11 14 .15 11 14 .17 11 14 .19 11 14 .21
22 22 22 22 22 22 22 22 22 22 22
21 24 .25 21 24 .20 21 24 21 24 .27 21 24 21 24 21 24 .14 21 24 .16 21 24 .18 21 24 .20 21 24 .12
32 32 32 32 32 32 32 32 32 32 32
31 34 .27 31 34 31 34 31 34 31 34 31 34 31 34 .22 31 34 .23 31 34 .24 31 34 .26 31 34 .26
42 42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 .22 41 44 .23 41 44 .24 41 44

Solutions
Name: Date:
– Complete the information regarding the relays shown by:

Indicating the current path in which the respective contact is used.
Specifying the function fulfilled by the contact set (normally open or normally
closed contact).
Relay Current path Function: Function:

Normally Normally
open contact closed
contact
Relay K9 Current path 19 X
Current path 20 X
Current path 24 X
Current path 26 X
Relay K10 Current path 12 X
Current path 21 X
Current path 26 X

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams.
1A1
1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

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

Solutions
Exercise 6: Ansteuerung eines Schachtmagazins
Name: Date:
Initial position
Cylinder 1A1 is in the retracted and position in the initial position.
Steps 1-2
energised; the changeover contact K1 (connected in the form of a normally open
contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1
is energised. The valve 1V1 reverses. The rear chamber of the cylinder 1A1 is filled
with compressed air whilst the front chamber is exhausted. The cylinder 1A1
advances.
If pushbutton S1 (normally open contact) is no longer actuated, the relay K1 is de-

energised and the changeover switch K1 (connected in the form of a normally open
contact) opens. This also causes the coil 1M1 to be de-energised.
Steps 2-3
Once the cylinder has reached its forward end position, the piston rod actuates the
electrical limit switch 1B2. The changeover switch 1B2 (connected in the form of a
normally open contact) closes and the relay K2 is energised. The changeover contact
K2 (connected in the form of a normally open contact) closes and the solenoid coil
1M2 is energised. The valve 1V1 reverses into the initial position again.
The front chamber of the cylinder 1A1 is filled with compressed air whilst the rear
chamber is exhausted. The cylinder returns into the retracted end position again.
As soon as the electrical limits switch 1B2 is no longer actuated (changeover

contact, connected in the form of a normally open contact), the relay K2 is de-
energises and the changeover contact K2 (connected in the form of a normally open
contact) opens. This also causes the coil 1M2 to be de-energised.

Solutions
Name: Date:
an equipment list.
below.
1 Limit switch (normally open contact)
2 Relay
1 Manifold
Equipment list

Solutions
Name: Date:
Fundamentals: Calculation of piston force Sheet 1 of 3
The piston of a double-acting cylinder is of a diameter of 20 mm and the piston rod

of a diameter of 8 mm. The frictional losses within the cylinder are 10 %.
– Calculate the effective piston force in the advance and return stroke at an
operating pressure of 6 bar (600 kPa).
To be calculated Solution
Advance stroke F = 188 N
Return stroke F = 158 N

Solutions
Name: Date:
Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3
A relay of an electropneumatic circuit is designated as follows: 580 Ω, 1 W
– Calculate the permissible operating voltage which ensures that no overload

occurs on the relay.
Max. Operating A maximum operating voltage of 24 volts is calculated on the basis of the
voltage formula
V2
P = V ⋅ I = I2 ⋅ R =
R

Solutions
Name: Date:
Triggering of the advancing movement of a cylinder piston rod is to be achieved by

means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both
pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into
the actuated position causing the piston rod to advance. If at least one of the
pushbuttons is released, the valve switches into the initial position and the piston
rod retracts.
– Create an appropriate function table and the logic symbol.
Note
0 means: Pushbutton not actuated, i.e. piston rod not advancing
S1 S2 1M1 1V1
0 (not actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)
0 (not actuated) 1 (actuated) 0 (not actuated) 0 (not actuated)
1 (actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)
1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)
Function table
S1 & 1M1
S2
Logic symbol

Solutions
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

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

Solutions
Name: Date:
Initial position
The cylinder 1A1 is in the retracted end position in the initial position.
If the cylinder is in the retracted end position, then the electrical limit switch 1B1 is
actuated (changeover contact, connected in the form of a normally open contact)
and the changeover switch 1B1 closed and the relay K2 energised.
Steps 1-2
energise. The changeover contact K1 (in the form of a normally open contact) closes
and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised.
The double solenoid valve 1V1 reverses. The piston end of cylinder 1A1 is filled with
compressed air whilst the piston rod end is exhausted and cylinder 1A1 advances.
As soon as the cylinder 1A1 moves out of the retracted end position, limit switch 1B1
is no longer actuated and the changeover switch 1B1 opens. This causes the
normally open contact K2 to open and the solenoid coil 1M1 to be no longer
energised. However the double solenoid valve still remains in the righthand
switching position.
Steps 2-3
Once the cylinder reaches its forward end position, the piston rod actuates the
electrical limit switch 1B2 (changeover contact, connected in the form of a normally
open contact). The changeover switch 1B2 closes and the relay K3 is energised. The
closing of the changeover contact K3 (connected in the form of a normally open
contact), also causes the solenoid coil 1M2 to be energised. The
valve 1V1 reverses.
The piston rod chamber of cylinder 1A1 is filled with compressed air whilst the
piston end is exhausted. The cylinder moves into the retracted end position again.
As soon as the electrical limit switch 1B2 is no longer actuated (changeover contact,
connected in the form of a normally open contact), the relay K3 is de-energised and
the changeover contact K3 (connected in the form of a normally open contact)
opens. This also causes the coil 1M2 to be de-energised. The cylinder remains in the

Solutions
Name: Date:
an equipment list.
below.
2 Limit switch (normally open contact)
3 Relay
1 Manifold
Equipment list

Solutions

Solutions
Name: Date:
Fundamentals: Signal storage Sheet 1 of 3
The actuation of the pushbutton must be stored if the piston rod of a double-acting
cylinder is to advance even if the pushbutton is only briefly actuated. This signal
storage can be effected either in the power section or in the signal control section of
a circuit.
– Describe how signal storage is devised in the power section or signal control
section respectively.
Place of signal storage Description: Signal storage
Signal storage in the A double solenoid valve is to be used for signal storage.
power section Owing to the static friction of the valve piston, the double solenoid valve
maintains its switching position even when the corresponding solenoid
coil is no longer energised.
Signal storage in the By means of a spring-return solenoid valve with self-latching loop .
signal control section The relay coil is energised and a contact closes. Once the ON pushbutton
is released, current continues to flow through the coil via the closed
contact. The relay remains in the actuated position and therefore also the
spring-returned solenoid valve. Actuation of an OFF pushbutton causes the
current to be interrupted. Depending on the configuration of the two
pushbuttons, differentiation is made between dominant setting or
dominant resetting self-latching loops.

Solutions
Name: Date:
Fundamentals: Analysing circuits Sheet 2 of 3
– Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2-
way solenoid valve with manual override, double-acting cylinder) in the event of
– Power failure
– Pressure failure
– Pressure and power failure.
Power failure Pressure failure
The spring-return solenoid valve switches into The solenoid valve switches into the normal
the normal position, the double-acting cylinder position due to the reduced operating
moves into the retracted end position. The pressure, the double-acting cylinder is without
solenoid valve and consequently the cylinder pressure and assumes an undefined position.
can be switched manually using the manual
override.

Solutions
Name: Date:
Fundamentals: Logic functions Sheet 3 of 3
The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated.
– Draw up the appropriate function table and the logic symbol.
Note
0 means: Pushbutton S1 not actuated, i.e. lamp P1 off
1 means: Pushbutton S1 actuated, i.e. lamp P1 illuminated
S1 P1
0 (not actuated) 1 (actuated)
1 (actuated) 0 (not actuated)
Function table
1
S2 P1
Logic symbol

Solutions
Name: Date:
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1

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

Solutions
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position in the initial position.
Steps 1-2
contact) in current path 2 closes and activates the self-latching loop of relay K1. In
addition, the changeover contact K1 in current path 3 closes and the solenoid coil
1M1 of the 5/2-way solenoid valve 1V1 is energised. The valve 1V1 reverses. The
piston end of cylinder 1A1 is then filled with compressed air whilst the piston rod
side is exhausted. Cylinder 1A1 advances.
Steps 2-3
Actuation of pushbutton S2 (normally closed contact) cancels the self-latching loop
of relay K1. The changeover contact K1 (connected in the form of a normally open
contact) in current path 3 opens and the relay K1 is de-energised. The valve 1V1
reverses via the return spring.
The piston rod end of cylinder is filled with compressed air whilst the piston end is
exhausted. the cylinder returns into the retracted end position.

Solutions
Name: Date:
an equipment list.
below.
1 Pushbutton (normally closed contact)
1 Relay
1 Manifold
Equipment list

Solutions

Solutions
Name: Date:
A latching relay circuit is required in order to store a signal in the signal control
section.
– The relay coil is to be energised by pressing pushbutton S1. Complete the

electrical circuit diagram below so that the relay latches after the pushbutton S1
is released.
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44

Solutions
Name: Date:
An additional normally closed contact is required in order to cancel a set latching

circuit.
Differentiation is made between two groups depending on the configuration of this
normally closed contact:
• Dominant setting self-latching loop
• Dominant resetting self-latching loop
– Complete the electrical circuit diagram so that the self-latching loop is reliably
cancelled via the actuation of a pushbutton S2.
+24 V 1 2 +24 V 1 2
12 14
13 12 14 K1
S1 K1 11
14 11
13 31
S1 S2
31 14 32
S2
32
A1 A1
K1 K1
A2 A2
0V 12
0V 12
11 14 .2 11 14 .2
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Electrical circuit diagram; left: Dominant resetting self-latching loop; right: Dominant setting self-latching loop

Solutions
Exercise 9: Expansion of a diverting device
Name: Date:
The various circuits for signal storage exhibit different behaviour:

• with simultaneously applicable set and reset conditions
• in the event of power failure or cable fracture
– Complete the table and enter the behaviour of the respective valve.
Valve position unchanged/valve is actuated/valve switches to normal position
Signal storage via Signal storage via electrical latching circuit

double solenoid combined with spring-return valve
valve
Dominant setting Dominant resetting
Set and reset signal shared Valve position Valve is actuated Valve switches to
unchanged normal position
Power failure Valve position Valve switches to Valve switches to

unchanged normal position normal position

Solutions
Name: Date:
Fundamentals: Limit switches and proximity sensors Sheet 4 of 4
The function of limit switches and proximity sensors is to acquire information and to
transmit this for signal processing.
These include:
Mechanical position switches (limit switches), magnetic proximity sensors (reed
switches), optical proximity sensors, capacitive proximity sensors, inductive
proximity sensors
– Allocate the designations to the corresponding symbols in the table.
Designation Symbol
Magnetic proximity sensor (reed switch) BN
BK
BU
Optical proximity sensor BN
BK
BU
Inductive proximity sensor BN
BK
BU
Mechanical position switch (limit switch)

2 4
Capacitive proximity sensor BN
BK
BU

Solutions
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1

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

Solutions
Exercise 9: Exansion of a diverting device
Name: Date:
Initial position
If cylinder 1A1 is in the retracted end position, then the proximity sensor 1B1 is
actuated, and the relay K2 is energised; the changeover contact K2 (connected in the
form of a normally open contact) in current path 7 closes.
Steps 1-2
contact) in current path 2 closes and activates the self-latching loop of relay K1. In
addition the changeover contact K1 (connected in the form of a normally open
contact in current path 7 closes and the solenoid coil 1M1 of the 5/2-way double
solenoid valve 1V1 is energised. The double solenoid valve 1V1 reverses. The rear
chamber of the cylinder 1A1 is now filled with compressed air whilst the front
chamber is exhausted. Cylinder 1A1 advances. As soon as the cylinder 1A1 moves
out of the retracted end position, proximity sensor 1B1 is no longer actuated. This
also causes the changeover contact K2 (connected in the form of a normally open
contact) in current path 7 to open and current no longer flows through the solenoid
coil 1M1. The double solenoid valve nevertheless remains in the righthand switching
position.
Steps 2-n
The proximity sensor 1B2 is actuated when the cylinder reaches the forward end
position and the relay K3 is energised. The changeover contact K3 (connected in the
form of a normally open contact) in current path 8 closes and the solenoid coil 1M2
is energised. This causes the valve 1V1 to return into the initial position and the
cylinder 1A1 to return into the retracted end position. The relay K3 is de-energised
as soon as proximity sensor 1B2 is no longer actuated; the changeover contact K3
(connected in the form of a normally open contact) in current path 8 opens, causing
the coil 1M2 to be de-energised.
Since the electrical latching circuit of relay K1 is still active, the solenoid coil 1M1
receives another switching pulse as soon as the retracted end position is reached so
that the cylinder 1A1 immediately advances again.

Solutions
Name: Date:
Step n-(n+1)
The oscillating movement of cylinders 1A1 can be interrupted by means of pressing
pushbutton S2 (normally closed contact), thereby cancelling the self-latching loop of
relay K1. The cylinder moves into the retracted end position and remains there.

Solutions
Name: Date:
an equipment list.
below.
2 Proximity sensor, electronic
1 Pushbutton (normally closed contact)
3 Relay
1 Manifold
Equipment list

Solutions

Solutions
Name: Date:
In contrast with limit switches proximity sensors are switched contactlessly and
without an external mechanical actuating force.
– Describe the design and function of a magnetic proximity sensor (reed switch).
Description: Design and function Symbol Schematic representation
Reed switches are magnetically actuated

proximity sensors, which consist of two contact
blades located inside an inert gas filled glass
tube. The effect of a magnet causes the two
blade contacts to be closed thereby enabling an
electrical current to flow. In the case of reed
switches in the form of normally closed contacts,
the contact blades are pretensioned by means of
small magnets. This pretension is overcome by a
much stronger switching magnet. Reed switches
have a long service live and minimal switching
time (approx. 0.2 ms).
They are maintenance-free, but must not be used
in areas subject to strong magnetic fields, (e.g. in
the proximity of resistance welders).

Solutions
Name: Date:
As regards polarity there are two different designs of electronic proximity sensors,
i.e. PNP or NPN
– Describe the differences between these two types.
PNP NPN
In the case of negative switching sensors a In the case of positive switching sensors, zero
supply voltage is applied at the output in the voltage is applied at the output in the absence of a
absence of a part within the response range of part within the response range of the sensor. The
the sensor. The approaching of a workpiece or approaching of a workpiece or machine part causes
machine part causes the output to switch to 0V the output to switch so that supply voltage is
voltage. applied.

Solutions
Name: Date:
Fundamentals: Pressure switches Sheet 3 of 5
Pressure sensitive sensors, so-called PE converters, are used to monitor pressure in

a system.
– Describe the mode of operation of a PE converter.
Description of mode of operation
With a PE converter, a pneumatic pressure signal switches an electrical signal generator (generally in
the form of a changeover switch); consequently a pneumatic input signal is output as an electrical
signal.
If the switching pressure is adjustable, this is known as a pressure sensor.

Solutions
Name: Date:
Fundamentals: Pressure sensor Sheet 4 of 5
Pressure sensors can be divided into two groups whereby differentiation is made
between:
• Pressure sensors with mechanical contact (mechanical principle of action)
• Pressure sensors with electronic switching
(electronic principle of action)
– Describe the purpose and function of the pressure sensor shown below.
Description: Purpose and function Symbol Schematic representation
Pressure sensors are used in order to generate

an electrical output signal at a defined
pressure.
With this mechanically operating pressure
sensor, the pressure acts on a piston surface.
The piston moves, if the force resulting from
the pressure exceeds the spring force, and
actuates the changeover contact. The
switching pressure can be set by pretensioning
the spring, hence this pressure sensor is
knows as a pressure switch.

Solutions
Name: Date:
Fundamentals: Choice of proximity sensors Sheet 5 of 5
The end positions of a drive cylinder are to be sensed by means of proximity

sensors.
The following requirements apply regarding the proximity sensors:
• The end positions of the piston rod are to be sensed contactlessly
• The proximity sensors are to be insensitive to dust
• The piston rod and trip cam of the cylinder are made of metal
– Choose which proximity sensors meet the specified requirements and explain
your reasons for this.
Proximity sensor Reason
Inductive proximity sensor Both proximity sensors operate contactlessly and without
or mechanical actuation. Both proximity sensors are insensitive
magnetic proximity sensor to dirt. Since the trip cam is made of metal, both inductive as
well as magnetic proximity sensors are feasible.

Solutions
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
1B3
p
2 2
1V1 4 2
1M1 1M2
5 3
1

Solutions
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B1 BN 1B2 BN 1B3 BN

13 12 14
BK BK BK
S1 K2
p
14 11
BU BU BU
12 14 12 14
K1 K3
11 11
A1 A1 A1
K1 K2 K3 1M1 1M2
A2 A2 A2
0V 12 12 12
11 14 .7 11 14 .8 11 14 .8
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Solutions
Name: Date:
Initial position
The proximity sensor 1B1 is actuated if the cylinder 1A1 is in the retracted end
position. This causes the relay K1 to be energised and the changeover contact K1
(connected in the form of a normally open contact) in current path 7 to be closed.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the solenoid coil 1M1 of
the 5/2-way double solenoid valve 1V1 to be energised. The double solenoid valve
1V1 reverses and cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of
the retracted end position, the proximity sensor 1B1 is no longer actuated. This
causes the changeover contact K1 (connected in the form of a normally open
contact) in current path 7 to open and the solenoid coil 1M1 is no longer current-
carrying. The double solenoid coil nevertheless remains in the righthand switching
position.
Steps 2-3
When the cylinder reaches the forward end position, the proximity sensor 1B2 is
actuated and the relay K2 energised. The changeover contact K2 (connected in the
form of a normally open contact) in current path 8 closes. In the meantime, the
pressure sensor 1B3 measures the pressure applied at cylinder 1A1. The pressure
sensor (programmed as a normally open contact) switches if the pressure is
identical or greater than the set required value and the relay K3 is energised; the
changeover contact K3 (connected in the form of a normally open contact) in current
path 8 closes and the solenoid coil 1M2 is now energised. This causes the valve 1V1
to reverse and the cylinder 1A1 to move into the retracted end position.
As soon as the proximity sensor 1B2 is no longer actuated, the relay K2 is de-
energised and the changeover contact K2 (connected in the form of a normally open
contact) opens.
The pressure sensor (programmed as normally open contact) switches off if the set
required value is not met and the relay K3 is de-energised; the changeover contact
K3 (connected in the form of a normally open contact) in current path 8 opens
thereby also causing the coil 1M2 to be de-energised.

Solutions
Name: Date:
an equipment list.
below.
1 Pressure sensor
3 Relay
1 Manifold
Equipment list

Solutions

Solutions
Name: Date:
Fundamentals: Designing the displacement-step diagram Sheet 1 of 3
– Design the displacement-step diagram for the problem definition described.
S1
1 2 3 4=1
1
1B2
1A1
0
2B2
1
2A1
0

Solutions
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the pallet loading
station.
1A1 2A1
1B2 2B2
1V2 1 1 1V3 2V2 2
2 2 1
1V1 4 2 2V1 2
1M1 1M2 2M1

5 3 1 3
1

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

Solutions
Name: Date:
Initial position
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position.
Steps 1-2
Actuation of pushbutton S1(normally open contact) causes the relay K3 to be
energised. The changeover contact K3 (connected in the form of a normally open
contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid coil 1V1 is
energised. The double solenoid valve 1V1 reverses and the cylinder 1A1 advances.
As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay
K3 is de-energised and the changeover contact K3 (connected in the form of a
normally open contact) opens.
Consequently, the coil 1M1 is also de-energised.
Steps 2-3
As soon as the cylinder 1A1 reaches the forward end position, the proximity sensor
1B2 switches and the relay K1 is energised. The changeover contact K1 (connected
in the form of a normally open contact) in current path 8 closes and the solenoid coil
2M1 of the 3/2-way solenoid valve 2V1 is energised. The valve 2V1 reverses and the
cylinder 2A1 advances.
Steps 3-4
The proximity sensor 2B2 is actuated when the cylinder 2A1 reaches the forward end
position and the relay K2 is energised. The changeover contact K2 (connected in the
form of a normally open contact) in current path 7 closes. The solenoid coil 1M2 is
now energised, thereby causing the valve 1V1 to reverse and the cylinder 1A1 to
move into the retracted end position.
Relay K1 is de-energised as soon as the cylinder 1A1 moves out of the forward end
position. The normally open contact K1 in current path 8 opens and the solenoid coil
2M1 is de-energised. The return spring switches the valve 2V1 into the initial
position again and the cylinder 2A1 moves into the retracted end position.

Solutions
Name: Date:
an equipment list.
below.
3 Relay
1 Manifold
Equipment list

Solutions

Solutions
Name: Date:
Fault finding in simple electropneuamtic circuits Sheet 1 of 4
The following fault occurs in the circuit shown below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and
remain in the forward end position.
– Describe what the potential cause of the fault could be.
1A1 2A1
1B2 2B2
1V2 1 1 1V3 2V2 2
2 2 1
1V1 4 2 2V1 2
1M1 1M2 2M1

5 3 1 3
1

Solutions
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
List of potential causes of faults
Sensor 2B2 at cylinder 2A1 maldjusted, sensor faulty
Line interruption in current path 3 (e.g. cable break or loose connection)
Line interruption in signal line of sensor 2B2, current path 4(e.g. cable break or loose connection)
Line interruption in earthing wire of 1M2, current path 7 (e.g. cable break or loose connection), valve
coil 1M2 faulty
Line interruption in earthing wire of relay K2, current path 4 (e.g. cable break or loose contact), relay
K2 faulty
Line interruption in current path 7, supply line of relay contact 14 (relay K2) or supply line of relay
contact 11 (relay K2) after valve coil 1M2 (e.g. cable break or loose contact)

Solutions
Name: Date:
A cable break occurs at the points marked in the circuit shown below.
– Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44

Solutions
Name: Date:
Fault Effect of fault
Break in earthing wire of Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Relay K1 is not energised => Relay contact in
relay K1, current path 2 current path 8 (changeover contact, connected in the form of normally open contact) does not switch =>
Piston rod of cylinder 2A1 does not move into the forward end position (remains retracted), sensor 2B2 is
not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
Break in signal wire of Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder2A1 moves into the
sensor 2B2, forward end position, sensor 2B2 is actuated => Relay K2 is not energised => Relay contact in current path 7
current path 4 (changeover contact, connected in the form of a normally open contact) does not switch => Piston rod of 1A1
and piston rod of cylinder 2A1 remain advanced.
Break in supply line of relay Current path 5 is not closed, relay K3 is not energised, no reaction in response to start signal => Piston rod
K3, current path 5 of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted.
Break in supply line of relay Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 moves into the
contact 14 forward end position, sensor 2B2 is actuated => Relay K2 is energised, relay contact in current path 7
(relay K2), current path 7 (changeover contact, connected in the form of a normally open contact) switches, but valve coil 1M2 is not
energised due to cable break => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced.
Break in earthing wire 2M1, Piston rod of cylinder 1A1 advances => Sensor 1B2 is actuated => Relay K1is energised, relay contact in
current path 8 current path 8 (changeover contact, connected in the form of a normally open contact) switches, but valve
coil 2M1 is not energised due to cable break => Piston rod of cylinder 2A1 remains retracted, piston rod of
1A1 remains advanced.

Solutions
Name: Date:
List of faults Sheet 1 of 1
Simulation of faults Cause of fault Effect of fault
Displace sensor 1B2 on cylinder Sensor 1B2 at cylinder Piston rod of cylinder 1A1 advances, sensor 1B2 is briefly actuated =>
1A1 in the retracted end position 1A1 maladjusted Piston rod of cylinder 2A1 does not move up to the forward end position,
direction sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains
advanced since 1M2 is not actuated.
Remove sensor 1B2 signal line or Cable break in signal line Piston rod of cylinder 1A1 advances => No sensor signal, i.e. sensor 1B2
displace sensor at forward end of sensor 1B2, or sensor is not actuated => Piston rod of cylinder 2A1 remains retracted, piston
position maladjusted rod of cylinder 1A1 remains advanced.
Remove sensor 2B2 signal line or Cable break in signal line Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston
displace sensor at forward end of sensor 2B2, or sensor rod of cylinder 2A1 advances into the forward end position, no sensor
position maladjusted signal, i.e. sensor 2B2 is not actuated => Piston rod of cylinder 1A1 and
piston rod of cylinder 2A1 remain advanced.
Interrupt current path 2 (e.g. Cable break in earthing Piston rod of cylinder 1A1 advances => Piston rod of cylinder 2A1
earthing wire of relay K1, signal wire of 2M1, K1 or supply remains retracted since current path 2 or current path 8 is interrupted.
line or current path 8, e.g. supply lines of relay contact
lines of relay contact 14 or relay 14/11 (relay K1)
contact 11 (relay K1), remove
earthing wire of 2M1
Interrupt earthing wire of relay K2, Cable break in earthing Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 advance and
current path 4 or current path 7, wire of 1M2, K2 or supply remain in the forward end position.
or remove relay K2 or supply lines lines of relay contact
of relay contact 14 or relay contact 14/11 (relay K2)
11 (relays K2), earthing wire of
1M2
Interrupt earthing wire of relay K3, Cable break in earthing No reaction to start signal => Piston rod of cylinder 1A1 and piston rod of
current path 5 or current path 6 wire 1M1, K3 or supply cylinder 2A1 remain retracted.
Remove 1M1 or K3 or supply line line of relay contact 14 at
of relay contact 14 at K3 K3

Solutions
Name: Date:
Notes for the trainer Sheet 1 of 1
Notes for the trainer

It is advisable to deal with this exercise after solving exercise 11 of TP 201, since the
correct configuration of circuit will then be available and in tested form.
The fault can be directly built into the circuit by the trainer (see list of simulation of
faults).
It is important to make sure that trainees proceed systematically during fault finding.
Alternative
If the circuit of exercise 11 is not available fully assembled, it is also possible to
carry out the fault finding theoretically:
• The trainer explains the fault („cylinder 1A1 advances, the circuit then comes to a
stop.“)
• Trainees then localise the fault with the help of the function chart.
• Trainees draw up a list of potential causes of faults and describe how they
proceed during the fault finding (where do you need to measure, what needs to
be checked).

Part D – Appendix
Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets Single-acting cylinder _____________________________________________ 152887

Double-acting cylinder ____________________________________________ 152888
Manifold________________________________________________________ 152896
Relay, 3 off______________________________________________________ 162241
Signal input plate, electrical ________________________________________ 162242
Proximity sensor, optical __________________________________________ 178577
Limit switch, electrical, actuated from the left__________________________ 183322
Limit switch, electrical, actuated from the right ________________________ 183345
Pressure sensor with display _______________________________________ 539757
One-way flow control valve_________________________________________ 539773
2 x 3/2-way solenoid valve with LED, normally closed ___________________ 539776
5/2-way solenoid valve with LED ____________________________________ 539777
5/2-way double solenoid valve with LED______________________________ 539778
Start-up valve with filter control valve ________________________________ 540691
Proximity sensor, electronic, with cylinder mounting ____________________ 540695
© Festo Didactic GmbH & Co. KG • 541090 D-1

Organiser
Equipment set in the organiser
All components of the equipment set for the technology package TP201 are stored in
an organiser within a Systainer. The organiser also serves as a drawer insert for use
in conjunction with our range of laboratory furniture.
D-2 © Festo Didactic GmbH & Co. KG • 541090

Assembly technology The components of the equipment set are intended for assembly on the Festo
Didactic profile plate, which consists of 14parallel T-slots, 50 mm apart.
Three variants are available for the assembly of equipment on the profile plate:
Variant A
A latching system, without auxiliary means, clamping mechanism using a lever and
spring, adjustable in the direction of the slot, for lightweight non-loadable
components.
Variant B
A rotary system, without auxiliary means, knurled nut with locking disc and T-head
bolts, vertical or horizontal alignment, for medium weight loadable components .
Variant C
A screw system, with auxiliary means, socket head screw with T-head bolt, vertical
and horizontal alignment, for heavy loadable components and equipment which is
rarely released from the profile plate.
The proven ER units on plug-in board can be attached to the profile plate with
adapters.
In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide
is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back
whereby the component can be removed from or attached to the profile plate.
Components are aligned along the slot and can be moved in the direction of the slot.
With variant B, components are attached to the profile plate by means of a T-head
bolt and blue knurled nut. A locking disc serves to fix the device in position, which
can be secured in any 90° direction. Devices can thus be mounted on the profile
plate either lengthwise or diagonally to the slot.
Once the desired locking disc position is set, the device is mounted on the profile
plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in
the slot by 90° owing to thread friction. The component is pressed against the profile
plate by further turning the knurled nut.
© Festo Didactic GmbH & Co. KG • 541090 D-3

Variant C is used for heavy or similar devices, screwed on to the profile plate only
once or very seldom. Components are attached by means of socket head screws
with internal hex and T-head bolts.
The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be
mounted on the profile plate using adapters. A black plastic adapter is required for
each locating pin. The adapters are plugged into the T-slot, positioned at intervals of
50 mm and secured by means of a 90° turn. The locating pins of the ER unit are
plugged into the adapter holes.
Plastic tubing The polyurethane tubing is particularly flexible and kink resistant.
Technical data
Pneumatics
Colour Silver metallic
Outer diameterr 4 mm
Inner diameter 2.6 mm
Minimum bending radius within

temperature range of -35 to +60°C 17 mm
Maximum operating pressure
within temperature range of -35 to +30°C 10 bar (1000 kPa)

within temperature range of +30 to +40°C 9 bar (900 kPa)
within temperature range of +40 to +60°C 7 bar (700 kPa)
Subject to change
D-4 © Festo Didactic GmbH & Co. KG • 541090

152887
Single-acting cylinder
Design The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic
retainer. The unit is mounted on the profile plate via quick release detent system
with two blue trip grip nuts (mounting alternative "B").
Function The piston rod of the single-acting cylinder moves into the forward end position
through the supply of compressed air. When the compressed air is switched off, the
piston is returned to the retracted end position via a return spring.
The magnetic field of a permanent magnet, which is attached to the cylinder piston,
actuates the proximity switches.
Technical data Pneumatic
Medium Compressed air, filtered (lubricated or unlubricated)
Design Piston cylinder
Operating pressure max. 1000 kPa (10 bar)
Piston diameter 20 mm
Max. stroke length 50 mm
Thrust at 600 kPa (6 bar) 139 N
Spring return force min. 13.6 N
Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152888
Double-acting cylinder
Design The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic
retainer. The unit is mounted on the profile plate via a quick release detent system
with two triple grip nuts (mounting alternative "B").
Function The piston rod of the double-acting cylinder is reversed by means of alternating
supply of compressed air. End position cushioning at both ends prevents a sudden
impact of the piston on the cylinder housing. The end position cushioning can be
adjusted by means of two regulating screws.
The magnetic field of a permanent magnet attached to the cylinder piston actuates
the proximity switches.
Design Piston cylinder
Operating pressure max. 1000 kPa (10 bar)
Piston diameter 20 mm
Max. stroke length 100 mm
Thrust at 600 kPa (6 bar) 189 N
Return force at 600 kPa (6 bar) 158 N
Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
152896
Manifold
Design The manifold with eight self-sealing push-in fittings is screwed on to a universal
plate. The unit is mounted on the profile plate via a quick release detent system with
blue lever (mounting alternative "A").
Function The manifold with a common P-supply enables a control system to be supplied with
compressed air eight individual connections.
Connection 1 QS-1/8-6 for plastic tubing PUN 6 x 1

8 QSK-1/8-4 for plastic tubing PUN 4 x 0.75
162241
Relay, 3-off
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
Design This component consists of three relays with connections and two bus-bars for the
power supply. All electrical connections are in the form of 4 mm sockets. The unit
can be mounted in a mounting frame or on the profile plate using four plug-in
adapters.
162241
Relay, 3-off
2 3
A1 A2 4 2 1
7 6
Function The relay consists of a coil with a core (1) and winding (3) with connection lugs (7),
an armature (4), a return spring (2) and a contact assembly with four changeover
contacts (5) and connection lugs (6). When power is applied to the coil connections,
current flows through the winding, creating a magnetic field. The armature is pulled
onto the coil core and the contact assembly is actuated. Electrical circuits are
opened or closed via this assembly.
When the electrical current is removed, the magnetic field collapses and the
armature and contact assembly are returned to their original position by a return
spring.
Note The switching status of the relays is indicated by LEDs, which are protected against
incorrect polarity.
The four changeover contacts of the contact assembly can be used as normally-open
contacts (1), normally-closed contacts (2) or changeover contacts (3).
2/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
162241
Relay, 3-off
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Example of application: Circuit diagram, electrical
+24 V 1 2 +24 V 1 2
A1 12 14 A1 12 14
K1 K1
A2 11 A2 11
Changeover switch connected as Changeover switch connected as

normally-open contact normally-closed contact
Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate
162241
Relay, 3-off
Technical data Electrical
Voltage 24 V DC
Contact assembly 4 changeover contacts
Contact rating Max. 5 A
Contact interrupt rating Max. 90 W
Pichup time 10 ms
Drop-off time 8 ms
Connections For 4 mm safety connector plug
Electromagnetic compatibility
Emitted interference tested to EN 500 81-1
Noise immunity tested to EN 500 82-1
162242
Signal input plate, electrical
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
Design This component consists of two illuminated pushbuttons in the form of momentary-
contact switches and one illuminated pushbutton in the form of a detented switch.
All electrical connections are in the form of 4 mm safety connectors. The unit can be
mounted in a mounting frame or on the profile plate using four plug-in adapters.
Function The illuminated pushbutton in the form of a detented switch consists of a contact
assembly with two normally-open contacts and two normally-closed contacts,
together with a colourless transparent pushbutton cap with a miniature lamp. The
contact assembly is actuated by pressing this cap. Electrical circuits are opened or
closed via the contact assembly. When the cap is released, the switching status is
maintained. The contact assembly is returned to its initial position by pressing the
pushbutton a second time.
The illuminated pushbuttons in the form of momentary-contact switches consist of
a contact assembly with two normally-open contacts and two normally-closed
contacts, together with a colourless transparent pushbutton cap with a miniature
lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are
opened or closed via the contact assembly. When the cap is released, the contact
assembly returns to its initial position.
162242
Signal input plate, electrical
Note When power is applied to the connections of the visual indicator, the switching
status is displayed by the built-in miniature lamp in the pushbuttons.
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Example: Circuit diagram, electrical
Voltage 24 V DC
Contact assembly 2 normally-open contacts, 2 normally-closed contacts
Power consumption (miniature lamp) 0.48 W
Connections For 4 mm safety connector plug
178577
Design The optical proximity sensor with LED and electrical connections is assembled on a
polymer assembly base. The electrical connection is effected by means of safety
connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a
quick release detent system with blue triple grip nut (mounting alternative “B”).
Function Optical proximity sensors consist of two main modules, the emitter and the receiver.
In the case of diffuse sensor, these are built into one housing. The emitter of the
diffuse sensor emits a pulsating, red light which is within the visible spectral range.
The object to be detected reflects part of the light emitted. This light is detected by a
semiconductor device in the receiver which is also built into the sensor housing and
causes a change in the switching status.
The object to be detected may be reflective, matt, transparent or opaque. All that is
needed is for a sufficiently high proportion of light to be reflected directly or
diffusely.
The operational switching distance may be varied by means of a potentiometer. The
proximity sensor has a PNP output, i.e. the signal line is switched to the positive
potential in the switched status. The switch is designed as a normally closed
contact. The connection of the load takes place between the signal output of the
proximity sensor and the load. The switching status is indicated by a yellow LED. The
sensor is protected against polarity reversal, overload and short circuit.
178577
+24V-
BN +
B
BK
BU
Note The correct polarity of the applied voltage is necessary for proper functioning. The
connections for the operating voltage are colour coded as follows: red for positive,
blue for negative and black for the signal output. The load is connected to the
switching output and the negative terminal of the current supply.
Technical Data Electrical
Switching voltage 10 – 30 V DC
Residual ripple maximum 10%
Nominal switching distance 0 to 100 mm (adjustable)
Switching frequency maximum 200 Hz
Output function Normally open contact, positive switching
Output current maximum 100 mA
Protection class IP65
Connections for 4 mm safety connector plug or 3-pin socket
Cable with 4 mm safety connector plug
Eitted interference tested to EN 500 81-1
183322
Limit switch, electrical, actuated from the left
2 4
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design A microswitch with roller lever and electrical connections is installed in a plastic
housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant “B”).
Function This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.
The switch contacts are used to open or close a circuit. The microswitch returns to
its original position when the roller lever is released.
183322
Limit switch, electrical, actuated from the left
Note The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds
are high, the limit switch should be actuated by the trip cam of a cylinder only in the
specified direction. The limit switch must not be actuated from the front.
Design Mechanically-actuated electrical microswitch in limit-switch

housing
Voltage 24 V DC
Switching frequency Max. 200 Hz
Reproducible switching accuracy 0.2 mm
Switch travel 2.7 mm
Actuation force 5N
Connection For 4 mm safety connector plug or 3-pin plug socket
183345
Limit switch, electrical, actuated from the right
2 4
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design A microswitch with roller lever and electrical connections is installed in a plastic
housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant “B”).
Function This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.
The switch contacts are used to open or close a circuit. The microswitch returns to
its original position when the roller lever is released.
183345
Limit switch, electrical, actuated from the right
Note The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds
are high, the limit switch should be actuated by the trip cam of a cylinder only in the
specified direction. The limit switch must not be actuated from the front.
Design Mechanically-actuated electrical microswitch in limit-switch

housing
Voltage 24 V DC
Switching frequency Max. 200 Hz
Reproducible switching accuracy 0.2 mm
Switch travel 2.7 mm
Actuation force 5N
Connection For 4 mm safety connector plug or 3-pin plug socket
539757
Pressure sensor with display
Design The pressure sensor with display is screwed onto the adapter plate plate. The unit is
attached via the grid system with the blue lever (assembly variant „A“).
Function The pressure sensor is a piezoresistive relative pressure transducer with integrated
amplifier and built-in temperature compensation. The pressure to be measured is
transferred onto a silicone coated piezoresistive element. The signal change
generated therein is output as a voltage or switching signal at the connector plug via
an intergrated amplifer.
539757
Pressure sensor with display
+24V-
BN
B
p BK
BU
Note The polarity of the applied voltage is to be observed for the correct functioning of
the device. The connections for the operating voltage are to be identified by colour:
Red for positive and blue for negative. The signal output is black. The load is to be
connected to the switch output and to the negative pole of the power supply.
Technical data Electrics
Switching voltage 15 – 30V DC
Residual ripple Max. 10%
Operating pressure 0 to 10 bar (0 to 1000 kPa)
Analogue output 0 to 10 V
Output function Normally open contact, positive switching
Switching current Max. 150 mA
Connection Plug M8x1
Cable With 4 mm jack plug
Emitted interference Tested to EN 500 81-1
Noise immunity Tested to EN 500 82-1
539773
One-way flow control valve
1 2
Design The adjustable one-way flow control valve is screwed into the function plate,
incorporating a straight push-in fitting. The unit is slotted into the profile plate via a
quick release detent system with a blue lever (mounting alternative “A”).
Function The one-way flow control valve consists of a combination of a flow control valve and
a non-return valve.
The non-return valve blocks the flow of air in one direction, whereby the air flows via
the flow control valve. The throttle cross section is adjustable by means of a knurled
screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the
direction of flow control on the housing. In the opposite direction, the air flow is
unrestricted via the non-return valve.
Technical Data Pneumatic
Medium Compressed air, filtered, (lubricated or unlubricated)
Design One-way flow control valve
Pressure range 20 to 1000 kPa (0.2 to 10 bar)
Standard nominal flow rate in throttled direction: 0 – 110 l/min

free flow direction: 110 l/min (Throttle open)
65 l/min (Throttle closed)
Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75
539776
2 x 3/2-way solenoid valve with LED, normally closed
1M1
1 3
1M1
Design This 3/2-way single solenoid valve with push-in fittings is attached to a function
plate which is equipped with a P port and silencer. The two electrical connections
are equipped with safety connectors. The unit is mounted on the profile plate using
a quick release detent system with a blue lever (mounting alternative "A").
Function The solenoid valve is reversed when voltage is applied to the solenoid coil (1 2)
and brought back into its initial position (1 0) by a return spring when the signal
is removed. The switching status is displayed via an LED in the terminal housing. The
valve is equipped with a manual override.
Note The solenoid coil is characterised by very low power consumption and low heat
generation. The electrical connection incorporates protection against incorrect
polarity for the LED and a protective circuit.
539776
2 x 3/2-way solenoid valve with LED, normally closed
Design Spool valve, pilot-actuated, with return spring
Pressure range 300 to 800 kPa (3 to 8 bar)
Switching time at 600 kPa (6 bar) On: 20 ms

Off: 33 ms
Standard nominal flow rate 1000 l/min
Connection QS 3 for plastic tubing PUN 4 x 0.75
Electrical
Voltage 24 V DC
Duty cycle 100 %
Connection M8x1 central plug, cable with socket and 4 mm safety plugs
539777
5/2-way single solenoid valve with LED
4 2
1M1
5 1 3
1M1
Design This 5/2-way single solenoid valve with push-in fittings is bolted onto a function
plate which is equipped with a P port and silencer. The two electrical connections
a snap-lock system with a blue lever (mounting variant "A").
Function The solenoid valve is reversed when voltage is applied to the solenoid coil (1 4)
and brought back into its initial position (1 2) by a return spring when the signal
is removed. The switching status is shown by an LED in the terminal housing. The
valve is equipped with a manual override.
generation. The electrical connection incorporates protection against incorrect
polarity for the LED and a protective circuit.
539777
5/2-way single solenoid valve with LED
Design Spool valve, pilot-actuated, with return spring
Switching time at 600 kPa (6 bar) On: 25 ms

OFF: 40 ms
Connection QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
Electrical
Voltage 24 V DC
Duty cycle 100 %
539778
5/2-way double solenoid valve with LED
4 2
1M1 1M2
5 1 3
1M1 1M2
Design This 5/2-way double solenoid valve with push-in fitting is bolted onto a function
plate which is equipped with a P port and silencer. The four electrical connections
a snap-lock system with a blue lever (mounting variant "A").
Function The double solenoid valve is reversed when voltage is applied to a solenoid coil and
remains in this switching position after the signal is removed until an opposed signal
is applied. The presence of switching signals is shown by the LEDs in the terminal
housings. The valve is equipped with a manual override.
generation. The electrical connections incorporate protection against incorrect
polarity for the LEDs and protective circuits.
539778
5/2-way double solenoid valve with LED
Design Spool valve, pilot-actuated
Switching time at 600 kPa (6 bar) 15 ms
Connection 3 QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
Electrical
Voltage 24 V DC
Duty cycle 100 %
540691
2
3
1
2
3
Design The filter regulator with pressure gauge, on/off valve, push-in fitting and quick
coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a
metal bowl guard. The unit is mounted on the profile plate by means of cheese head
screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling
socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.
Function The filter with water separator cleans the compressed air of dirt, pipe scale, rust and
condensate.
The pressure regulator adjusts the compressed air supplied to the set operating
pressure and compensates for pressure fluctuations. An arrow on the housing
indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The
pressure gauge shows the preset pressure. The on/off valve exhausts the entire
control. The 3/2-way valve is actuated via the blue sliding sleeve.
540691
Note When constructing a circuit, please ensure that the filter regulator is installed in the
vertical position. The pressure regulator is fitted with an adjusting knob, which can
be turned to set the required pressure. By sliding the adjusting knob towards the
housing, the setting can be locked.
Medium Compressed air
Design Sintered filter with water separator, diaphragm control valve
Assembly position Vertical ±5°
Standard nominal flow rate * 110 l/min
Upstream pressure 100 to 1000 kPa (1 to 10 bar)
Operating pressure 50 to 700 kPa (0.5 to 7 bar)
Connection Coupling plug for coupling socket G1/8 QS push-in fitting for
plastic tubing PUN 6 x 1
* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar),
Differential pressure: 100 kPa (1 bar).
540695
Proximity sensor, electronic, with cylinder mounting
Design The proximity sensor consists of the sensor, mounting kit and cable . The cable is
equipped with a socket and three jack plugs.
Function This proximity sensor emits an electrical signal when approaching a magnetic field
(e.g. permanent magnet on a cylinder piston). The electrical connections are
moulded into the cable. The switching status is indicated via an LED. The yellow LED
is illuminated when actuated.
+24V-
BN +
B
BK
BU
Note The polarity of the applied voltage is to be observed for the correct functioning of
the device. The wires inside the socket cable must therefore be allocated by colour:
Red (BN) for positive, blue (BU) for negative and black (BK) for the signal output. In
this case, the load (relay) is connected to the sensor and to the negative pole. The
switch is protected against reverse polarity but not against short circuit.
540695
Proximity sensor, electronic, with cylinder mounting
Technical data Electrics
Switching voltage 10 to 30 V DC
Switching current Max. 200 mA
Switching accuracy ±0.1 mm
Switching time On: 0.5 ms

Off: 0.5 ms
Connection M 8x1 plug socket for socket with cable
Cable With 4 mm jack plug
Emitted interference Tested to EN 500 81-1
Noise immunity Tested to EN 500 82-1

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541090 EN

Order No.: 541090

The copying, distribution and utilisation of this document as well as the

2 © Festo Didactic GmbH & Co. KG • 541090

Exercise 1: Realising a sorting device ____________________________________A-3

© Festo Didactic GmbH & Co. KG • 541090 3

Exercise 1: Realising of a sorting device __________________________________C-3

Organiser __________________________________________________________ D-2

4 © Festo Didactic GmbH & Co. KG • 541090

Festo Didactic’s Learning System for Automation and Technology is orientated

The technology packages deal with the following technologies: Pneumatics,

© Festo Didactic GmbH & Co. KG • 541090 5

All the training packages are of identical structure:

The hardware consists of didactically designed industrial components and systems.

6 © Festo Didactic GmbH & Co. KG • 541090

Basic Level TP201 is suitable for basic training in electropneumatic control

Advanced Level TP202 focuses on further training in electropneumatic control

Working pressure must not exceed a maximum of p = 6 bar = 600 kPa.

Optimum operational reliability is achieved if the control system is operated

© Festo Didactic GmbH & Co. KG • 541090 7

8 © Festo Didactic GmbH & Co. KG • 541090

© Festo Didactic GmbH & Co. KG • 541090 9

10 © Festo Didactic GmbH & Co. KG • 541090

The technology package TP200 consists of numerous individual training media as

Important elements of • Fixed workstation with Festo Didactic profile plate

Textbooks Basic Level TP201

Workbooks Basic Lvel TP201

Optional Teachware Sets of overhead transparencies and overhead projector

© Festo Didactic GmbH & Co. KG • 541090 11

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

IW-PEP Maintenance and servicing in control technology– pneumatic and electropneumatic

EP-AL Electropneumatics for vocational training

Information regarding further training media is available in our catalogues and on

12 © Festo Didactic GmbH & Co. KG • 541090

• To familiarise yourself with the design and mode of operation of a

© Festo Didactic GmbH & Co. KG • 541090 13

14 © Festo Didactic GmbH & Co. KG • 541090

To familiarise yourself with the design •

To familiarise yourself with the design • • •

To be able to calculate piston forces •

To familiarise yourself with the design •

To familiarise yourself with the design • •

To be able to select a solenoid valve •

To be able to identifiy and draw the •

To be able to convert solenoid valves. •

To be able to explain and design an • •

To be able to explain and design an • • •

To familiarise yourself with different • •

To familiarise yourself with logic • •

To be able to calculate electrical •

© Festo Didactic GmbH & Co. KG • 541090 15

To familiarise yourself with latching • •

To be able to explain and design an •

To be able to design a pressure- •

To familiarise yourself with the mode •

To familiarise yourself with •

To be able to realise a sequence •

To be able to detect and eliminate •

16 © Festo Didactic GmbH & Co. KG • 541090

Equipment set – Basic Level Description Order No. Quantity

5/2-way solenoid valve 539777 1

Blanking plug 153267 10