Hydraulics

Electrohydraulics

Festo worldwide

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

France
Festo Eurl
ZA des Maisons Rouges
8 rue du clos sainte Catherine
94360 Bry-sur-Marne
Tel. +33 (0) 820 20 46 40 (numro indigo),
Fax +33 (0) 820 20 46 41
E-mail: info_fr@festo.com

Austria
Festo Gesellschaft m.b.H.
Linzer Strae 227
1140 Wien
Tel. +43 (0)1 910 75-0, Fax +43 (0)1 910 75-250
E-mail: automation@festo.at
Belarus
IP Festo
Masherov avenue, 78
220035 Minsk
Tel. +375 (0)17 204 85 58,
Fax +375 (0)17 204 85 59
E-mail: info_by@festo.com
Belgium
Festo Belgium sa
Rue Colonel Bourg 101
1030 Bruxelles
Tel. +32 (0)2 702 32 11, Fax +32 (0)2 702 32 09
E-mail: info_be@festo.com
Belgium
Festo Belgium nv
Kolonel Bourgstraat 101
1030 Brussel
Tel. +32 (0)2 702 32 11, Fax +32 (0)2 702 32 09
E-mail: info_be@festo.com
Brazil
Festo Brasil Ltda
Rua Guiseppe Crespi, 76
Jd. Santa Emlia
04183-080 So Paulo / SP -Brasil
Tel. +55 (11) 5013-1600,
Fax +55 (11) 5013-1801
E-mail: linhadireta@br.festo.com
Bulgaria
Festo EOOD
1592 Soa
Bul. Christophor Kolumb 9
Tel. +359 (0)2 960 07 12,
Fax +359 (0)2 960 07 13
E-mail: info_bg@festo.com
Canada
Festo Inc.
5300 Explorer Drive
Mississauga, Ontario L4W 5G4
Tel. +1 (0)905 624 90 00,
Fax +1 (0)905 624 90 01
E-mail: info_ca@festo.com
Chile
Festo S.A.
Avenida Amrico Vespucio, 760
Pudahuel
Santiago
Tel. +56 2 690 28 00, Fax +56 2 690 28 60
E-mail: info.chile@cl.festo.com
China
Festo (China) Ltd.
1156 Yunqiao Road,
Jinqiao Export Processing Zone,
Pudong,
Shanghai 201206
Tel. +86 21 60 81 51 00, Fax +86 21 58 54 03 00
E-mail: info_cn@cn.festo.com
Colombia
Festo Ltda.
Autopista Bogot - Medelln Km 6 (costado sur)
Tenjo, Cundinamarca
Tel. +57 (1) 865 7729,
Fax +57 (1) 865 7729 Ext. 287
E-mail: mercadeo@co.festo.com
Croatia
Festo d.o.o.
Nova Cesta 181
10000 Zagreb
Tel. +385 (0)1 619 19 69,
Fax +385 (0)1 619 18 18
E-mail: info_hr@festo.com
Czech Republic
Festo, s.r.o.
Modansk 543/76
147 00 Praha 4
Tel. +420 261 09 96 11, Fax +420 241 77 33 84
E-mail: info_cz@festo.com
Denmark
Festo A/S
Islevdalvej 180
2610 Rdovre
Tel. +45 70 21 10 90, Fax +45 44 88 81 10
E-mail: info_dk@festo.com
Estonia
Festo OY AB Eesti Filiaal
A.H. Tammsaare tee 118B
12918 Tallinn
Tel. +372 666 1560, Fax +372 666 15 6
E-mail: info_ee@festo.com

Germany
Festo Didactic GmbH & Co. KG
Rechbergstr. 3
73770 Denkendorf
Germany
Tel. +49 (0)711 346 70,
Fax +49 (0)711 34 75 48 85 00
E-mail: did@de.festo.com
Germany
Festo AG & Co. KG
Postfach
73726 Esslingen
Ruiter Strae 82
73734 Esslingen
Tel. +49 (0) 711 347 0, Fax +49 (0) 711 347 2628
E-mail: info_de@festo.com
Greece
Festo Ltd.
40 Hamosternas Ave.
P.C. 11853 Athens
Tel. +30 210 341 29 00, Fax +30 210 341 29 05
E-mail: info_gr@festo.com
Hong Kong
Festo Ltd.
6/F New Timely Factory Building,
497 Castle Peak Road,
Kowloon, Hong Kong
Tel. + 852 27 43 83 79, Fax + 852 27 86 21 73
E-mail: info_hk@festo.com
Hungary
Festo Kft.
Csillaghegyi t 32-34.
1037 Budapest
Hotline +36 1 436 51 00
Tel. +36 1 436 51 11, Fax +36 1 436 51 01
E-mail: info_hu@festo.com
India
Festo Controls Private Ltd.
Festo Controls Pvt. Ltd.
35/3, Shamanna Garden
Bannerghatta Road
Bangalore 560 030
Tel. +91 (0)1800 425 0036,
Fax +91 (0)1800 121 0036
E-mail: sales_in@festo.com
Indonesia
PT. Festo
Jl. Tekno V Blok A/1 Sektor XI
Kawasan Industri BSD
Serpong -Tangerang 15314
Banten - Indonesia
Tel. +62 (0) 21 27 50 79 00,
Fax +62 (0) 21 27 50 79 98
E-mail: sales_id@festo.com

Latvia
Festo SIA
A. Deglava iela 60
1035 Riga
Tel. +371 67 57 78 64, Fax +371 67 57 79 46
E-mail: info_lv@festo.com
Lithuania
Festo, UAB
Partizan 63M
50306 Kaunas
Lietuva
Tel. +370 (8)7 32 13 14, Fax +370 (8)7 32 13 15
E-mail: info_lt@festo.com
Malaysia
Festo Sdn. Berhad
10 Persiaran Industri
Bandar Sri Damansara
Wilayah Persekutuan
52200 Kuala Lumpur
Tel. +60 (0)3 62 86 80 00,
Fax +60 (0)3 62 75 64 11
E-mail: info_my@festo.com
Mexico
Festo Pneumatic, S.A.
Av. Ceyln 3,
Col. Tequesquinhuac
54020 Tlalnepantla
Estado de Mxico
Tel. +52 (01)55 53 21 66 00,
Fax +52 (01)55 53 21 66 55
E-mail: festo.mexico@mx.festo.com
Netherlands
Festo B.V.
Schieweg 62
2627 AN Delft
Tel. +31 (0)15 251 88 99,
Fax +31 (0)15 251 88 67
E-mail: info@festo.nl
New Zealand
Festo Ltd.
20 Fisher Crescent
Mount Wellington
Auckland
Tel. +64 (0)9 574 10 94, Fax +64 (0)9 574 10 99
E-mail: info_nz@festo.com
Nigeria
Festo Automation Ltd.
Motorways Centre, First Floor, Block C
Alausa, Ikeja,
Lagos
Tel. +234 (0)1 794 78 20,
Fax +234 (0)1 555 78 94
E-mail: info@ng-festo.com
Norway
Festo AS
Ole Deviks vei 2
0666 Oslo
Tel. +47 22 72 89 50, Fax +47 22 72 89 51
E-mail: info_no@festo.com
Peru
Festo S.R.L.
Amador Merino Reyna 480
San Isidro
Lima
Tel. +51 (1) 219 69 60, Fax +51 (1) 219 69 71
E-mail: festo.peru@pe.festo.com

Iran
Festo Pneumatic S.K.
# 2, 6th street, 16th avenue,
Km 8, Special Karaj Road
P.O.Box 15815-1485
Teheran 1389793761
Tel. +98 (0)21 44 52 24 09,
Fax +98 (0)21 44 52 24 08
E-mail: Mailroom@festo.ir

Philippines
Festo Inc.
KM 18, West Service Road
South Super Highway
1700 Paranaque City
Metro Manila
Tel. +63 (2) 77 66 888, Fax +63 (2) 82 34 220/21
E-mail: info_ph@festo.com

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

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

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

Portugal
Festo Automao, Unipessoal, Lda.
Rua Manuel Pinto De Azevedo, 567
Apartado 8013
P-4109601 Porto
Contact Center: 707 20 20 43
Tel. +351 22 615 61 50, Fax +351 22 615 61 89
E-mail: info@pt.festo.com

Italy
Festo SpA
Via Enrico Fermi 36/38
20090 Assago (MI)
Tel. +39 02 45 78 81, Fax +39 02 488 06 20
E-mail: info_it@festo.com
Japan
Festo K.K.
1-26-10 Hayabuchi
Tsuzuki-ku
Yokohama 224-0025
Tel. +81 (0)45 593 5610 / -5611,
Fax +81 (0)45 593 5678
E-mail: info_jp@festo.com
Korea South
Festo Korea Co., Ltd.
Gasan Digital 1-ro
Geumcheon-gu
Seoul #153-803
Tel. +82 1666 0202, Fax +82 (0)2 864 70 40
E-mail: sales_kr@kr.festo.com

Romania
Festo S.R.L.
St. Constantin 17
010217 Bucuresti
Tel. +40(0)21 403 95 00,
Fax +40 (0)21 310 24 09
E-mail: info_ro@festo.com
Russia
OOO Festo-RF
Michurinskiy prosp., 49
119607 Moscow
Tel. +7 495 737 34 00, Fax +7 495 737 34 01
E-mail: info_ru@festo.com
Singapore
Festo Pte. Ltd.
6 Kian Teck Way
Singapore 628754
Tel. +65 62 64 01 52, Fax +65 62 61 10 26
E-mail: info@sg.festo.com

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

Fundamentals

Slovenia
Festo d.o.o. Ljubljana
IC Trzin, Blatnica 8
1236 Trzin
Tel. +386 (0)1 530 21 00,
Fax +386 (0)1 530 21 25
E-mail: info_si@festo.com
South Africa
Festo (Pty) Ltd.
22-26 Electron Avenue
P.O. Box 255
Isando 1600
Tel. +27 (0)11 971 55 00,
Fax +27 (0)11 974 21 57
E-mail: info_za@festo.com

Textbook

Spain
Festo Pneumatic, S.A.U.
Avenida Granvia, 159
Distrito Econmico Granvia L'H
08908 Hospitalet de Llobregat
Barcelona
Tel. +34 901243660, Fax +34 902243660
E-mail: info_es@festo.com
Sweden
Festo AB
Stillmansgatan 1
Box 21038
200 21 Malm
Tel. +46 (0)20 38 38 40, Fax +46 (0)40 38 38 10
E-mail: order@festo.se
Switzerland
Festo AG
Moosmattstrasse 24
8953 Dietikon ZH
Tel. +41 (0)44 744 55 44,
Fax +41 (0)44 744 55 00
E-mail: info_ch@festo.com
Taiwan
Festo Co., Ltd.
Head Ofce
9, Kung 8th Road
Linkou 2nd Industrial Zone
Linkou Dist., New Taipei City
24450 Taiwan, R.O.C.
Tel. +886 (0)2 26 01-92 81,
Fax +886 (0)2 26 01 92 86-7
E-mail: festotw@tw.festo.com

M1

M2

Thailand
Festo Ltd.
Viranuvat Building, 6th - 7th Floor.
1250 Bangna - Trad Road (Soi 34)
Bangna, Bangkok 10260
Tel. +66 2746-8700, Fax +66 2746-8370
E-mail: info_th@festo.com
Turkey
Festo San. ve Tic. A.S.
Tuzla Mermerciler Organize
Sanayi Blgesi 6/18
34956 Tuzla - Istanbul/TR
Tel. +90 (0)216 585 00 85,
Fax +90 (0)216 585 00 50
E-mail: info_tr@festo.com
Ukraine
DP Festo
ul. Borisoglebskaya,11
04070, Kiev
Tel. +380 (0)44 233 6451,
Fax +380 (0)44 463 70 96
E-mail: orders_ua@festo.com
United Kingdom
Festo Limited
Applied Automation Centre
Caswell Road
Brackmills Trading Estate
Northampton NN4 7PY
Tel. ++44 (0)1604 / 66 70 00,
Fax ++44 (0)1604 / 66 70 01
E-mail: info_gb@festo.com
United States
Festo Corporation (New York)
395 Moreland Road
P.O. Box 18023
Hauppauge, NY 11788
Call Toll-free 800/993 3786
Fax Toll-free 800/963 3786
Tel. +1(631) 435 08 00, Fax +1(631) 435 80 26
E-mail: customer.service@us.festo.com
Venezuela
Festo C.A.
Av. 23 esquina con calle 71
N 22-62, Edif. Festo.
Sector Paraso
Maracaibo - Venezuela
Tel. +58 (261) 759 11 20/759 41 20/759 44 38,
Fax +58 (261) 759 04 55
E-mail: festo@festo.com.ve
Vietnam
Festo Co Ltd
(Cong Ty TNHH FESTO)
No. 1515 1516 Van Dai Dong Street
Ward An Phu, District 2
Ho Chi Minh City
Tel. +84 (8) 62 81 44 53 4454,
Fax +84 (8) 62 81 4442
E-mail: info_vn@festo.com

Textbook

Finland
Festo Oy
Mkituvantie 9
PL 86
01511 Vantaa
Tel. +358 (09) 87 06 51,
Fax +358 (09) 87 06 52 00
E-mail: info_@festo.com

Hydraulics Electrohydraulics, Fundamentals

Argentina
Festo S.A.
Edison 2392
(1640) Martnez
Prov. Buenos Aires
Tel. +54 (011) 4717 82 00,
Fax +54 (011) 47 17 82 82
E-mail: info@ar.festo.com

Festo Didactic
574181 en

Order no.
Revision level:
Authors:
Editor:
Graphics:
Layout:

574181
08/2013
Renate Aheimer, Christine Lffler, Dieter Merkle, Georg Prede,
Klaus Rupp, Dieter Scholz, Burkhard Schrader
Frank Ebel
Doris Schwarzenberger
09/2013, Frank Ebel

Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com

Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, is prohibited. Offenders shall be held liable for damages. All rights
reserved, in particular the right to file patent, utility model and registered design applications.

Contents
Preface ________________________________________________________________________________ 10
1

The functions of a hydraulic system __________________________________________________ 11

1.1
1.2
1.3
1.4

Hydraulics what does it mean? _____________________________________________________

Stationary hydraulics ______________________________________________________________
Mobile hydraulics _________________________________________________________________
Attributes of hydraulics ____________________________________________________________

Physical fundamentals of hydraulics _________________________________________________ 15

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.13.1
2.13.2
2.14
2.15

Pressure ________________________________________________________________________
Pressure transmission _____________________________________________________________
Force transmission ________________________________________________________________
Displacement ratio ________________________________________________________________
Pressure boosting _________________________________________________________________
Volumetric flow rate _______________________________________________________________
Continuity equation _______________________________________________________________
Pressure measurement ____________________________________________________________
Temperature measurement _________________________________________________________
Volumetric flow rate measurement ___________________________________________________
Types of flow _____________________________________________________________________
Friction, heat, pressure drop ________________________________________________________
Energy and power _________________________________________________________________
Energy __________________________________________________________________________
Power __________________________________________________________________________
Cavitation _______________________________________________________________________
Throttle points ___________________________________________________________________

11
11
12
13

15
18
19
20
21
22
22
23
24
24
25
27
31
31
34
37
38

Hydraulic fluids __________________________________________________________________ 40

3.1
3.2
3.3
3.4

Functions of hydraulic fluids ________________________________________________________

Types of hydraulic fluid ____________________________________________________________
Characteristics and requirements ____________________________________________________
Viscosity ________________________________________________________________________

Components of the power supply section _____________________________________________ 47

4.1
4.2
4.3
4.4
4.5
4.5.1

Drive ___________________________________________________________________________
Pump ___________________________________________________________________________
Couplings _______________________________________________________________________
Tanks ___________________________________________________________________________
Filters ___________________________________________________________________________
Return filter ______________________________________________________________________

Festo Didactic GmbH & Co. KG 574181

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41
42
43

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48
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55
57
59

Contents

4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.6
4.7
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6

Intake filters _____________________________________________________________________

Pressure filters ___________________________________________________________________
Filter arrangement ________________________________________________________________
Bypass filtering ___________________________________________________________________
Contamination indicators ___________________________________________________________
Determining the differential pressure of a pressure filter _________________________________
Cooling _________________________________________________________________________
Heating _________________________________________________________________________
Hydraulic accumulators ____________________________________________________________
Design and mode of operation _______________________________________________________
Piston accumulators _______________________________________________________________
Diaphragm accumulators ___________________________________________________________
Bladder accumulators _____________________________________________________________
Safety regulations_________________________________________________________________
Safety Equipment _________________________________________________________________

59
60
60
63
63
64
65
66
67
67
69
70
71
72
73

Drives __________________________________________________________________________ 74

5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.2

Hydraulic cylinders ________________________________________________________________

Single-acting cylinders _____________________________________________________________
Double-acting cylinders ____________________________________________________________
End-position cushioning ____________________________________________________________
Seals ___________________________________________________________________________
Mounting options _________________________________________________________________
Exhaust _________________________________________________________________________
Characteristic data ________________________________________________________________
Resistance to buckling _____________________________________________________________
Selecting a cylinder _______________________________________________________________
Hydraulic motors _________________________________________________________________

Characteristic values and designs of hydraulic valves ___________________________________ 88

6.1
6.2
6.3
6.3.1
6.3.2
6.4
6.5

Characteristic values of valves _______________________________________________________

Actuating force ___________________________________________________________________
Designs _________________________________________________________________________
Poppet valves ____________________________________________________________________
Slide valves ______________________________________________________________________
Switching overlap _________________________________________________________________
Control edges ____________________________________________________________________

Pressure regulators _______________________________________________________________ 95

7.1
7.2

Pressure-relief valves ______________________________________________________________ 95

Pressure-reducing valves ___________________________________________________________ 97

74
74
75
78
79
80
80
80
82
84
85

88
89
89
90
91
92
94

Festo Didactic GmbH & Co. KG 574181

Contents

Directional control valves _________________________________________________________ 100

8.1
8.2
8.2.1
8.2.2
8.2.3
8.3
8.3.1
8.3.2
8.3.3
8.4
8.4.1
8.5
8.5.1
8.6
8.6.1
8.6.2
8.6.3
8.7
8.7.1
8.7.2
8.8
8.8.1
8.8.2

Functions _______________________________________________________________________
Design _________________________________________________________________________
Directional control valve designs ____________________________________________________
Connection options for directional control valves ______________________________________
Performance data for 4/3-way solenoid valves ________________________________________
Actuation methods for directional control valves _______________________________________
Manually and mechanically actuated directional control valves ___________________________
Solenoid actuated directional control valves __________________________________________
Power failures and wire breaks with solenoid actuated directional control valves ____________
2/2-way valves __________________________________________________________________
2/2-way stem actuated valve _______________________________________________________
3/2-way valves __________________________________________________________________
Directly actuated 3/2-way solenoid valve with spring return______________________________
4/2-way valves __________________________________________________________________
Transitional positions _____________________________________________________________
4/2-way hand lever valve with spring return __________________________________________
Directly actuated 4/2-way double solenoid valve with detent _____________________________
4/3-way valves __________________________________________________________________
4/3-way solenoid valve, spring centred, mid-position closed _____________________________
Influence of the mid-position _______________________________________________________
Pilot control of a directional control valve _____________________________________________
Piloted 4/3-way solenoid valve _____________________________________________________
Comparison of piloted and directly actuated solenoid valves _____________________________

Shut-off valves __________________________________________________________________ 119

9.1
9.2
9.3

Non-return valve _________________________________________________________________ 119

Piloted non-return valve ___________________________________________________________ 120
Piloted double non-return valve ____________________________________________________ 122

10

Flow control valves ______________________________________________________________ 123

10.1
10.2
10.3

Flow control and orifice valves ______________________________________________________ 123

One-way flow control valve ________________________________________________________ 126
Flow control valves _______________________________________________________________ 127

11

Proportional valves ______________________________________________________________ 132

11.1
11.1.1
11.1.2
11.1.3
11.1.4

Design and function of a proportional solenoid ________________________________________

Design of a proportional solenoid ___________________________________________________
Function of a proportional solenoid__________________________________________________
Actuation of pressure, flow control and directional control valves _________________________
Armature position control _________________________________________________________

Festo Didactic GmbH & Co. KG 574181

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100
100
102
103
103
104
105
105
106
106
107
108
109
110
110
111
112
113
115
116
116
118

132
132
132
133
134

Contents

11.2
11.2.1
11.2.2
11.3
11.3.1
11.3.2
11.3.3
11.3.4
11.4

Design and function of proportional pressure regulators ________________________________

Pressure-relief valve ______________________________________________________________
Pressure-reducing valve ___________________________________________________________
Design and function of proportional flow control valves and directional control valves ________
Proportional flow control valves ____________________________________________________
Directly actuated proportional directional control valve _________________________________
Piloted proportional directional control valve __________________________________________
Advantages and disadvantages of piloted proportional valves ____________________________
Proportional valve designs _________________________________________________________

135
135
136
137
137
137
138
139
140

12

Accessories _____________________________________________________________________ 141

12.1
12.1.1
12.1.2
12.2
12.3
12.4
12.4.1
12.4.2
12.4.3
12.5
12.6
12.6.1

Hoses and piping ________________________________________________________________

Hoses__________________________________________________________________________
Piping _________________________________________________________________________
Connecting plates ________________________________________________________________
Exhaust valves __________________________________________________________________
Pressure gauges _________________________________________________________________
Pressure gauge with Bourdon tube measuring unit _____________________________________
Pressure gauge with capsule-type or diaphragm element ________________________________
Piston-type pressure gauge ________________________________________________________
Pressure sensors ________________________________________________________________
Volumetric flow meters ___________________________________________________________
Flow meter______________________________________________________________________

13

Basic principles of electrical engineering ____________________________________________ 155

13.1
13.2
13.2.1
13.2.2
13.2.3
13.3
13.4
13.4.1
13.4.2
13.4.3
13.4.4
13.5
13.6

Direct current and alternating current ________________________________________________

Ohms law ______________________________________________________________________
Electrical conductors _____________________________________________________________
Electrical resistance ______________________________________________________________
Source voltage __________________________________________________________________
Electrical power _________________________________________________________________
The function of a solenoid _________________________________________________________
Structure of a solenoid ____________________________________________________________
Solenoid applications _____________________________________________________________
Inductive resistance with AC voltage _________________________________________________
Inductive resistance with DC voltage _________________________________________________
Function of an electrical capacitor ___________________________________________________
Function of a diode _______________________________________________________________

141
142
147
149
150
151
151
152
152
153
153
153

155
156
156
156
157
157
158
158
158
159
159
159
160

Festo Didactic GmbH & Co. KG 574181

Contents

13.7
13.7.1
13.7.2
13.7.3
13.7.4
13.7.5
13.7.6
13.7.7

Measurements in an electrical circuit ________________________________________________

Definition: measure ______________________________________________________________
Safety instructions _______________________________________________________________
Procedure for performing measurements in the electrical circuit __________________________
Voltage measurement ____________________________________________________________
Current measurement_____________________________________________________________
Resistance measurement __________________________________________________________
Error sources while performing measurements in an electrical circuit ______________________

14

Electrical components ____________________________________________________________ 165

14.1
14.2
14.2.1
14.2.2
14.2.3
14.3
14.3.1
14.3.2
14.3.3
14.4
14.4.1
14.4.2
14.5
14.5.1
14.6
14.7
14.8

Power pack _____________________________________________________________________

Electrical input elements __________________________________________________________
NO contact _____________________________________________________________________
NC contact ______________________________________________________________________
Changeover contact ______________________________________________________________
Sensors ________________________________________________________________________
Limit switches ___________________________________________________________________
Proximity sensors ________________________________________________________________
Pressure switches ________________________________________________________________
Relays and contactors ____________________________________________________________
Relays _________________________________________________________________________
Contactors ______________________________________________________________________
Programmable logic controllers _____________________________________________________
Design and function of a PLC _______________________________________________________
Overall layout of the signal control section ____________________________________________
Solenoids ______________________________________________________________________
Spark arresting for solenoid valves __________________________________________________

15

Workflow descriptions for processing machines and production systems __________________ 180

15.1
15.1.1
15.1.2
15.2
15.2.1
15.2.2
15.2.3
15.2.4
15.2.5
15.2.6
15.2.7

Function diagrams _______________________________________________________________

Scope of the function diagram ______________________________________________________
Displacement-step diagrams _______________________________________________________
Sequence description by means of GRAFCET per EN 60848_______________________________
The basic principle of a GRAFCET ____________________________________________________
Steps __________________________________________________________________________
Transition condition ______________________________________________________________
Actions_________________________________________________________________________
Sequence selection ______________________________________________________________
Returns and jumps _______________________________________________________________
Structuring of GRAFCETs __________________________________________________________

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161
161
161
162
162
163
163
164

165
165
166
166
166
167
167
167
171
172
173
174
175
176
176
177
179

180
180
181
182
182
182
183
184
187
188
188

Contents

16

Design of circuit diagrams_________________________________________________________ 189

16.1
16.1.1
16.1.2
16.1.3
16.1.4
16.2
16.2.1
16.2.2
16.2.3
16.2.4
16.3
16.3.1
16.3.2

Hydraulic circuit diagrams _________________________________________________________

Arrangement of circuit symbols in the hydraulic circuit diagram ___________________________
Position of cylinders and directional control valves _____________________________________
Identification key for components ___________________________________________________
Technical information _____________________________________________________________
Electrical circuit diagram __________________________________________________________
Electrical circuit diagram of an electro-hydraulic control system___________________________
Identification of components _______________________________________________________
Logic element tables for relays and contactors_________________________________________
Actuated contacts and sensors _____________________________________________________
Terminal connection diagram_______________________________________________________
Structure of a terminal connection diagram ___________________________________________
Wiring for an electro-hydraulic control system _________________________________________

189
189
191
191
193
194
195
196
197
198
198
201
203

17

Safety measures for electro-hydraulic control systems _________________________________ 204

17.1
17.2
17.2.1
17.2.2
17.2.3
17.3
17.3.1
17.3.2
17.3.3
17.4
17.4.1
17.4.2
17.4.3
17.5
17.5.1
17.6
17.6.1
17.6.2
17.6.3

Hazards and protective measures ___________________________________________________

Effects of electric current on the human body__________________________________________
Effects of electric current __________________________________________________________
Electrical resistance of the human body ______________________________________________
Variables influencing the risk of accident _____________________________________________
Protective measures against accidents with electric current ______________________________
Protection against direct contact ____________________________________________________
Earthing ________________________________________________________________________
Protective extra-low voltage _______________________________________________________
Control panel and indicators _______________________________________________________
Mains switch ____________________________________________________________________
Emergency stop _________________________________________________________________
Control elements for an electro-hydraulic control systems _______________________________
Protecting electrical equipment against environment influences __________________________
Identification of the degree of protection _____________________________________________
Safety principles for electro-hydraulic systems ________________________________________
Layout of an electro-hydraulic system ________________________________________________
Commissioning an electro-hydraulic system ___________________________________________
Repair and maintenance of an electro-hydraulic system _________________________________

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207
208
208
208
208
209
209
209
210
212
213
214
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18

Circuit symbols __________________________________________________________________ 216

18.1
Circuit symbols for hydraulic components ____________________________________________
18.1.1 Circuit symbols for hydro pumps and hydraulic motors __________________________________
18.1.2 Circuit symbols for valves__________________________________________________________
18.1.3 Circuit symbols for directional control valves __________________________________________
18.1.4 Circuit symbols for actuation methods _______________________________________________
18.1.5 Circuit symbols for pressure regulators ______________________________________________
18.1.6 Circuit symbols for flow control valves _______________________________________________
18.1.7 Circuit symbols for shut-off valves___________________________________________________
18.1.8 Circuit symbols for cylinders _______________________________________________________
18.1.9 Circuit symbols for other components ________________________________________________
18.1.10 Measuring devices _______________________________________________________________
18.2
Circuit symbols for electrical components ____________________________________________
18.2.1 Circuit symbols for basic functions __________________________________________________
18.2.2 Circuit symbols for electromechanical drives __________________________________________
18.2.3 Circuit symbols for relays and contactors _____________________________________________
18.2.4 Circuit symbols for sensors ________________________________________________________

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216
217
217
219
220
220
221
221
222
223
223
223
225
226
226

Standards _____________________________________________________________________________ 227

Index _________________________________________________________________________________ 228

Festo Didactic GmbH & Co. KG 574181

Preface
Hydraulics is the study of the flow characteristics of fluids. This manual places emphasis on the generation
of forces and motion with the help of fluids. Hydraulic fluid is the transmission medium in the field of
hydraulics.
Hydraulics and electro-hydraulics are successfully used in many areas of industrial automation. For
example, woodworking machines, machine tools, processing systems, presses, plastics processing
machines and conveyor systems are operated all over the world with electro-hydraulic control systems.
Electro-hydraulic control systems are used for many applications in the field of mobile hydraulics as well, for
instance in farm vehicles, road construction vehicles and municipal vehicles.
As an introduction to this subject matter, this manual first of all examines the design and function of the
components which are used to set up hydraulic and electro-hydraulic control systems. The following
chapters describe operating sequences, the layout of circuit diagrams and safety measures.
Changing requirements and technical developments have dramatically altered the appearance of control
systems. The keywords bus networking and proportional hydraulics are mentioned here to mention just
two examples. Close-knit interaction of fluid engineering with microelectronics, sensor technology and
information technology results in numerous innovations in the field of oil-hydraulic drives and control
systems.
We invite readers of this manual to send us tips, feedback and suggestions for improvement.
Please send your comments and suggestions to did@de.festo.com,
or to Festo Didactic GmbH & Co. KG, P.O. Box 10 07 10, D-73707 Esslingen, Germany.

The authors

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1 The functions of a hydraulic system

1.1 Hydraulics what does it mean?
Hydraulic systems are used in modern production facilities and manufacturing equipment.
Hydraulics is understood as the generation of force and motion with the help of hydraulic fluid. The
hydraulic fluid is the energy transmission medium.

The importance of hydraulics in automation technology is a reflection of its diverse range of applications.
Basically, we differentiate between:
Stationary hydraulics
Mobile hydraulics
As opposed to stationary hydraulics, which is permanently installed at a given location, mobile hydraulics
travels on wheels or treads. One of the characteristic features of mobile hydraulics is that the valves are
frequently directly actuated by hand. In contrast, solenoid valves are used primarily for stationary
hydraulics.
Hydraulics are also used in shipbuilding, mining and aviation technology. Aviation hydraulics plays a special
role, because safety is of utmost important in this area. In order to illustrate the various functions which can
be fulfilled by hydraulics, a number of typical applications are included as examples in the following pages.

1.2 Stationary hydraulics

The following fields of application are significant in the area of stationary hydraulics:
Manufacturing and assembly machines
Injection moulding machines
Transfer lines
Mill trains
Hoists and conveyors
Lifts
Presses
A typical area of application is machine tool manufacturing.

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1 The functions of a hydraulic system

Figure 1.1: Lathe, press with overhead tank

Tools and workpieces are hydraulically clamped in modern CNC machine tools. Feed units and spindle drives
may also be designed with hydraulic technology.

1.3 Mobile hydraulics

Fields of application for mobile hydraulics include:
Construction machines
Dump trucks, gripper arms, loading platforms
Hoists and conveyors
Farm machinery
Hydraulics is used for many applications in the field of construction machinery. In the case of the excavator,
for example, travelling motion, as well as all working motion such as lifting, gripping, swivelling etc., is
powered by means of hydraulics.
Working motion which is executed in straight lines is generated by linear drives (cylinders), and rotary
motion is executed by means of rotary drives (motors, semi-rotary drives).

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1 The functions of a hydraulic system

Figure 1.2: Mobile hydraulics, excavator

1.4 Attributes of hydraulics

Advantages of hydraulics

Disadvantage of hydraulics

Transmission of great forces through the use of small

components, i.e. high power density

Environmental contamination due to oil leaks (fire hazard, danger

of accident)

Accurate positioning

Susceptible to contamination

Start-up from standstill under maximum load

Danger due to high pressure (cutting jet)

Gentle work and reversing

Temperature sensitive (viscosity changes)

Good controllability and adjustability

Unfavourable degree of efficiency

Favourable heat dissipation

Uniform, load-independent motion, because fluids are hardly
compressible at all

Table 1.1: Hydraulics advantages and disadvantages

There are other technologies in addition to hydraulics, by means of which forces, motion and signals can be
generated in the field of control technology:
Mechanical
Electrical
Pneumatic

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1 The functions of a hydraulic system

The fact that each technology has its own preferred range of applications must be taken into consideration.
A comparison of typical data for the three most widely used technologies electrical, pneumatic and
hydraulic is provided in Table 1.2.
Electrical

Hydraulic

Pneumatic

Leakage

Contamination

No disadvantages except loss

of energy

Environmental influences

Danger of explosion in certain

area, temperature sensitive

Susceptible to temperature

Explosion-proof, temperature
sensitive

Difficult, only in small

Limited, with the help of gases

Lightweight

Energy storage

fluctuation, fire hazard in the

event of leakage

quantities with batteries

Energy transmission

Unlimited, with loss of energy

Up to 100 m
flow velocity v = 2 to 6 m/s

Up to 1000 m
flow velocity v = 20 to 40 m/s

Operating speed

v = 0.5 m/s

v = 1.5 m/s

Energy costs

Minimal

High

Very high

Linear motion

Difficult and expensive, small

Easily accomplished with

Easily accomplished with

forces, speed can only be

controlled at great expense

cylinders, good controllability

of speed, very high forces

cylinders, limited forces, speed

is very load-dependent

Rotary motion

Easy and powerful

Easy, high torque values, low

rotational speeds

Easy, not very powerful, high

rotational speeds

Positioning accuracy

Accuracies of down to

Depending on how much is

Accuracies of down to 0.1 mm

0.05 mm and better can be

achieved

invested, accuracies of down to

are possible without load

reversals

Very good values can be

Good because oil can hardly be

compressed at all

Poor because air is

compressible

Not overload-proof, poor

Overload-proof, very high

Overload-proof, force limited by

degree of efficiency due to

forces can be generated with

compressed air and cylinder

downstream mechanical

high system pressures of up to

elements, very high forces can

be achieved

600 bar
(F < 3000 kN)

diameter
(F < 30 kN to 6 bar)

Rigidity

achieved thanks to

0.05 mm and better can be

achieved

intermediate mechanical
elements
Forces

Table 1.2: Comparison, electrical hydraulic pneumatic

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