Basic Level of Electro Pneumatics

Electropneumatics
Advanced level
Workbook
TP 202
With CD-ROM
+24 V 8 9 10 11 12 13 14 15 16 17
... ...
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 22 24
K1 K6 K2 K7 K4 K8 K3 K9 K1 K10
11 11 11 11 11 11 11 11 21 21
12 14
K5
11
12 14 22 24 22 24 22 24 22 24
K10 K6 K7 K8 K9
11 21 21 21 21
A1 A1 A1 A1 A1
K6 K7 K8 K9 K10
A2 A2 A2 A2 A2
... ...
0V 12 12 12 12 12
11 14 .9 11 14 .11 11 14 .13 11 14 .15 11 14 .8
22 22 22 22 22
21 24 .10 21 24 .12 21 24 .14 21 24 .16 21 24 .17
32 32 32 32 32
31 34 .18 31 34 .18 31 34 .19 31 34 .20 31 34 .21
42 42 42 42 42
41 44 41 44 .19 41 44 .20 41 44 .21 41 44
1A1+ 2A1+ 2A1- 1A1-
Festo Didactic
541091 EN
Order No.: 541091
Edition: 04/2012
Authors: W. Haring, M. Metzger, R.-C. Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 09/2015 Susanne Durz
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

All rights reserved.
+49 711 3467-0 www.festo-didactic.com
+49 711 34754-88500 did@de.festo.com
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
• The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her
own training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical
colleges and training centres, the right of use shall also include use by school and college students and
trainees at the purchaser's site/location for teaching purposes.
• The right of use shall in all cases exclude the right to publish the copyright material or to make this
available for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow
access by a wide variety of users, including those outside of the purchaser's site/location.
• Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part,
shall require the prior consent of Festo Didactic.
Table of contents
Preface ____________________________________________________________________________________ V
Introduction _______________________________________________________________________________ VII
Work instructions and safety precautions _____________________________________________________ VIII
Technology package for electro-pneumatics (TP 200) _____________________________________________ X
Learning objectives for the advanced level (TP 202) ______________________________________________ XI
Allocation of learning objectives per exercise ___________________________________________________ XII
Equipment set for the advanced level (TP 202) _________________________________________________ XIV
Allocation of components per exercise ________________________________________________________ XVII
Tools for the trainer ______________________________________________________________________ XVIII
Structure of the exercises _________________________________________________________________ XVIII
Designations of the components_____________________________________________________________ XIX
CD-ROM contents _________________________________________________________________________ XIX
Learning goals for the basic level (TP 201) _____________________________________________________ XXI
Solutions
Exercise 1: Implementing a diverting device _____________________________________________________ 1

Exercise 2: Placing beverage bottles __________________________________________________________ 11
Exercise 3: Implementing a sorting station _____________________________________________________ 19
Exercise 4: Machining key blanks _____________________________________________________________ 31
Exercise 5: Bending mounting brackets ________________________________________________________ 41
Exercise 6: Sorting out empty jars from a filling system ___________________________________________ 51
Exercise 7: Bonding components _____________________________________________________________ 61
Exercise 8: Selecting operating modes _________________________________________________________ 69
Exercise 9: Machining key blanks with emergency stop function ___________________________________ 79
Exercise 10: Bending mounting brackets with emergency stop function _____________________________ 89
Exercise 11: Transporting chocolate bars with emergency stop function _____________________________ 97
Exercise 12: Eliminating a malfunction at a machining station ____________________________________ 107
© Festo Didactic 541091 III

Exercises

IV © Festo Didactic 541091

Use for intended purpose
The training package for electropneumatics may only be used:

• For its intended purpose in teaching and training applications
• When its safety functions are in flawless condition
The components included in the training package are laid out in accordance with the latest technology, as
well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and
the components may be impaired, if they are used improperly.
The training system from Festo Didactic has been developed and manufactured exclusively for training and
vocational education in the field of automation technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment sets in situations which serve any
purpose other than training and/or vocational education, unless such damages have been caused by Festo
Didactic due to malicious intent or gross negligence.
© Festo Didactic 541091 V

Preface
Festo Didactic’s training system for automation technology is geared towards various educational
backgrounds and vocational requirements. The training system is therefore broken down as follows:
• Technology-oriented training packages
• Mechatronics and factory automation
• Process automation and control technology
• Robotino® – training and research with mobile robots
• Hybrid learning factories
The technology packages deal with various technologies including pneumatics, electro-pneumatics,
hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,
electrical engineering and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual packages, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.
VI © Festo Didactic 541091

All training modules have the same structure:
• Hardware
• Teachware
• Software
• Seminars
The hardware is comprised of industrial components and systems that are specially designed for training
purposes.
The structure of the teachware corresponds to that of the hardware. It includes:

• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, supplementary instructions and solutions)
• Transparencies and videos (for dynamic instruction)
The teaching and learning media are available in several languages. They’re intended for use in classroom
instruction, but are also suitable for self-study.
Where software is concerned, computer training programs, as well as simulation, visualisation, project
engineering, design engineering and programming software, are made available.
A wide range of seminar offerings covering the contents of the training packages round off the programme
for training and vocational education.
If you have any suggestions or feedback about this manual,

please send us an e-mail at did@de.festo.com.
The authors and Festo Didactic look forward to your feedback.
© Festo Didactic 541091 VII

Introduction
This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic.
This system provides a solid basis for practice-oriented vocational and further training. Technology package
TP 200 is comprised exclusively of electropneumatic control systems.
Advanced Level TP 202 focuses on further training in electropneumatic control technology. The two
equipment sets enable you to construct complex combinational circuits with logic operations of input and
output signals and program controls
Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate.
A short-circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is used for DC
voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar (800 kPa) can be used for
compressed air supply.
Optimum operational reliability is achieved if the control system is operated unlubricated at a working
pressure of p = 5 bar = 500 kPa.
The equipment set of Basic Level TP 201 is used to construct complete control systems for all of the 12
problem definitions. The theoretical fundamentals to help you understand this collection of exercises can be
found in the
• textbook Electropneumatics
Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices,
etc.).
VIII © Festo Didactic 541091

Work instructions and safety precautions
General
• Trainees should only work with the circuits under the supervision of a trainer.
• Observe specifications included in the data sheets for the individual components and in particular all
safety instructions!
• Faults which may impair safety must not be generated in the training environment and must be
eliminated immediately.
Mechanical setup
• Mount all the components securely onto the profile plate.
• Adhere to instructions regarding positioning of the components.
Electrical setup
• Use low voltage only (max. 24 V DC).
• Electrical connections must only be established and interrupted in the absence of voltage!
• Only use connecting cables with safety plugs for electrical connections.
• Only pull the plug when disconnecting connecting cables – never pull the cable.
Pneumatics
• Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
• Do not switch on the compressed air until all of the tubing connections have been completed and
secured.
• Do not disconnect tubing while under pressure.
• Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
• Danger of accident due to tubing slipping off!
– Use shortest possible tubing connections.
– Wear safety glasses.
– In the event that tubing slips off:
Switch compressed air supply off immediately.
• Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
• Switch compressed air supply off before dismantling the circuit.
• Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.
© Festo Didactic 541091 IX

Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
• Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply
clip the components into the slots on the profile plate. Release the components from the slots by
turning the blue lever.
• Variant B, bolt system
Components with medium load capacity (e.g. pneumatic cylinders). These components are clamped to
the profile plate with T-head bolts. The blue, knurled nut is used for clamping and loosening.
• Variant C, screw system
For components with high load capacity and components which are seldom removed from the profile
plate (e.g. on-off valve with filter regulator). The components are secured with socket head screws and
T-head bolts.
X © Festo Didactic 541091

Technology package for electro-pneumatics (TP 200)
The TP 200 technology package consists of a multitude of training materials and seminars. The subject
matter of this package is electro-pneumatic controllers. The individual components included in the TP 200
technology package can also be included in other modules.
Important elements of the TP 200

• Permanent workstation with Festo Didactic profile plate
• Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)
• Equipment sets or individual components
• Visual training materials
• Practical training models
• Complete laboratory setups
Training documentation
Textbooks TP 201 basic level

Fundamentals of pneumatic control technology
Maintenance of pneumatic components and systems
Workbooks TP 201 basic level

TP 202 advanced level
Optional teachware Set of transparencies and overhead projector

Magnetic symbols, drawing template
Electro-pneumatics WBT, pneumatics WBT
Electrical engineering WBTs 1 and 2, electronics WBTs 1 and 2
Set of cutaway models with storage case
FluidSIM® Pneumatik simulation software
Seminars
P100 Basic pneumatics knowledge for machine operators
P111 Fundamentals of pneumatics and electro-pneumatics
P121 Maintenance and troubleshooting for pneumatic and electro-pneumatic systems
P-OP Tracking down waste – economic use of pneumatics
P-NEU Pneumatics refresher and update
IW-PEP Repair and maintenance in the field of control technology – pneumatic and electro-pneumatic systems
P-AL Pneumatics for vocational education
P-AZUBI Pneumatics and electro-pneumatics for trainees
Please refer to the current seminar schedule for event locations, dates and prices.
You’ll find further training materials in our catalogue and on the Internet. The training system for automation
technology is continuously updated and expanded. Transparency sets, videos, CD-ROMs and DVDs, as well
as textbooks, are offered in several languages.
© Festo Didactic 541091 XI

Learning objectives for the advanced level (TP 202)
• Become familiar with the setup and function of valve terminals.

• Be able to use valve terminals in accordance with specified requirements.
• Be able to create a displacement-step diagram for sequence controls.
• Be able to convert a function chart into a GRAFCET chart.
• Be able to resolve overlapping signals in sequence controls using the group method.
• Recognise overlapping signals in sequence controls.
• Be able to setup a step sequence using valves with spring return.
• Be able to setup a step sequence using double pilot valves.
• Become familiar with the modes of operation of various proximity switches.
• Be able to select proximity switches which are appropriate for the conditions.
• Become familiar with logic operations and implement them.
• Become familiar with the setup and function of a pneumatic-electric converter.
• Become familiar with options for querying pressure and time in electro-pneumatic controllers.
• Become familiar with the possible uses of an on-delay timing relay.
• Become familiar with operating modes and learn to set up circuits with which single cycle and
continuous cycle operating modes can be implemented.
• Become familiar with the function of an electrical preset counter and learn to use it in circuits.
• Be able to develop and set up the emergency stop function for a controller using valves with spring
return.
• Be able to develop and set up the emergency stop function for a controller using double pilot valves.
• Be able to develop and set up a specified motion sequence in the event of an emergency stop.
• Be able to set up the following emergency stop condition: “cylinder remains in its momentary position
in the event of an emergency stop”.
• Become familiar with the setup and mode of operation of a 5/3-way solenoid valve.
• Be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.
• Be able to integrate the reset operating mode into a controller.
• Learn to detect and eliminate errors in complex electro-pneumatic controllers.
XII © Festo Didactic 541091

Allocation of learning objectives per exercise
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning objectives
Become familiar with the setup and function of valve • •

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

specified requirements.
Be able to resolve overlapping signals in sequence •

controls using the group method.
Be able to create a displacement-step diagram for • • •

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

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

spring return.
Recognise overlapping signals in sequence controls. •
Be able to setup a step sequence using double pilot •

valves.
Become familiar with the modes of operation of •

various proximity switches.
Be able to select proximity switches which are •

appropriate for the conditions.
Become familiar with logic operations and implement •

them.
Become familiar with options for querying pressure •

and time in electro-pneumatic controllers.
Become familiar with the setup and function of a •

pneumatic-electric converter.
Become familiar with the possible uses of an on-delay •

timing relay.
© Festo Didactic 541091 XIII

Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning goals
Become familiar with operating modes and learn to set • •

up circuits with which single cycle and continuous
cycle operating modes can be implemented.
Become familiar with the function of an electrical •

preset counter and learn to use it in circuits.
Be able to develop and set up the emergency stop •

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

function for a controller using double pilot valves.
Be able to develop and set up a specified motion •

sequence in the event of an emergency stop.
Be able to set up the following emergency stop •

condition: “cylinder remains in its momentary position
in the event of an emergency stop”.
Become familiar with the setup and mode of operation •

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

way solenoid valves.
Be able to integrate the reset operating mode into a •

controller.
Be able to detect and eliminate errors in complex •

electro-pneumatic controllers.
XIV © Festo Didactic 541091

Equipment set for the advanced level (TP 202)
The equipment set for the advanced level has been put together for vocational training in the field of electro-
pneumatic control technology. The two equipment sets (TP 201 and TP 202) include components which are
necessary for mastering the predefined learning objectives and can be supplemented with other equipment
sets for the training system for automation technology as desired.
Equipment set for the advanced level (TP 202, order no. 540713)
Designation Order no. Quantity
Proximity switch, inductive 548643 1
Proximity switch, capacitive 548651 1
Emergency-stop button 183347 1
Relay, 3-way 162241 2
Non-return valve, piloted 540715 2
Signal input, electrical 162242 1
Valve terminal with 4 valve slices (MMJJ) 540696 1
Preset counter, electrical 1677856 1
Time relay, 2-way 162243 1
© Festo Didactic 541091 XV

Equipment set symbols
Designation Symbol
Relay, 3-way
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 21
14 22
13 21
14 22
13 21
14 22
13 21
14 22
XVI © Festo Didactic 541091

Designation Symbol
Time relay, 2-way
17 27 35 45
A1
with switch-on delay

A2
18 28 36 46
17 27 35 45
A1
with switch-off delay

A2
18 28 36 46
Preset counter, electrical
A1 1 R1
A2 R2
4 2
Proximity switch, inductive
Proximity switch, capacitive
Emergency-stop button
13 21
14 22
Non-return valve, piloted

2
1 21
© Festo Didactic 541091 XVII

Allocation of components per exercise
TP 202 equipment set
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Component
Proximity switch, inductive 1
Proximity switch, capacitive 1
Emergency-stop button 1 1 1
Relay 2 6 6 6 6 6 4 5 6 6 6 6
Pushbutton, electrical, normally open 2 1 1 1 1 1 1 2 1 3 1
Pushbutton, electrical, normally closed 1
Non-return valve, piloted 2
Valve terminal with 4 valve slices (MMJJ) 1 1 1 1 1 1 1 1 1 1 1 1
Preset counter, electrical 1
Time relay, 2-way 1
XVIII © Festo Didactic 541091

Tools for the trainer
Learning objectives
The basic learning objectives for these exercises are the systematic drafting of circuit diagrams, as well as
the practical setup of the controller on the profile plate. This direct interaction involving both theory and
practice ensures faster progress and longer-lasting learning. Concrete, individual learning objectives are
assigned to each exercise. Important learning objectives are in parentheses in the revision sections.
Required time
The time required for working through the exercises depends on the student’s previous knowledge of the
subject matter. For a skilled labourer in the field of metalworking or electrical installation the time required
is approx. 2 weeks. For a technician or engineer it is approx. 1 week.
Equipment set elements

The exercise book and the equipment set match each other. For all 12 exercises, you’ll need the components
included in the equipment set for the TP 201 basic level.
Each exercise in the basic level can be set up on a profile plate.
Structure of the exercises
All 12 exercises in part A have the same structure and are broken down into:
• Title
• Learning objectives
• Presentation of the problem
• Layout
• Parameters
• Project assignment
• Worksheets
The trainer’s manual includes the solutions for all 12 exercises.
© Festo Didactic 541091 XIX

Designations of the components
Pneumatic components are designated in circuit diagrams in accordance with DIN ISO 1219 2. All the
components included in any given circuit have the same primary identifying number. Letters are assigned
depending on each respective type of component. Consecutive numbers are assigned if several components
of the same type are included within a single circuit. Pressure lines are designated with a P and are
numbered separately.
Drives: 1A1, 2A1, 2A2 ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
Sensors: 1B1, 1B2 ...
Signal inputs: 1S1, 1S2 ...
Accessories: 0Z1, 0Z2, 1Z1 ...
Pressure lines: P1, P2 ...
CD-ROM contents
The CD-ROM supplied provides you with additional media. The contents of parts A (exercises) and C
(solutions) have been saved as PDF files.
The CD-ROM contains the following folders:
• Demo
• FluidSIM® circuit diagrams
• Industrial applications
• Presentations
• Videos
Demo
A demo version of the FluidSIM® pneumatics software package is included on the CD-ROM. This demo
version is also suitable for testing controllers developed by the user.
FluidSIM® circuit diagrams

The FluidSIM® circuit diagrams for all 12 exercises included in the technology package are contained in this
directory.
XX © Festo Didactic 541091

Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks or to supplement project presentations.
Presentations
This directory contains short presentations for the components included in the technology package. These
can be used, for example, to create project presentations.
Videos
Several short videos of industrial applications in their actual environments round off the media provided
with the technology package.
© Festo Didactic 541091 XXI

Learning goals for the basic level (TP 201)
• Become familiar with the setup and mode of operation of a single-acting cylinder.
• Become familiar with the setup and mode of operation of a double-acting cylinder.
• Be able to calculate piston forces based on specified values.
• Become familiar with the setup and mode of operation of a 3/2-way solenoid valve.
• Become familiar with the setup and mode of operation of a double solenoid valve.
• Be able to select solenoid valves based on the specified requirements.
• Be able to recognise and sketch the various types of actuation for directional control valves.
• Be able to convert solenoid valves.
• Be able to explain and set up direct actuation.
• Be able to explain and set up indirect actuation.
• Become familiar with logic operations and set them up.
• Become familiar with various types of end-position control and learn to select the appropriate type.
• Be able to calculate characteristic electrical values.
• Become familiar with latching circuits with varying performance features.
• Be able to explain and set up an electrical latching circuit with dominant breaking signal.
• Be able to set up a pressure dependent controller.
• Become familiar with the setup and mode of operation of magnetic proximity switches.
• Become familiar with displacement-step diagrams and learn to create them for specific problems.
• Be able to implement sequence control with two cylinders.
• Be able to detect and eliminate errors in simple electro-pneumatic controllers.
XXII © Festo Didactic 541091

TP 201 equipment set
Designation Order no. Quantity
2 x 3/2-way solenoid valve, normally closed 567198 1
5/2-way double solenoid valve 567200 2
5/2-way solenoid valve 567199 1
Blanking plug 153267 10
Double-acting cylinder 152888 2
One-way flow control valve 193967 4
Pressure sensor 572745 1
Single-acting cylinder 152887 1
On-off valve with filter regulator 540691 1
Limit switch, electrical, actuated from left 183322 1
Limit switch, electrical, actuated from right 183345 1
Plastic tubing, 4 x 0.75, 10 m 151496 2
Proximity switch, electronic 540695 2
Proximity switch, optical 572744 1
Relay, 3-way 162241 2
Signal input, electrical 162242 1
Push-in sleeve 153251 10
Push-in T-connector 153128 20
Distributor block 152896 1
© Festo Didactic 541091 XXIII

XXIV © Festo Didactic 541091
Contents
Solutions

© Festo Didactic 541091 XXV

XXVI © Festo Didactic 541091
Exercise 1:
Implementing a diverting device
Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of valve terminals.
• You’ll be able to use valve terminals in accordance with specified requirements.
Presentation of the problem

Beverage bottles will be diverted from one conveyor to another by means of a diverting device. The diverting
panel is advanced when one of the pushbuttons is activated. The bottle is transferred and transported in the
opposite direction. The diverting panel is returned to its initial position when another pushbutton is
activated.
Layout
Diverting device for beverage bottles
© Festo Didactic 541091 1

Exercise 1: Implementing a diverting device
Parameters
• A double-acting cylinder will be used.
• The cylinder will be controlled indirectly via pushbutton.
• In the event of a power failure, the cylinder’s piston rod should remain in its current position.
Project assignment
1. Answer the questions and complete the tasks relating to the learning content.
2. Draw the pneumatic and electrical circuit diagrams.
3. Create an equipment list.
4. Set up the pneumatic and electrical circuits.
5. Check the circuit sequence.
Control sequence
1. Cylinder 1A1 is in the rear end-position.
2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the cylinder travels
to the front end-position.
3. After activating pushbutton S2, 5/2-way double solenoid valve 1V1 is reversed again and the cylinder
travels to the rear end-position.
2 © Festo Didactic 541091

Fundamentals: installation
The layout, tubing and wiring of the components of an electro-pneumatic controller should be selected so
that the total costs for the components, installation and maintenance are as low as possible. With regard to
wiring, selection is made between:
• Conventional wiring technology, e.g. terminal strips
• Modern installation concepts, e.g. wiring with multi-pin plug connection
With regard to layout and the number of drives, as well as tubing, a selection is made between:
• Individual mounting for solenoid operated directional control valves
• Block-type mounting (manifold block or valve terminal)
Comparison of required tubing connections
– Compare the concepts listed above using the controller for this exercise as an example with regard to
minimising tubing connections.
Note
Use the individual valves from TP 201 and the MPA valve terminal from TP 202, as well as the
associated technical descriptions.
Components Individual mounting of Block-type mounting of Savings with block-type

directional control valves directional control valves mounting
Tubing
Number of compressed air 1 0 1

distributors
Number of tubes for supplying 1 0 1

compressed air distributor
Number of tubes for compressed 3 1 2

air supply to the control loops
Number of tubes between 6 6 -

directional control valves and
cylinder
Silencers
Number of silencers for control 6 1 5

loops

Reducing required tube connections
– Which concept enables a reduction of the required tubing connections? Place an X next to your selection
and justify your decision.
Individual mounting of Block-type mounting Reason

directional control of directional control
valves valves
If the directional control valves in the control loops are mounted on a valve
terminal, one length of tubing is adequate for compressed air supply to all control
loops, and one silencer vents all of the exhaust air.
X
Compared with individual mounting, this solution eliminates numerous tubing
connections and silencers, as well as the need for a compressed air distributor.
The amount of work required for tubing is reduced correspondingly.
Note

Comparison of required wiring
minimising wiring.
Components Cables Number of Number of

terminals/components with terminals/components with
conventional wiring multi-pin plug
Control cabinet 1 1
Terminal strip 1 in the control Earth cable 1 2

cabinet
Supply power (24 V) 1 2
PLC outputs (actuation of 6 6

solenoid coils)
PLC inputs (evaluation of 6 6

proximity switches)
Terminal strip 1 in the control cabinet, total 14 16
Cables from control cabinet to Cables between terminal Cable harness or single cable Cable harness or single cable
terminal box strips 1 and 2 with 14 cores with 8 cores
Terminal strip 2 Proximity switch (3 cores 18 18

(in the control cabinet) per proximity switch)
Solenoids 12 -
(2 cores per solenoid)
Terminal strip 2, total 30 18
Cables to directional control 30 18

valves and sensors
Connection of the solenoid 6 cables with 2 cores each -
coils
Wiring table
Note

Reducing required wiring
– Which concept enables you to reduce the wiring? Place an X next to your selection and justify your
decision.
Conventional wiring Multi-pin plug

Reason
technology
All valves included in the controller are arranged on the MPA valve terminal (with MP
connection).
As compared with conventional wiring, many of the terminals at terminal strip 2 and
X
the cables to the solenoid coils are eliminated when the valve terminal is connected
with a multi-pin plug.
Wiring is thus reduced, and maintenance and troubleshooting are simplified.
Note

Completing the pneumatic circuit diagram with individual valves
– Complete the pneumatic circuit diagram for the diverting device with individual valves.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Pneumatic circuit diagram with individual
Completing the pneumatic circuit diagram with valve terminal
– Complete the pneumatic circuit diagram for the diverting device with valve terminal.
1A1
1V2 1 1 1V3
2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit diagram with valve terminal

Completing the electrical circuit diagram
– Complete the electrical circuit diagram for the diverting device.
+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
Electrical circuit diagram

Sequence description
– Describe the controller’s working sequence.
Initial position
In its initial position, cylinder 1A1 is in the rear end-position.
Step 1-2
When pushbutton S1 (NO contact) is activated, relay K1 is picked up and changeover contact K1 in
current path 3 is closed.
The electrical circuit of solenoid coil 1M1 is closed. 5/2-way double solenoid valve 1V1 is reversed
as a result.
The piston end of cylinder 1A1 is pressurised while the piston rod end is exhausted. The piston rod
in cylinder 1A1 advances.
As soon as pushbutton S1 (NO contact) is no longer activated, relay K1 is released and changeover
contact K1 in current path 3 is opened.
The electrical circuit of solenoid coil 1M1 is opened.
Step 2-3
When pushbutton S2 (NO contact) is activated, relay K2 is picked up and changeover contact K2 in
current path 4 is closed.
The electrical circuit of solenoid coil 1M2 is closed. As a result, 5/2-way double solenoid valve 1V1
is returned to its initial position.
The piston rod end of cylinder 1A1 is pressurised while the piston end is exhausted. The piston rod
in cylinder 1A1 travels to the rear end-position.
As soon as pushbutton S2 (NO contact) is no longer activated, relay K2 is released and changeover
contact K2 opens.
The electrical circuit of solenoid coil 1M2 is opened.

Creating an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Create an equipment list by entering the required devices to the table below.
Quantity Designation
1 Cylinder, double-acting
2 One-way flow control valve
1 5/2-way double solenoid valve (slice J in the valve terminal)
2 Pushbutton (normally open)
2 Relay
1 Distributor block
1 On-off valve with filter regulator
1 Compressed air source
1 24 V DC power supply unit
Equipment list

Contents
Exercises

© Festo Didactic 541091 I

II © Festo Didactic 541091
Exercise 1:
Implementing a diverting device
Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of valve terminals.
• You’ll be able to use valve terminals in accordance with specified requirements.
Presentation of the problem

Beverage bottles will be diverted from one conveyor to another by means of a diverting device. The diverting
panel is advanced when one of the pushbuttons is activated. The bottle is transferred and transported in the
opposite direction. The diverting panel is returned to its initial position when another pushbutton is
activated.
Layout
Diverting device for beverage bottles

Parameters
• A double-acting cylinder will be used.
• The cylinder will be controlled indirectly via pushbutton.
• In the event of a power failure, the cylinder’s piston rod should remain in its current position.
Project assignment
1. Answer the questions and complete the tasks relating to the learning content.
2. Draw the pneumatic and electrical circuit diagrams.
3. Create an equipment list.
4. Set up the pneumatic and electrical circuits.
5. Check the circuit sequence.
Control sequence
1. Cylinder 1A1 is in the rear end-position.
2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the cylinder travels
to the front end-position.
3. After activating pushbutton S2, 5/2-way double solenoid valve 1V1 is reversed again and the cylinder
travels to the rear end-position.
2 Name: __________________________________ Date: ____________ © Festo Didactic 541091

Fundamentals: installation
The layout, tubing and wiring of the components of an electro-pneumatic controller should be selected so
that the total costs for the components, installation and maintenance are as low as possible. With regard to
wiring, selection is made between:
• Conventional wiring technology, e.g. terminal strips
• Modern installation concepts, e.g. wiring with multi-pin plug connection
With regard to layout and the number of drives, as well as tubing, a selection is made between:
• Individual mounting for solenoid operated directional control valves
• Block-type mounting (manifold block or valve terminal)
Comparison of required tubing connections
minimising tubing connections.
Note
Components Individual mounting of Block-type mounting of Savings with block-type

directional control valves directional control valves mounting
Tubing
Number of compressed air

distributors
Number of tubes for supplying

compressed air distributor
Number of tubes for compressed

air supply to the control loops
Number of tubes between

directional control valves and
cylinder
Silencers
Number of silencers for control

loops
© Festo Didactic 541091 Name: __________________________________ Date: ____________ 3

Reducing required tube connections
– Which concept enables a reduction of the required tubing connections? Place an X next to your selection
and justify your decision.
Individual mounting of Block-type mounting Reason

directional control of directional control
valves valves
Note

Comparison of required wiring
minimising wiring.
Components Cables Number of Number of

terminals/components with terminals/components with
conventional wiring multi-pin plug
Control cabinet
Earth cable
Supply power (24 V)

Terminal strip 1 in the control
PLC outputs (actuation of
cabinet
solenoid coils)
PLC inputs (evaluation of

proximity switches)
Terminal strip 1 in the control cabinet, total
Cables from control cabinet to Cables between terminal

terminal box strips 1 and 2
Proximity switch (3 cores

Terminal strip 2 per proximity switch)
(in the control cabinet) Solenoids
(2 cores per solenoid)
Terminal strip 2, total
Cables to directional control

valves and sensors Connection of the solenoid
coils
Wiring table
Note

Reducing required wiring
– Which concept enables you to reduce the wiring? Place an X next to your selection and justify your
decision.
Conventional wiring Multi-pin plug

Reason
technology
Note

Completing the pneumatic circuit diagram with individual valves
– Complete the pneumatic circuit diagram for the diverting device with individual valves.
4 2
1M1 1M2
5 3
1
Pneumatic circuit diagram with individual valves
Completing the pneumatic circuit diagram with valve terminal
– Complete the pneumatic circuit diagram for the diverting device with valve terminal.
0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit diagram with valve terminal

Completing the electrical circuit diagram
– Complete the electrical circuit diagram for the diverting device.
+24 V 1 2 3 4
A1 A1
K1 K2 1M1 1M2
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
Electrical circuit diagram

Sequence description
– Describe the controller’s working sequence.
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Creating an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Create an equipment list by entering the required devices to the table below.
Quantity Designation
Equipment list

Basic Level of Electro Pneumatics

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© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

Exercise 1: Implementing a diverting device _____________________________________________________ 1

© Festo Didactic 541091 III

Exercise 1: Implementing a diverting device _____________________________________________________ 1

IV © Festo Didactic 541091

The training package for electropneumatics may only be used:

© Festo Didactic 541091 V

VI © Festo Didactic 541091

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

If you have any suggestions or feedback about this manual,

© Festo Didactic 541091 VII

VIII © Festo Didactic 541091

© Festo Didactic 541091 IX

X © Festo Didactic 541091

Important elements of the TP 200

Textbooks TP 201 basic level

Workbooks TP 201 basic level

Optional teachware Set of transparencies and overhead projector

P100 Basic pneumatics knowledge for machine operators

P111 Fundamentals of pneumatics and electro-pneumatics

P121 Maintenance and troubleshooting for pneumatic and electro-pneumatic systems

P-OP Tracking down waste – economic use of pneumatics

P-NEU Pneumatics refresher and update

P-AL Pneumatics for vocational education

P-AZUBI Pneumatics and electro-pneumatics for trainees

© Festo Didactic 541091 XI

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

XII © Festo Didactic 541091

Become familiar with the setup and function of valve • •

Be able to use valve terminals in accordance with • •

Be able to resolve overlapping signals in sequence •

Be able to create a displacement-step diagram for • • •

Be able to convert a function chart into a GRAFCET •

Be able to setup a step sequence using valves with •

Recognise overlapping signals in sequence controls. •

Be able to setup a step sequence using double pilot •

Become familiar with the modes of operation of •

Be able to select proximity switches which are •

Become familiar with logic operations and implement •

Become familiar with options for querying pressure •

Become familiar with the setup and function of a •

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

© Festo Didactic 541091 XIII

Become familiar with operating modes and learn to set • •

Become familiar with the function of an electrical •

Be able to develop and set up the emergency stop •

Be able to develop and set up the emergency stop •

Be able to develop and set up a specified motion •

Be able to set up the following emergency stop •

Become familiar with the setup and mode of operation •

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

Be able to integrate the reset operating mode into a •

Be able to detect and eliminate errors in complex •

XIV © Festo Didactic 541091

Designation Order no. Quantity

Proximity switch, inductive 548643 1

Proximity switch, capacitive 548651 1

Emergency-stop button 183347 1

Relay, 3-way 162241 2

Non-return valve, piloted 540715 2

Signal input, electrical 162242 1