FESTO TRAININGS

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PNEUMATICS
P111 - Industrial Pneumatics

Course Objective

This course covers the principles of pneumatic technology. To provide the participant with an understanding of the
construction and function of pneumatic components used in automation. Participants will also be able to read, design and
construct simple pneumatic circuits.

Course Content

 Characteristics of pneumatic systems:

- Properties of compressed air
- Advantages and disadvantages of compressed air
- Structural and signal flow of pneumatic systems

 Compressed air generation, distribution and preparation:

- Different types of compressors and dryers
- Design of piping system
- Role of service units

 Construction and principle of pneumatic valves:

- Directional control valves
- Non-return valves
- Flow control valves
- Pressure control valves
- Combinational valves

 Construction and principle of working elements:

- Linear and rotary working elements
- Logical AND/OR - function of switch-on signal

 ISO symbols for signal, controls and working elements in accordance to ISO 1219
- Recognizing and drawing of pneumatic symbol

 Development and layout of simple controls:

- Direct and indirect manual controls
- Direct and indirect stroke-dependent controls

 Operation of pneumatic sequencing circuits

- Representation of working sequence

 Simulation and practical exercise

P121 - Maintenance of Pneumatics Equipment and Systems

Course Objective

To provide the participant with the knowledge of understanding pneumatic systems from the maintenance perspective, a
systematic approach to maintenance, troubleshooting and design of pneumatic circuits is practiced.

Course Content

 Compressed air preparation:

- Need for clean compressed air
- Compressed air receiver
- Air drying
- Distribution of compressed air
- Calculation of pipe diameter
- Air service unit

 Function and construction of pneumatic equipment:

- Directional control valves
- Other pneumatic valves
- Pneumatic actuators

 Methods for the development of pneumatic systems:

- Control chain
- Design and layout of circuit diagram

 Maintenance requirements of pneumatic systems

- Parts subject to wear-and-tear
- Preventive maintenance

 Operation of pneumatic sequencing circuits:

- Working sequence
- Methods of representation
- Design using cascade control method

 ISO Pneumatic symbols according to ISO 1219/ISO 5599

 Simulation and practical exercises

ELECTROPNEUMATICS
EP211 – Introduction to Electro-Pneumatics

Course Objective

Provide participants with the skills and knowledge of electric components as well as to develop an ability to read, design and
construct simple electro-pneumatic controls.

Course Content

 Characteristics of Electro-pneumatic systems

 Function and use of electro-pneumatic components:

- Electrical switches
- Electrical contacts
- Electrical relays
- Basic sensors

 Design of Logic Circuits:

- YES
- NOT
- OR
- AND

 Recognizing and drawing of electro-pneumatic symbols:

- Solenoid operated directional control valves

 Representation of motion sequences and operating status

 Drawing of pneumatic and electrical circuit diagrams

 Development and layout of simple controls:

- Direct and indirect manual controls
- Direct and indirect stroke-dependent controls
- Logical AND/OR function of switch-on signals

 Simulation and practical exercise

EP221 – Maintenance of Electro-Pneumatics Equipment and Systems

Course Objective
To provide participants with a wider knowledge of components that are subject to wear and the possible sources of faults. A
systematic approach to fault finding is practised as in the reading of complex elctro-pneumatic circuits and understanding of
fundamental controls and circuits and as well as to develop an ability to read, design and construct simple electro-pneumatic
controls.

Target Group

 Industrial personnel, maintenance staff, technicians, operators, designers and engineers

Course Content

 Compressed air preparation:

- Need for clean compressed air
- Compressed air receiver
- Air drying
- Distribution of compressed air
- Calculation of pipe diameter
- Air service unit

 Function and construction of electro-pneumatic equipment:

- Solenoid operated directional control valves
- Pneumatic actuators
- Switches, contact and relay
- Sensors; Proximity Sensors and Pressure Sensors

 Methods for the development of electro-pneumatic systems:

- Control chain
- Design and layout of circuit diagram
- Basic logic function, timer and counter function

 Maintenance requirements of pneumatic systems

- Parts subject to wear-and-tear
- Preventive maintenance

 Operation of electro-pneumatic sequencing circuits:

- Working sequence
- Methods of representation

 SO Pneumatic symbols according to ISO 1219/ISO 5599

 Simulation and practical exercises

PROGRAMMABLE LOGIC CONTROLLERS (PLC)

PLC311 - Fundamentals of PLC (FESTO CPX-CEC-C1)

Course Objective
The objective of the program is to provide the participants with basic knowledge of the construction and operation of
programmable logic controllers as well as to develop the ability to write simple programs and operate control systems. It is also
to acquaint the participants with the application possibilities of using PLC. Codesys-tried and tested, globally introduced
hardware-independent software from 3S-offers a Controller Development System according to the IEC 61131-3 with all
defined programming languages independent of the hardware manufacturer. This course demystifies Codesys and gives
participants confidence in using it.

Course Content

 Function and applications of PLC

 Components of a PLC:
- Hardware and software
- Programming device
- General structure of PLC program

 PLC addresses:
- Input / Output listing
- Electrical and pneumatic circuit diagram
- Input / Output devices

 Programming Languages according to IEC 61131-3

 Introduction to the Codesys programming environment

 Commissioning of a PLC:
- Checking the hardware
- Transferring and testing of software
- Optimisation of software
- Commissioning of the system

 Communication interface with PLCs

 Procedure for creating a PLC program

 Programming of control task:

- Logic functions
- Sequence tasks
- Timing sequence
- Counting sequence

 Multitasking with the PLC:

- Manual / Auto mode
- Emergency stop
- Single / Continuous cycle
- Parallel programs

 Simulation and practical exercises

PLC312 - Electro-Pneumatic Automation with Omron PLC (CP1L/CP1E)

Course Objective

To provide the participants with a basic knowledge of the construction and principle operation of Omron CP1L/CP1E
programmable logic controllers as well as to develop the ability to write simple programs and operate control system. It is also
to acquaint the participants with the application possibilities of using PLC.
Course Content

 Structure of a Programmable Logic Controllers

- Components of a PLC
- Program memory

 Familiarization with Omron PLC and CX-Programmer

- PLC addressing
- Introduction to Omron CX-Programmer (software
  programming tool for Omron PLC)

 Function of PLC

 Type of PLC System

 Commissioning of a PLC

 Criteria for the use of mechanical, magnetic, optical, capacitive and inductive proximity sensors

 Circuit developments and diagram design

 Programming in LADDER Diagrams

 Development of sequence and logic control systems

 Memory function:
- Operation of FLAG
- Keep commands

 Timer and Counter applications

 Simulation and practical exercises

HYDRAULICS
HY511 - Industrial Hydraulics

Course Objective

The objective of the program is to provide the participants with the fundamental and the importance of physical principles of
hydraulics. It is also to acquaint the participants with the hydraulic elements commonly used in industry and to develop the
ability to read, design and construct simple hydraulic circuits.
Course Content

 Fundamental physical principles of hydraulics:

- Physical quantities and units in hydraulics
- Basic physical laws of hydraulics
- Calculation e.g. force, speed and output

 ISO hydraulic symbols according to ISO 1219/ISO 5599

 Hydraulic system:
- Basic hydraulic system
- Advantages and disadvantages of hydraulics

 Components of hydraulic power pack 

 Characteristics and function of hydraulic actuators

 Characteristics and function of hydraulic valves:

- Pressure control valves
- Directional control valves
- Flow control valves
- Non-return valves

 Basic circuits with single and double-acting cylinders

 Positioning of cylinders

 Measurement of cylinder times and pressure

 Types and properties of hydraulic fluids

 Development and layout of simple controls:

- Basic hydraulic circuits

 Maintaining uniform pressure with pressure regulators

 Simulation and practical exercise

EH611 – Introduction to Electro-Hydraulics

Course Objective

The objective of the program is to provide the participants with an understanding of electrical control of hydraulic elements
commonly used in industry as well as to develop the ability to read, design and construct electro-hydraulic circuits..

Course Content
  Fundamental physical principles of electro-hydraulics:
- Physical quantities and units in electro-hydraulics
- Basic physical laws of electro-hydraulics
- Calculation e.g. force, speed and output

 Function and use of electrical and hydraulic components such as switches, push buttons and single solenoid valves

 Recognizing and reading of electrical and hydraulic components such as switches, push buttons and single solenoid
valves

 Design, assemble, and test basic electro-hydraulic circuits

 Recognizing and reading of electrical and hydraulic symbols

 Development and reading of standard circuit diagrams

 Representation of control tasks in operation diagrams

 Direct and indirect control of actuators

 Manual and automatic operation

 Stroke and pressure-dependent controls

 Interlocking circuits

 Rapid traverse circuits

ELECTRONICAL DRIVES

Course Objective

To provide participant with the fundamental knowledge and skill on the different electric motors and its application. Participants
will also be able to incorporate the motors to the electrical drive units.

Course Content

 Introduction to Electrical Motors

- How does an electric motor work?
 - Fundamentals
- Output characteristics

 Types of industrial motors: AC and DC motors

 Stepper Motors
- Introduction
- Variable resistance (VR) stepper motors
- Permanent magnet (PM) stepper motors
- Hybrid stepper motors
- Phases of stepper motors
- Stepping angles of stepper motors
- Advantages and disadvantages of stepper motors
- Benefits of stepper motors
- Applications of stepper motors

 Servo Motors
- Introduction
- How servo motors work?
- Brushless servo motors.
- Servo motor controllers.
- Feedback systems.
- Advantages and disadvantages of servo motors
- Benefits of servo motors
- Applications of servo motors

 Electric Drives
- Introduction
- Types of electric drives
- Advantages and disadvantages of different drive designs
- Applications of electric drives

 Complete systems
- Using the different motors with the different drives
- Applications of electric drive systems

 Simulation and practical exercises

COMBINATIONS
PN13 Advanced Design of Pneumatic Systems

Course Objective

To provide participant with the fundamental knowledge and skill on the different electric motors and its application. Participants
will also be able to incorporate the motors to the electrical drive units.

Course Content
  Functions and characteristics of electro-pneumatic components:
- Air supply components
- Directional control valves
- Other pneumatic valves
- Switches and contacts
- Electrical sensors
- Actuators

 Fundamentals and definitions in control technology: Signal flow and control chain

 ISO electrical and pneumatic symbols according to ISO 1219

 Basic circuits of pneumatic systems

 Types of control: sequence control and Opposing signals circuits

 Sequence control system:

- Motion sequence representation
- Signal control with signal cut-off

 Methods of designing circuit diagrams for pneumatic controls: cascade method and shift register method

 Basic circuits of electro-pneumatic systems

 Methods of designing circuit diagrams for electro-pneumatic controls:

- Pneumatic memory method
- Electrical memory method
- Electrical cascade method
- Electrical stepper method

 Sequence control with auxiliary conditions:

- On/off and auto mode
- Single/continuous cycle
- Emergency off, etc

 Simulation and practical exercises

PN81 Design Handling Systems in Industrial

Course Objective

To provide participant with the fundamental knowledge and skill on handling technology with pneumatics for industrial handling
and assembly applications.

Course Content
  Introduction to handling technology
- Automated handling - definition
- Basic principles of handling
- Handling with pneumatics

 Pneumatic handling systems

- Introduction
- Pneumatic drives
- Guide units
- End effectors
- Pneumatic control elements (valves)

 Handling with vacuum

- Vacuum fundamentals
- Vacuum generators
- Suction cups
- Selection of suction cups
- Application of vacuum components

 Handling with grippers

- Introduction to grippers
- Classification of grippers
- Selection of grippers
- Application area of grippers
- Criteria to select grippers

 Modular handling systems

- Requirements of handling and assembly technology
- Modular handling systems
- Special handling units
- Software calculation and simulation

SN41 Operate Electrical Sensors

Course Objective

To provide the participant with knowledge of operating principles of the various types of proximity sensors used for handling
and processing technology, including the analysis of sensing range and response characteristics of these sensors.

Course Content

 Fundamentals of sensors
  Functions, characteristics and uses of binary proximity sensors:
o Magnetic proximity sensors
o inductive proximity sensors
o Capacitive proximity sensors
o Optical proximity sensors
o Ultrasonic proximity sensors

 Functions, characteristics and uses of displacement sensors:

o Analogue inductive sensors
o Analogue optical sensors
o Analogue ultrasonic sensors
o Potentiometer

 Functions, characteristics and uses of force sensors:

o Strain gauges
o Load cell

 Functions, characteristics and uses of pressure sensors:

o Pressure switch
o Pneumatic-electronic sensor
o Pressure sensor

 Connection and circuit technology:

o Two-wire connection
o Three-wire connection
o Four-wire connection
o PNP and NPN

 Simulation and practical exercises

PN11 Industrial Pneumatics and Electro-Pneumatic Controls

Course Objective

To provide the participant with an understanding of the construction and function of pneumatic and electric components used
in automation. Participants will also be able to read, design and construct simple pneumatic circuits.

Course Content
  Characteristics of pneumatic systems:
- Properties of compressed air
- Advantages and disadvantages of compressed air
- Structural and signal flow of pneumatic systems

 Compressed air generation, distribution and preparation:

- Different types of compressors and dryers
- Design of piping system
- Role of service units

 Construction and principle of pneumatic valves:

- Directional control valves
- Non-return valves
- Flow control valves
- Pressure control valves
- Combinational valves

 Construction and principle of working elements

 Basic pneumatic circuits

 Characteristics of electro-pneumatic systems

 Components and assemblies in the electrical signal control section:

- Electrical switches
- Electrical contacts
- Electrical relays
- Basic sensors
- Solenoid operated directional control valves

 ISO electrical and pneumatic symbols according to ISO 1219

 Development and layout of simple controls: Basic pneumatic circuits and Electro-pneumatic circuits

 Operation of pneumatic sequencing circuits:

- Representation of working sequence

 Simulation and practical exercises

PN12 Maintenance and Troubleshooting on Pneumatic and Electro-Pneumatic Systems
Course Objective

To provide the participant with the knowledge of understanding pneumatic systems from the maintenance perspective, a
systematic approach to maintenance, troubleshooting and design of pneumatic circuits is practiced. Extend your specialist
knowledge of complex pneumatic and electro-pneumatic control systems and improve your methodical skills.

Course Content
  Compressed air preparation

 Physical principles of pneumatic and electro-pneumatic systems

 Function and construction of pneumatic components

- Directional control valves
- Other pneumatics valves
- Pneumatic actuators

 Function and construction of electrical equipment

- Switches and relay
- Common sensors
- Solenoid operated directional control valves

 ISO electrical and pneumatics symbols according to ISO1219

 Methods for the development of pneumatic systems:

- Control chain
- Design and layout of circuit diagram
- Basic logic functions, timer and counter function

 Operation of pneumatics and electro-pneumatic sequence control system

- Working sequence
- Method of representation
- Signal control with signal cut-off

 Part subject to wear and tear

 Possible causes of failure on individual components

 Different types of valve terminal actuation

 Perform routine maintenance and fault tracing procedure on pneumatic and electro-pneumatic control system

 Preventive maintenance and safety regulation

 Practical exercises and systematic troubleshooting

MPS Station – Application Training of PLC (Omron CP1L/CP1E)

Course Objective

Maintaining flexibility despite a high degree of automation is one of the most important challenges in many manufacturing
companies. It demands the integration and networking of different controls in a complex automation system. This training aims
for participant who has interest for complex control task with various actuators and sensors and to translate into operational
PLC programs. On completion of the course the participant knows when to use the CX-Programmer and masters the basic
features and simple programming.
Course Content

 Structuring and developing complex control tasks into operational PLC programs.

 Commissioning and simulation the control system based on IEC 61131-3 standard.

 Familiarization of different input and output devices on the Modular Production Systems (MPS)

 Troubleshooting by distinguishing the input and output signals from a PLC

 Understanding of electrical complex circuit diagrams and standard PLC language

 Applications of limit switches, magnetic, optical, capacitive and inductive proximity sensors

 Application of Memory Functions, Timer and Counter Functions in PLC

 Development of logic program for the Modular Production Systems (MPS)

- as individual stations or with two stations

 Best practice commissioning - can avoid damage and failure in the case of user-specific errors through safe and
precise intervention

ME422 - Mechatronics

Course Objective

The aim of the seminar is to reinforce the knowledge and competence of the participants in the Mechanical, Electrical and
Electronic aspects of typical operations in a manufacturing environment. At the completion of the course, the participant will be
able to assemble, commission and troubleshoot PLC controlled manufacturing system.

Course Content
  Review on Pneumatics, Electro-Pneumatics, Sensors & PLC
technologies

 Practical work on typical manufacturing operations via

functional laboratory stations as regards:
- Mechanical assembly
- Pneumatic tubing
- Electrical wiring
- PLC programming
- Commissioning
- Troubleshooting
- PLC networking of laboratory stations to form a typical
industrial system

 Practical exercises

E 311 - Basic PLC

Course Objective

To enable participants to understand the design and principle of operation of Programmable Logic Controllers (PLC’s) write
and implement simple programs and be familiar with applications of PLC’s in industries.

Course Content

 Advantages of a PLC as compared to conventional electrical relay-based controls

  Function of the system components of a PLC

 Circuit development and wiring diagrams

 Criteria for the use of mechanical, optical, capacitive and inductive proximity sensors

 Logical and sequence control

 Time dependent controls using timers

 Controls using counters

 Modification of programs by inserting or deleting control commands

 Programmable and commissioning of Programmable Logic Control

 Practical exercise

E 322 - Advanced PLC

Course Objective

At the end of the seminar, the participant should be able to translate control tasks into fully operational PLC programs - test
and document these programs using the control system.

Course Content

 Programming of counter functions

 Programming of timer functions

  Programming using multitasking features

 Interrupt programming

 Display and modification of the status of the functional components and error messages in the PLC test system

 Troubleshooting

 Documentation, software management and filing

 Practical exercises

E 333 - Industrial PLC (Basic & Advanced)

Course Objective

To enable participants to understand the design and principle of operation of Programmable Logic Controllers (PLC’s)
write and implement simple programs and be familiar with applications of PLC’s in industries. At the end of the seminar, the
participants should be able to translate control tasks into fully operational PLC programs - test and document these programs
using the control system.

Course Content

 Advantages of a PLC as compared to conventional controls such as electrical, electro-pneumatics or electro-

hydraulic controls
  Function of the system components of a PLC

 Commissioning of Programmable Logic Controller (PLC)

 Criteria for the use of mechanical, optical, capacitive and inductive proximity sensors

 Development of sequence and logic control system

 Defining appropriate control system for a given control task

 Modification of programs by inserting or deleting control commands

 Time dependent controls using timers

 Control using counters

 Programming of a timer and counter function

 Programming using multitasking features

 Interrupt programming and Trouble-shooting

 Practical exercises

PC 911 - Process Control (P.I.D.)

Course Objective

At the end of the seminar, the participant should be able to understand the principle of measurement and control of process
variables such as temperature, flow rate, level and pressure. The participant should be able to understand the principle of
operation, characteristics and configuration of PID controllers.

Course Content

 Definition of closed and open-loop controls

 Closed-loop control in everyday industrial applications

  Standard and terminologies

 P.I.D and PD diagrams

 EMC diagrams

 System statistics & dynamic behavior

 Dynamic response characteristics

 Temperature (T) measurement & control

 Pressure (P) measurement & control

 Level (L) measurement & control

 Flow (F) measurement & control

 Features & technical specification of industrial controllers

 Setting of the controller parameters

 Process (T.P.L.F.) control optimization & monitoring

 Practical exercises

EP211 - Electro-Pneumatic Controls

Course Objective

To provide the participant with knowledge of electrically actuated valves and components as well as to develop his ability to
read, design and construct simple Electro-Pneumatic controls.

Course Content

 Physical principles of pneumatic and electrical systems

 Functions and uses of electro-pneumatic components

 Recognizing and drawing electro-pneumatic symbols

  Representation of motion sequences and operating status

 Drawing of pneumatic and electrical circuit diagrams

 Direct and indirect manual controls

 Direct and indirect stroke-dependent controls

 Logical And/or functions

 Time dependent controls with time-delay valves

 Pressure dependent controls with PE converters

 Pre-select counters

 Troubleshooting electro-pneumatic controls

 Practical exercises

PV 221 - Basic Vacuum Technology

Course Objective

At the end of this seminar, the participants learn about the basic specifics of vacuum compared to compressed air. The main
topics covered are production of vacuum, selection of the right suction cups, and opportunities for cost reduction.

Course Content

 Basic terminologies

 Vacuum ranges

 Vacuum generation in handling technology

 Mode of operation of displacement pumps

  Ejectors

 Vacuum components in handling technology

 Valve

 Vacuum gauges

 Vacuum reservoirs

 Suction cups

 Bellow suction cups

 Suction cup selection

 Vacuum security valves

 Practical exercises

PN111 - Pneumatic Controls & Design

Course Objective

At the end of this seminar, the participant should be able to understand how air is compressed, prepared, distributed and used
in pneumatic controlled machines. Participants should also be able to design, construct and troubleshoot pneumatic control
circuits.

Course Content

 Physical principles of pneumatics

 Function and use of pneumatic components

 Recognizing and drawing of symbols and circuit diagrams

 Representation of motion sequences and operating status

  Drawing of pneumatic circuit diagrams according to standards
 Direct and indirect manual controls

 Direct and indirect stroke-dependent controls

 Logical And/or functions

 Time dependent controls using time-delay valves

 Pressure dependent controls using pressure sequence valves

 Troubleshooting simple pneumatic controls

 Safety regulations

 Practical exercises

PN121 - Pneumatic Maintenance & Troubleshooting

Course Objective

At the end of the seminar, the participant should be able to: (1) Design and read pneumatic and electro-pneumatic control
circuits; (2) Localize, identify and correct faults in industrial pneumatic installations; and (3) Operate and maintain pneumatic
cylinders, valves and components.

Course Content

 Properties of compressed air

 Air generation, preparation and distribution

 Physical principles of pneumatic

 Function and use of pneumatic components

  Recognizing and drawing of symbols & circuit diagrams

 Motion sequences and operating status

 Function and design of equipment and wear parts

 Practical construction of various controls

 Systematic circuit design

 Troubleshooting and fault detection

 Preventive maintenance and safety regulations

 Cost factor in repair work

 Practical exercises

AR 70 - Applied Robotics

Course Objective

The aim of the seminar is to introduce the participants to fundamentals and applications of robotics, including maintenance
and safety at work. At the completion of the course, the participant will be able to program commission an industrial robot in a
typical manufacturing environment.

Course Content

 Definition of robots

 Scope of applications

 Types of robot, their modes of motion and operational space

 Design and function of co-ordinate System

 Types of robots control design

  Teach-in and on-line programming of simple handling task

 Positioning of robot by means of manual operating console

 Travelling along certain paths of movement

 Design optimization of robot motions in time and space

 Safety precautions for industrial robots and their environment

 Practical exercises in hardware and software

SAB - 222 Binary and Analogue Sensor Technology & Applications

Course Objective

To enable participants to understand the design and principle of operation of binary and analogue sensors. Draw and applied
simple circuits and be familiar with applications of sensors in industries

Course Content

 Mode of operation, technical data, characteristics, selection and applications of binary and analogue sensors

 Binary Sensor
- Reed switch
- Magnetic
- Inductive
- Capacitive
- Optical
- Ultrasonic
 Analogue Sensor
- Inductive
- Optical
- Ultrasonic
- Strain Gauges
- Force Sensor
- Pressure Sensor

 Typical industrial applications

 Practical exercises