FESTO Ušteda Energije

Energy_Questions_A5_140808.qxp:Layout 1 14.08.
2008 13:33 Uhr Seite 1
Energy Saving
Description
555 662
en0508a
[736 421]
Contents and general instructions
Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leonard Lau
Editors . . . . . . . . . . . . . . . . . . . . . . . . . . . U. Will, S. Lensdorf
Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en
Layout . . . . . . . . . . . . . . . . . . Festo AG & Co. KG, Abtl. SV−P
Type setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DUCOM
Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en 0508a
Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL−EN
Designation . . . . . . . . . . . . . . . . . . . . . . . . P.BE−FESS−01−EN
Order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555 662 . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [736 421]
E (Festo AG&Co., D73726 Esslingen, Federal Republic

. . of Germany 2008)
Internet: http://www.festo.com
E−Mail: service_international@festo.com
The copying, distribution and utilization of this document as

well as the communication of its contents to others without
expressed authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved, in
particular the right to carry out patent, utility model or
ornamental design registration.
Festo P.BE−FESS−01−EN en 0508a I

II Festo P.BE−FESS−01−EN en 0508a

Contents
Important user instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
1. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1
1.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 1−4

1.1.1 Tip 1 Use single acting cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−4
1.1.2 Tip 2 Use clamping modules to hold cylinder in position . . . . . . . . . . . . 1−8
1.1.3 Tip 3 Use cylinders with integrated valve and flow controllers . . . . . . . 1−10
1.1.4 Tip 4 Use correct dimensioned cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 1−12
1.2 Case 2 Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . . 1−14
1.2.1 Tip 1 Use special seals in cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−14
1.2.2 Tip 2 Use round piston/piston rod cylinders . . . . . . . . . . . . . . . . . . . . . . 1−16
1.2.3 Tip 3 Use guides to prevent deflection of piston rods . . . . . . . . . . . . . . 1−18
1.2.4 Tip 4 Use flexible couplings to prevent deflection of piston rods . . . . . 1−20
1.3 Case 3 Reduction in friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−22
1.3.1 Tip 1 Choose cylinders with less sealing points . . . . . . . . . . . . . . . . . . . 1−22
1.3.2 Tip 2 In dusty environment, use lubricated compressed air . . . . . . . . . 1−24
1.3.3 Tip 3 If cylinder is operated at more than 1 m/s, use lubricated com
pressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−26
1.3.4 Tip 4 In dusty environment, use covers wipers for exposed piston rod . 1−28
1.4 Case 4 Reduction in Pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30
1.4.1 Tip 1 Reduce working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30
1.4.2 Tip 2 Reduce working pressure of non−productive stroke . . . . . . . . . . . 1−32
2. Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

2.1.1 Tip 1 Select valve terminal according to flow rate for optimum
performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−4
2.1.2 Tip 2 Select valve size according to flow rate for optimum performance 2−6
2.1.3 Tip 3 Select valve function carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−8
2.1.4 Tip 4 Supply lower pressure for external pilot supply . . . . . . . . . . . . . . 2−10
2.1.5 Tip 5 Use 5/2 valves with reversible port . . . . . . . . . . . . . . . . . . . . . . . . 2−12
Festo P.BE−FESS−01−EN en 0508a III

2.1.6 Tip 6 Use valve terminals with integrated (sandwich) pressure

regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
2.1.7 Tip 7 Shut off compressed air supply when inactive for long periods . . 2−16

2.2.1 Tip 1 Use valves with the poppet or cartridge design . . . . . . . . . . . . . . . 2−18
2.2.2 Tip 2 Use mainfold instead of individual valves . . . . . . . . . . . . . . . . . . . 2−20
2.3 Case 3 Reduction of electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−22

2.3.1 Tip 1 Use valves with reduction of holding current . . . . . . . . . . . . . . . . . 2−22
3. Air preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

3.1.1 Tip 1 Monitor compressed air consumption of machine/application . . 3−4
3.1.2 Tip 2 Use directly actuated pressure regulator instead of pilot
actuated pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6
3.1.3 Tip 3 Use automated drain instead of manual drain . . . . . . . . . . . . . . . . 3−8
3.2 Case 2 Reduction in pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10

3.2.1 Tip 1 Maintain required system pressure . . . . . . . . . . . . . . . . . . . . . . . . 3−10
3.2.2 Tip 2 Ensure filter elements are changed or maintained . . . . . . . . . . . . 3−12
3.2.3 Tip 3 Reduce system pressure − use pressure booster for specific
applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
4. Vacuum application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

4.1.1 Tip 1 Use vacuum switch with vacuum applications . . . . . . . . . . . . . . . . 4−4
4.1.2 Tip 2 Use the correct pressure supply for vacuum generators . . . . . . . . 4−8
4.1.3 Tip 3 Maintain integrated silencers and filters of vacuum
generators regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10
4.1.4 Tip 4 Use vacuum pump for applications that require constant vacuum 4−12
4.1.5 Tip 5 Place vacuum generator close to application . . . . . . . . . . . . . . . . . 4−14
4.1.6 Tip 6 Choose suitable succion cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20
IV Festo P.BE−FESS−01−EN en 0508a

5. Accessoires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1
5.1 Case 1 Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . 5−4

5.1.1 Tip 1 Ensure tubings are mounted properly . . . . . . . . . . . . . . . . . . . . . . 5−4
5.1.2 Tip 2 Use push/pull fittings with sealing lip . . . . . . . . . . . . . . . . . . . . . . 5−6
5.1.3 Tip 3 Select correct tubing design suitable to the purpose used for . . . 5−8
5.1.4 Tip 4 Tighten sealing rings for threading connections . . . . . . . . . . . . . . 5−10

5.2.1 Tip 1 Reduce the length of the tubing used . . . . . . . . . . . . . . . . . . . . . . . 5−12
5.2.2 Tip 2 Use multiple distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−15
5.2.3 Tip 3 Ensure that exhaust interfaces are suitable . . . . . . . . . . . . . . . . . . 5−18
6. Controllers and concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

6.1.1 Tip 1 Decentralise pneumatic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−4
6.1.2 Tip 1 Analyse high frequent operations to find energy waist . . . . . . . . . 6−6
6.2.1 Tip 1 Monitor continiously the energy status . . . . . . . . . . . . . . . . . . . . . 6−8
6.3 Case 3 Reduction in electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−10
6.3.1 Tip 1 Select positioning drive according to the specific demands . . . . . 6−10
6.3.2 Tip 2 Use self−locking lead screw drives . . . . . . . . . . . . . . . . . . . . . . . . . 6−12
Festo P.BE−FESS−01−EN en 0508a V

Important user instructions
Danger categories
This manual contains instructions on the dangers which may
occur if the product is not used correctly. These instructions
are marked with a heading (Warning, Caution, etc.), printed
on a shaded background and accompanied by a pictogram. A
distinction is made between the following danger categories:
Warning
This means that there is a danger of serious human injury
and damage to property if these instructions are not ob
served.
Caution
This means that there is a danger of human injury and
damage to property if these instructions are not observed.
Please note
This means that there is a danger of damage to property if
these instructions are not observed.
In addition, the following pictogram marks passages in the

text which describe activities involving electrostatically sensi
tive components:
Electrostatically sensitive components: Incorrect handling

may result in damage to the components.
VI Festo P.BE−FESS−01−EN en 0508a

Marking special information

The following pictograms mark passages in the text contain
ing special information.
Pictograms
Information:
recommendations, tips and references to other sources of
information.
Accessories:
information on necessary or useful accessories for the Festo
product.
Environment:
information on the environmentally−friendly use of Festo
products (savings).
Text markings
S The bullet denotes activities which can be carried out in

any sequence.
1. Figures denote activities which must be carried out in the

order specified.
Hyphens denote general activities.
Festo P.BE−FESS−01−EN en 0508a VII

Introduction
As a family enterprise Festo feels responsible also for long−

term questions to its products and technologie. Energy saving
in Pneumatics is one of the areas Festo is setting a focus with
our services and recommendations.
The purpose of this manual is to give prospective customers

and users of pneumatic components some tips and tricks on
how to maximise the advantages of using pneumatic compo
nents while maintaining low energy usage.
This manual for Energy Saving evolved out of necessity due

to the high energy loss in the world. In response to many re
quests from customers, Festo has decided to compile this
manual.
The result is a collection of tips and tricks that has a clear

structured reference layout, specifically designed for the
usage of both layman and experts to energy saving in pneu
matics. These information ranges from simple to advanced
application solutions in this field.
Not all tips and tricks may be applicable to your machine or

application. With this manual, we hope to be able to induce
you think of more ways to save energy with pneumatics.
VIII Festo P.BE−FESS−01−EN en 0508a

"The contents have been divided in six different sections,

making it easy for users of this manual to find precisely the
information they need:"
Cylinders
Valves
Air preparation
Vacuum application
Accessories
Controllers and concepts
It is important to note that while this manual is not designed

to solve all your questions you may have on the topic of En
ergy Saving. This represents a start of an ongoing process to
make more effective use of pneumatic energy in your existing
or future applications.
Please note
We strongly recommend contacting our Festo representa
tives to have further discussions on how to implement
some of the tips in this manual.
Some of the tips recommended will affect the functionality
and performance of your existing applications. While these
changes will reduce energy consumption, it is important to
consider how these changes will affect your application.
Festo P.BE−FESS−01−EN en 0508a IX

What is Energy Saving?

Energy saving means to be able to run your applications in
optimum performance while using the lowest possible energy.
In terms of pneumatic, this means to reduce leakages, loss in
pressure and loss during the conversion of pneumatic energy
to an action.
Energy saving opportunities are present everywhere in pneu

matics, it just takes minimal effort to recognise where energy
can be saved. However, it takes concerted efforts to ensure
that these energy savings can be maintained.
Why Energy Saving is important?

Pneumatic compressed air is not free. It takes an enormous
amount of electricity for an air compressor running in your
factory to produce compressed air. The higher the pressure
used in your system or application, the more cost goes into
producing this pressure. Every leakage present in your ap
plication, represents money being released into the atmos
phere with absolutely no return on investment!
With the raising price of worldwide crude oil prices, energy

cost are expected to increase higher. Reduction of energy
consumption equals to less overall opearting cost of your
factory saving money.
There are also environmental concerns in regards to the re

lease of CO2 gas. The less energy consumed means less CO2
emission to the atmosphere which is damaging the environ
ment we live in.
X Festo P.BE−FESS−01−EN en 0508a

How can Energy Saving be applied?

By simple change of design or by using components with
better characteristic in energy saving aspect. You can save
energy cost ranging from 10 % to 60 % (Eliminating leakages)
when running pneumatic applications.
Very often, by incorporating energy saving designs into your
applications. The capital cost of making these changes are
small when you compare with the savings throughout the life
of the machine or application.
How to use this manual?

This manual is divided into five different sections with several
sub−title under each sector. Each sub−title has several tips in
which energy saving could be achieved under specific condi
tions. Very often we are unable to illustrate the amount of
actual savings in terms of dollar and cents when the tips are
used. This is because normally no two application are operat
ing under exactly the same conditions and achieving the
same results.
To use this manual effectively, start from page 1 and move

through the pages progressively. Alternatively, you could turn
to the content page and search for the topics that you are
interested in.
Useful Festo software
1. Pneumatic dimensioning ProPneu
2. Fluidic muscle Festo MuscleSIM
3. Tubing selection Tube selector
4. Vacuum selection
5. Valve terminal
6. Mass moment of inertia calculation program
Visit Festo at www.festo.com for more information on

energy saving.
Festo P.BE−FESS−01−EN en 0508a XI

Energy saving Reduction Reduction Reduction Reduction Reduction

aspect of of of of of
leakage consump friction pressure electrical
tion loss power
Product range
Cylinder + + + O
Valves + O O O O
Air preparation O +
Vacuum + O
Accessories + +
Controllers O + O
+ = possibility highly given, o = possibility maybe given, = possibility less given
Fig.0/1: Overview about saving potential in different product ranges
XII Festo P.BE−FESS−01−EN en 0508a

Cylinder
Chapter 1
Festo P.BE−FESS−01−EN en 0508a 1−1

1. Cylinder
Contents
1. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

1.1.1 Tip 1 Use single acting cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−4
1.1.2 Tip 2 Use clamping modules to hold cylinder in position . . . . . . . . . . . . 1−8
1.1.3 Tip 3 Use cylinders with integrated valve and flow controllers . . . . . . . 1−10
1.1.4 Tip 4 Use correct dimensioned cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 1−12

1.2.1 Tip 1 Use special seals in cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−14
1.2.2 Tip 2 Use round piston/piston rod cylinders . . . . . . . . . . . . . . . . . . . . . . 1−16
1.2.3 Tip 3 Use guides to prevent deflection of piston rods . . . . . . . . . . . . . . 1−18
1.2.4 Tip 4 Use flexible couplings to prevent deflection of piston rods . . . . . 1−20
1.3 Case 3 Reduction in friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−22

1.3.1 Tip 1 Choose cylinders with less sealing points . . . . . . . . . . . . . . . . . . . 1−22
1.3.2 Tip 2 In dusty environment, use lubricated compressed air . . . . . . . . . 1−24
1.3.3 Tip 3 If cylinder is operated at more than 1 m/s, use lubricated com
pressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−26
1.3.4 Tip 4 In dusty environment, use covers wipers for exposed
piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−28
1.4 Case 4 Reduction in Pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30

1.4.1 Tip 1 Reduce working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30
1.4.2 Tip 2 Reduce working pressure of non−productive stroke . . . . . . . . . . . 1−32
1−2 Festo P.BE−FESS−01−EN en 0508a

1. Cylinder
Energy saving on cylinders
1 2 1 2
Double acting cylinder Single acting cylinder
Fig.1/1: Saving points at cylinders
Saving points at cylinders are as follows:
1 Inlet, outlet
2 Piston seals
3 Piston rod seals
4 Correct size
Rules for best performance are as follows:
1. Cleaning rods
2. Greasing rods
3. Changing seals
4. Correct loads

1. Cylinder
1.1 Case 1 Reduction in compressed air consumption
1.1.1 Tip 1 Use single acting cylinders
Advantage Disadvantage
Reduces volume of Need to use a bigger cylinder diameter than a double acting cylinder
compressed air uses needs (Force)
Reduces the number of inlet Unable to increase spring return time

ports
Low force for retracting
Short piston stroke
Related Festo products to save energy
ADVU DSNU MAS
ESNU/AEVU } See Fig.1/3 MAS } See Fig.1/4
Fig.1/2: Single acting cylinders
Caution
This may lead to changes in functionally and performance
of your application.
Savings
A 50 % reduction of compressed air volume. 44 % reduc
tion in potential leakage (number of connections).

1. Cylinder
Air filling of chamber

L 50 %
Air fiiling of tube
2 1
2 1
1
2 1 2
4 2
2
1 3
1 5 1 3 1
9 5
Fig.1/3: Consumption of air will drop by about 50% simply

by changing double acting cylinder (Example 1) to
single acting cylinder (Example 2). Cost is reduced
due to cheaper 3/2 way valve and one less flow
control valve.
Example 1
Volume of air
Double acting cylinder 0.1719 ltr
@ 25 mm, stroke 25 mm
Tubing @ 6 mm,
Length 100 mm
Piston rod @ ... mm
Potential leakage
Total number of connection ports 9

1. Cylinder
Example 2
Volume of air
Single acting cylinder 0.087 ltr
@ 25 mm, stroke 25 mm
Tubing @ 6 mm,
Length 100 mm
Piston rod @ ... mm
Potential leakage
Articulated arm system Using Fluidic Muscles to generate lifting force
5
1
2
6
3
4
1 Pneumatic cylinder to drive lever arm 4 360° turnable

2 Coupling gear unit 5 Cable, chain, belt or strap
3 Upper arm drive 6 Fluidic Muscie
Fig.1/4: Example of a single acting design replacing a double acting cylinder design.
In this application, the new MAS fluidic muscle cylinder is used.

1. Cylinder

1. Cylinder
1.1.2 Tip 2 Use clamping modules to hold cylinder in position
Clamping modules do not use compressed air to hold piston

in place.
Allows to interrupt the con Extended cylinder length

stant supply of compressed
air
Safety feature in case of air Additional air port

s pply failure
supply fail re
Lifetime of clamping module dependent on load/force
Piston rod may move, when re−pressurized
DNCKE DNC−...−EL
DNC−...−KP
DNCKE/KP } See Fig.1/6
Fig.1/5: Clamping module combinations
Caution
This may lead to changes in functionality and performance

1. Cylinder
Example 2
4 2
5 1 3
Example 1
Fig.1/6: Simplified circuit with constant supply of air

(Example 1) and with clamping unit to allow inter
ruption of air supply (Example 2)
Example 1
Potential leakage volume

Cylinder, @ 32 mm 1.2 ltr/hr
Valve 2 ltr/hr
Potential leakage points

Example 2
Volume of air
Total activated clamping module 0.00193 ltr/hr
Potential leakage

1. Cylinder
1.1.3 Tip 3 Use cylinders with integrated valve and flow controllers
Less external connection points reduces occurrence of leak

age.
Less tubing and connectors Unable to increase speed of cylinder if needed

used means less leakage and
volume
Quick response of cylinder
DNCV
DNCV } See Fig.1/8
Fig.1/7: Integrated valve−cylinder combination
Caution
Savings
Double length of tubing doubles compressed air consump
tion for re−pressuring after exhaust = double cost.

1. Cylinder
Example 1
Example 2
$ 2m $
1m
Fig.1/8: Energy is lost at every actuation with the volume of

air in unnecessary long tubing
Calculated average cost for 1 m3 succed air (Eur) 0.020

Pressure in system absolute (bar) 7.00
Example 1
Tubing diameter (mm) 8.00
Tubing length (mm) 1000.00
Volume in tubing (m3) 0.0000503
Value of encapsulated
compressed air (Cent) 0.001
Example 2
Tubing diameter (mm) 8.00
Tubing length (mm) 2000.00
Volume in tubing (m³) 0.0001
Value of encapsulated
compressed air (−cent) 0.002

1. Cylinder
1.1.4 Tip 4 Use correct dimensioned cylinders
Oversized cylinders slower the reaction time by filling large

volumes unnecessarily with air.
Undersized cylinders slower the reaction time by resistance in
air flow.
Best possible performance Detailed knowledge of all relations needed (force, speed, accuracy)
Fig.1/9: Dimensioning software ProPneu

1. Cylinder
Fig.1/10: Calculating the volume of compressed air used in cylinders with Festo’s
ProPneu software
(www.festo.com) / Engineering / Selection and Dimensioning / Pro Pneu
Check carefully the requirements concerning
S needed forces
S needed stroke
S needed speed, dynamic
S needed accuracy
S possibilities of reducing forces by using counter masses
S possibilities of reducing strokes by using levers
S possibilities of reducing pressure by using a bigger dia−

meter.
Fig.1/11: Counter mass

to reduce forces

1. Cylinder
1.2 Case 2 Reduction in compressed air leakage
1.2.1 Tip 1 Use special seals in cylinders
Life of seals will be extended if used in correct environments.
Different material of internal Lifetime of these special seals varies, normally lower than PU seals
seals designed for specified under normal conditions
applications
DNC....−S6 } See Fig.1/13
Fig.1/12: Special variants of cylinders

1. Cylinder
Symbol Type code indicator Description
S6 Heat−resistant Temperature−resistant
seals for tempera
tures up to 150 °C
Fig.1/13: Symbols for special variants of cylinders

1. Cylinder
1.2.2 Tip 2 Use round piston/piston rod cylinders
Non−round piston rods are difficult to seal properly, resulting

in higher leakages.
Better sealing surface Cylinder rod can be rotated
ADVU DRQD
DSNU
DRQD } See Fig.1/15 and Fig.1/16
Fig.1/14: Cylinders with round sealing lines
Caution

1. Cylinder
Fig.1/15: Vane type rotary actuator(Higher leakage rates

because of non−round sealing line)
Fig.1/16: Rack & Pinion type rotary actuator(Sealing design

similar to linear cylinders)

1. Cylinder
1.2.3 Tip 3 Use guides to prevent deflection of piston rods
Deflection of cylinder or piston rod damages seals in 1 direc

tion, causing leakage.
Protects the seals on cylinder Additional space needed for the guides
from lateral force
Protects seals from damage

during moving of piston rod
DFM FENG ADVUL
} See Fig.1/18 } See Fig.1/18
Fig.1/17: Guided actuators
Caution
This may lead to dimension changes.

1. Cylinder
Fig.1/18: Cylinders with guides will prevent deflection and

stress on the cylinder seals

1. Cylinder
1.2.4 Tip 4 Use flexible couplings to prevent deflection of piston rods
Misalignment affects the seals on the cylinders causing leak

ages.
Protect piston rod against Additional length extension

misalignment
Protects misalignment from

360 deg
FK−.. / SGS / KSG

} See Fig.1/20
Fig.1/19: Flexible coupling
Caution

1. Cylinder
Fig.1/20: Different flexible coupling options from Festo

1. Cylinder
1.3 Case 3 Reduction in friction
1.3.1 Tip 1 Choose cylinders with optimized sealing lines
This reduces occurance of leakages.
Less seals means less risk of Rodless cylinders (slot design) have large sealing surface, but save
wear and leakages installation space. New types have further developped sealing
methods.
DGC... } See Fig.1/22 DGO... } See Fig.1/23
Fig.1/21: Rodless cylinders with different sealing design

1. Cylinder
Fig.1/22: Festo DGC rodless cylinder has a special sealing

design that reduces leakages
Fig.1/23: Festo DGO rodless cylinder (Sealing design similar

to linear cylinder)

1. Cylinder
1.3.2 Tip 2 In dusty environment, use lubricated compressed air
Lubricated air slows down the wearing in dusty environment.

In normal cases non−lubricated air supply is recommended.
Prevents the dust entering the Maintenance of oil in lubricator is needed

cylinder, hardening the grease
Less heat generated within Contamination of environment if leakage exist and if exhaust is not
the cylinder filtered
LOE
Fig.1/24: Lubricator
Caution

1. Cylinder

1. Cylinder
1.3.3 Tip 3 If cylinder is operated at more than 1 m/s, use lubricated

compressed air
Lubricated air protects the seals to heat up and wear quickly.

In normal cases non−lubricated air supply is recommended.
Less heat generated within Contamination of environment if leakage exists and if exhaust is not
the cylinder filtered
LOE FRM
} See Fig.1/26
Fig.1/25: Lubricator
Caution

1. Cylinder
Supply with lubricated

compressed air
6 810
4 150 12
2 100200
14
150
0psi
bar 16
0
Supply without lubricated

compressed air
Fig.1/26: Seperated supply channels (lubricated/non lubri

cated)
Oil specifications for lubrication of Festo products:

Festo special oil OFSW−32 DIN 51524−HLP32,
Basic viscosity: 32cSt. at 40 °C
Amount: 25 mg/m3
(DIN ISO 8573−1, Class 5)

1. Cylinder
1.3.4 Tip 4 In dusty environment, use cover wipers for exposed

piston rod
Piston is protected and reduces occurrence of dust brought

into the cylinder.
Protect against accumulation Sometimes additional stroke length needed (for dust covers)
of dust on the piston rod friction is slightly higher than without dust cover
} less wear of the cylinder
rod seal If full stroke of cylinder not used, life of cylinder is reduced because
} less leakage of missing cleaning effect on the rest stroke
DNC..−R8 } See Fig.1/28
Fig.1/27: Cylinders with wiper seals
Caution

1. Cylinder
Symbol Type code Description

indicator
R8 The cylinder equipped with

Dust protection a hard−chrome plated pis
using wiper seals ton rod and a rigid scraper,
which protects against dry,
dusty media.
Fig.1/28: Symbols for cylinders with wiper seals

1. Cylinder
1.4 Case 4 Reduction in Pressure losss
1.4.1 Tip 1 Reduce working pressure
Reduction of supply pressure saves energy in the whole

down−stream branch.
Lower pressure means sav Performance factor of the application may be compromised
ings in costs
LR
LR−..−D } See Fig.1/30
Fig.1/29: Pressure regulators
Caution

1. Cylinder
Pressure (bar) Ratio of pressure Savings (%)

difference against 6 bar
3 4 (abs.) 4/7 = 0,57 43 %

4 5 (abs.) 5/7 = 0,71 29 %
5 6 (abs.) 6/7 = 0,85 15 %
6 7 (abs.) 7/7 = 1,00 0%
Fig.1/30: Every reduction in system pressure leads to direct

savings
If pressure is reduced, speed of cylinders is not necessarily

slower if the nozzles are opened on the other hand.

1. Cylinder
1.4.2 Tip 2 Reduce working pressure of non−productive stroke
Reduction of pressure to save energy.
Lower pressure means sav Speed of return may be compromised

in s in costs
ings
Exhaust through the regulator reduces its life because of ...
P2
P1
LRMA... } See Fig.1/32
Fig.1/31: Inline pressure regulators
Caution

1. Cylinder
single cylinder
4 2 4 2
6 bar 3 bar
5 1 3 5 1 3
L1 = 0 L1
L2 L2 = 0
combined cylinders
Fig.1/32: Addition of an inline regulator reduces pressure for non−working stroke

1. Cylinder
Tamb = 20 °C without regulator with regulator
Tube length L1 + L2 1m 1m
Outer Tube Diameter @A 8 mm 8 mm
Inner Tube Diameter @I 5,9 mm 5,9 mm
Tube volume 2,73 x 10−5 m3 2,73 x 10−5 m3
Inside volume flow control valve (GRLA) 1,8 x 10−6 m3
Inside volume regulator (LRMAQ−1/8−QS8) 2,5 x 10−6 m3
Cycles per minute 2 2
Cycles per year*) 1 048 320 1 048 320
Volume per year (compressed) 30,5 m3 31,23 m3
Volume per year (atmospheric) 209,8 m3 122,7 m3
Costs per m3 0,02 /m3 0,02 /m3
Costs per year 4,19 2,45
[%] 100 58
*) running all the time
Fig.1/33: Comparison in detail without invest costs

Valves
Chapter 2

2. Valves
Contents
2. Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

2.1.1 Tip 1 Select valve terminal according to flow rate for
optimum performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−4
2.1.2 Tip 2 Select valve size according to flow rate for optimum performance 2−6
2.1.3 Tip 3 Select valve function carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−8
2.1.4 Tip 4 Supply lower pressure for external pilot supply . . . . . . . . . . . . . . 2−10
2.1.5 Tip 5 Use 5/2 valves with reversible port . . . . . . . . . . . . . . . . . . . . . . . . 2−12
2.1.6 Tip 6 Use valve terminals with integrated (sandwich) pressure
regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
2.1.7 Tip 7 Shut off compressed air supply when inactive for long periods . . 2−16

2.2.1 Tip 1 Use valves with the poppet or cartridge design . . . . . . . . . . . . . . . 2−18
2.2.2 Tip 2 Use mainfold instead of individual valves . . . . . . . . . . . . . . . . . . . 2−20
2.3 Case 3 Reduction of electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−22

2.3.1 Tip 1 − Use valves with reduction of holding current . . . . . . . . . . . . . . . . . . . 2−22

2. Valves
Energy saving on valves
z{1}
Zone 1 Zone 2
1
Fig.2/1: Saving points at valve terminals (here: with pres
sure zones)
Saving points at valves are as follows:
1 Right dimensioning
1. Short distances between valve and actuator
2. Pressure zones for branches with lower pressure level

2. Valves
2.1.1 Tip 1 Select valve terminal according to flow rate for

optimum performance
By range of modules to select valve terminal according to

your requirements.
Select valve terminal ideal for

specific application
Avoid oversizing/undersizing
of valves
Festo valve terminal software } See Fig.2/3
Fig.2/2: Valve terminal configurator www.festo.com/products/dimensioning software or

www.festo.com/engineering/selection/selection&dimensioning/software

2. Valves
Fig.2/3: Festo valve terminal selection tool allows selection

from all valve terminal types from Festo
www.festo.com/products/dimensioning software
or www.festo.com/engineering/selection/selec
tion&dimensioning/software

2. Valves
2.1.2 Tip 2 Select valve size according to flow rate for optimum
performance
Avoid oversizing or undersizing of the valve.
Reduce volume of com

pressed air used
MPA Typ 44 (VTSA)
ProPneu for valves
} See Fig.2/5
Fig.2/4: Valve selection tool www.festo.com/products/dimensioning software/down

load for windows
Caution

2. Valves
Size of valve Flow rate (litre/min)
M5 180
M7 350
1/8" 800
1/4" 1,500
3/8" 2,900
1/2" 3,700
3/4" 7,500
1" 11,500
Fig.2/5: Relation of size and flow rates of valves
size 3 size 2 size 1
Fig.2/6: Possible mix on one platform of precise fitting

valve sizes

2. Valves
2.1.3 Tip 3 Select valve function carefully
5/2 Double solenoid valve
After switching pulse Two solenoids

current can be shut off
5/3 valve with closed position
After the cylinder reached the

end position pressure supply
can be shut off

2. Valves
Fig.2/7: Interruption of air supply if valve has switched

2. Valves
2.1.4 Tip 4 Supply lower pressure for external pilot supply or cylinder
back stroke
A different pressure can be used for external pilot supply on

valves.
Pilot supply can be lower then Additional connections required, which means potential leakage
working pressure (e.g. in high
pressure applications)
External pilot valves allows Additional connections are required for external pilot
lower working pressure
Fig.2/8: Valves with seperate pilot supply

2. Valves
Fig.2/9: Internal pilot valve uses supply pressure to assist

in switching of the spool in the valve
Fig.2/10: External pilot valve have additional ports (82, 84,

12, 14) for pilot supply pressure to switch the
spool in the valve

2. Valves
2.1.5 Tip 5 Use 5/2 valves with reversible port
In this configuration, exhaust air does not pass through the

pressure regulators, extending their life.
Reduction of supply pressure

for non−working stroke
} CPV (port 3 and 5 combined)

} MPA
} VTSA
} CPASC
} Tiger 2000
} See Fig.2/12 } ISO
Fig.2/11:
Caution

2. Valves
6 bar 3 bar
6 bar 3 bar
Fig.2/12: If valves are driven reversibly different pressure

can be supplied to port 3 and 5 for forward and
return stroke. Port 1 will be used as exhaust port in
this configuration.
Reversibility of valves means that the exhaust ports can be

used as supply ports and vice versa.
This is possible if the seals are designed in a symmetric way
so that no sealing lip will be lifted if pressure lies at the other
side.

2. Valves
2.1.6 Tip 6 Use valve terminals with integrated (sandwich) pressure regu−
lators
An integrated (sandwich) pressure regulator reduces the

working pressure for each single valve and the number of
connection points of the regulator (exhaust air do not pass
through regulator).
Integrated design reduces connections. Space for installation is increased
Individually adjusted pressure according to application needs
MPA
VTSA... } See Fig.2/3 Valve terminal software
Fig.2/13: Valve modules with integrated pressure regulators
Caution
Savings
Up to 50 % of energy can be saved if different pressure is
used.

2. Valves
Cost for 1 m3 air at 7 bar abso 0.020 Cycle per Minute 12.00
lute pressure (Eur)
Pressure in system absolute 7.00 1 Machine working time per day (hours) 14.00
(bar)
Tubing inner diameter (mm) 8.00 Number of working days per year 240.00
Tubing length (mm) 3000.00 Cycles per year 2419200.00
Volume in tubing (m3) 0.00015 Pressure of working stroke (bar) 5.00 2
Pressure of return stroke (bar) 3.00 3
Cylinder diameter (mm) 100.00 Energy saving for working stroke (Eur) 10.03
Stroke length (mm) 70.00 Energy saving for return stroke (Eur) 20.05
Cylinder volume (m3) 0.0005 Energy saving total per year (Eur) 30.08
Fig.2/14: Example calculation with reduced pressure lines

(approx.: stroke vol. = return vol.)
5 bar 3 bar
1 2
7 bar
Fig.2/15: Exhaust air does not pass through regulators, life is

therefore extended because the seals are less
stressed.

2. Valves
2.1.7 Tip 7 Shut off compressed air supply when inactive for long periods
Advantage Disatvantage
No leakage and no consump Piston rods of cylinders move freely and maybe suddenly
tion in the branch
Re−filling and re−pressurization required
If 3/2 valve is used, system air is purged
Related Festo Energy saving products
MSX−...−EE QH−... SOE−... F−...
} See Fig.2/17
Fig.2/16: Shut−off and softstarting valve
Caution
Savings
Potential leakages via pressurized cylinder and fittings
during non−movement would be totally removed by this.

2. Valves
Fig.2/17: This master on/off valve could be either manually

actuated or actuated by a solenoid
Examples for shut−off/interruption possibilities:
S vacuum generation with vacuum ejectors
S blowing air
S mechanical stirers (e.g. stiring paint, glue, ...)
S any process with participation of staff by means of pres

ence circuits (e.g. quality proof by air gap resistance is
shut off by means of light barriers if no staff is working).

2. Valves
2.2.1 Tip 1 Use valves with the poppet or cartridge design
Rubber sealed design principle has no leakage rate in com

parison to lapped spool design.
Less leakage rates compared Contains wearing parts

to lapp spool principle
Cartridge Poppet
CPASC Tiger Classic
CPV
04 (ISO)
MPA
Typ03 MIDI/MAXI
Typ 44 (ISO)
Fig.2/18: Valves with poppet or cartridge design
Caution

2. Valves
Fig.2/19: Poppet principle
Fig.2/20: Cartridge principle

2. Valves
2.2.2 Tip 2 Use mainfold instead of individual valves
Manifold reduces number of connectors used.
Less connections means less Distance from cylinders may affect performace of application
place for leakages
Space saving design Volume of air in tubing to cylinder is increased
Common compressed air sup

ply to manifold
Different pressure zone within

manifold possible
CPV... } See Fig.2/22 CPV−SC... } See Fig.2/22
Fig.2/21: Configurable manifolds to adapt to specific needs.
Caution

2. Valves
Zone 1 Zone 2
Fig.2/22: Valve terminals assembled at Festo are completely

tested concerning leackage aspects.

2. Valves
2.3 Case 3 Reduction of electrical power
2.3.1 Tip 1 − Use valves with reduction of holding current
After switching off solenoid

power supply is reduced
electrically without loss of
function
CPV
MPA
CPASC
Fig.2/23: Since the 1990ties used circuit sheme
Savings
Electrical savings up to 70 %.

Air preparation
Chapter 3

3. Air preparation
Contents
3. Air preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

3.1.1 Tip 1 Monitor compressed air consumption of machine/application . . 3−4
3.1.2 Tip 2 Use directly actuated pressure regulator instead of pilot
actuated pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6
3.1.3 Tip 3 Use automated drain instead of manual drain . . . . . . . . . . . . . . . . 3−8
3.2.1 Tip 1 Maintain required system pressure . . . . . . . . . . . . . . . . . . . . . . . . 3−10
3.2.2 Tip 2 Ensure filter elements are changed or maintained . . . . . . . . . . . . 3−12
applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16

3. Air preparation
Energy saving on Air supply
3 5
1 4 6 1
Fig.3/1: Saving points at air supply products
Saving points at regulators, filter units, oilers, tubes, fittings

are as follows:
1 Pressure level adjusted
2 Seal of bowl
3 Oil regulation as low as possible in order to avoid

washing out the life time lubrication
4 Drain tightening
5 Switch off valves if machine not needed

(2/2−valve to encapsulate the pressure downstream)
6 Pressure switches
1. Switch off as often as possible
2. Lowest pressure level as possible
3. Splitted pressure levels

3. Air preparation
3.1.1 Tip 1 Monitor compressed air consumption of machine/application
Any changes to normal air consumption can be detected at a

very early stage.
Comparison of consumption Cost of investment

gives indication of the
performance
Charting gives indication

when the peaks of usage are
SFE1−... MS..−SFE−... GFDM−...
SFE3−... SFET−...F
MS..SFE / SFE3 / SFE1 } See Fig.3/3
Fig.3/2: Monitoring devices

3. Air preparation
Fig.3/3: In−line detection of flow indicates abnormal

consumption
Fast response (response time depends on internal volume of

the piping and pressure etc.)
Free from readjustment and wrong detection caused by pres
sure change.
Can detect clogging of nozzle and/or filter.
Can detect incomplete suction like a sensor.

3. Air preparation
3.1.2 Tip 2 Use directly actuated pressure regulator instead of

precision pressure regulator
Reduce in use of compressed air with directly actuated pres

sure regulator because of self consumption of indirect actu
ated regulators.
Non−pilot actuated regulator Accuracy is not as good as with precision pressure regulator
do not use compressed air to
maintain accuracy
LR−... LRP−...
Fig.3/4: Directly actuated pressure regulators

3. Air preparation
Fig.3/5: Additional air volume with pilot actuated regula

tors
Precision regulator needs internal operation air consumption.

If accuracy of pressure regulation is not needed a standard
regulator is recommended.

3. Air preparation
3.1.3 Tip 3 Use automated drain instead of manual drain
If mositure is released periodically occurance of moisture into

products is reduced. Moisture affects seals and grease
conditions.
Collected moisture is released

regularly
Duration time when releasing

collected moisture is con
trolled
PWEA WA−...
Fig.3/6: Automated drain devices

3. Air preparation
Strengths of PWEA
High functionality, since the system reliably operates even in
the case of problematic condensate.
Large cross section: Even coarse contaminants and

coagulate are easily removed.
No pressure loss when emptying thanks to prompt seal

ing of the system.
Flexible areas of application, since the system automati

cally adapts to changing operating conditions (e.g. chang
ing viscosity of condensate and pressure fluctuations).
Prevention of downtimes thanks to alarm function! The

alarm mode is triggered after 60 s , if the condensate
drain is faulty. The solenoid valve then opens the valve
diaphragm at specific intervals.
External fault signal, a red LED flashes and a digital signal

applies., indicating the status.

3. Air preparation
3.2 Case 2 Reduction in pressure lost
3.2.1 Tip 1 Maintain required system pressure
Any changes to the required system pressure affects perform

ance. Registration of changes points to losses or manipula
tion.
Process operation is optimum
Ensure application is working

properly
FRCS... E11 ZVS−... MA...E−RG
Fig.3/7: Pressure keeping products

3. Air preparation
Lockable service units contribute to a remaining pressure

level.
A planned cascading of filtration ensures the less pressure

losses.
40 m 5 m finefiltered air
Fig.3/8: Filter cascade
Fig.3/9: Check for energy saving features
Configuration tools help to think energy saving (e.g. shut−off

valve yes/no, regulator lockable yes/no, different pressure
zones yes/no, inserted distributers yes/no, filter cascade
yes/no, ...).
Volume can help to equalize the pressure niveau if consump
tion is very dynamic.

3. Air preparation
3.2.2 Tip 2 Ensure filter elements are changed or maintained
Clogged filter units reduce efficiency of service units.
No pressure loss besause of

no clogged filter elements
Gives an indication of the

quality of compressed air
supply
MS...−LFM−...−DA } See MSLFMA } See Fig.3/11
Fig.3/10: Products with instruction of pressure fall

3. Air preparation
Fig.3/11: LFMA − Fine filter with visual indicator. Condition of

the filter element is indicated via the differential
pressure
Recommendation:
If the pressure drop inside a filter is more than 0, 3 bar,
change the filter elements in the service unit.
Example:
with old filter element with new filter element
Pressure drop in the filter 0,4 bar 0,2 bar
Pressure difference in supply 0,2 bar 0 bar
Consumption difference because of 2% 0%

pressure difference
Average consumption of the machine 612 l/min 600 l/min

320 786 m//year 314 496 m3/year
Costs per m3 succed air 0,02 / m3 0,02 / m3
Costs per year 6 416 6 290
Difference in the year 126 0
Costs of new filter element 0 11,80
Amortisation time ca. 1 month
Fig.3/12: Comparison of maintained and not maintained filter

3. Air preparation
Check pre−Filter (40 m / 5 m) if dirty or broken. They are

flown through from outside to inside and their condition can
be seen.
Fig.3/13: Different examples of weared filter cartridges

3. Air preparation

3. Air preparation
applications
Not all applications need to Pressure booster uses compressed air to boost pressure. Up to
be supplied with 8 bar 50% volume lost
pressure
Increase pressure only for Noise pollution

specific application, saving
energy cost for rest of
applications
DPA... } See Fig.3/15
Fig.3/14: Pressure booster
Caution
of your application investments.
Savings
Up to 15% savings after factoring the cost of investments.

3. Air preparation
Variant I Variant II
Supply 10 bar Supply 6 bar + 5 % of volume at 10 bar
via pressure booster
Purchase
Compressor 80.000 80.000

Cooler/refrigerating dryer
Operation
Costs m3 0.038 /m3 0.026 /m3

Delivery volume/min. 5.0 m3/min. 5.0 m3/min.
Operating hours/a 1.200 h/a 1.200 h/a
Delivery volume (p.a.) 360.000 m3/a 360.000 m3/a
plus 5 % for pressure
booster supply air: 18.000 m3/a
360.000 m3/a 378.000 m3/a
Delivery costs of compressor in 13.572 9.828

total
Total costs p.a.
Write−down 10% p.a. 8.000 /a 8.000 /a

New investment p.a. (pr. 1.000
boosters)
Operating costs 13.572 /a 9.828 /a
Total costs p.a. 21.572 /a 18.828 /a
Saving p.a. /a 2.744 /a
a= annum (year)
Fig.3/15: Costs balance with DPA (example)
Behind the booster a dryer or a filter may be needed, if the

pressure jump in the given ambient temperature causes con
densing of the air. A tank may be needed if bigger volume of
higher pressurised air is needed.

3. Air preparation
Supply/
Exhaust valve
Pneumatic
actuator
Pressure regulator for

low−pressure setting
Fig.3/16: Tank as buffer for bigger volumes

Vacuum application
Chapter 4

4. Vacuum application
Contents
4. Vacuum application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

4.1.1 Tip 1 Use vacuum switch with vacuum applications . . . . . . . . . . . . . . . . 4−4
4.1.2 Tip 2 Use the correct pressure supply for vacuum generators . . . . . . . . 4−8
4.1.3 Tip 3 Maintain integrated silencers and filters of vacuum generators
regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10
4.1.4 Tip 4 Use vacuum pump for applications that require constant vacuum 4−12
4.1.5 Tip 5 Place vacuum generator close to application . . . . . . . . . . . . . . . . . 4−14
4.1.6 Tip 6 Choose suitable succion cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20

Energy saving on Vacuum
2
1
Fig.4/1: Saving points at vacuum lines
Saving points at vacuum lines are as follows:
1 Pressure line
2 Vacuum line
3 Suction cup
1. Short pressure line distances
2. Short vacuum line distances
3. Adequate suction−cups for perfect sealing

4.1.1 Tip 1 Use vacuum switch with vacuum applications
Using a vacuum switch allows switching off the vacuum gen

erator when required pressure is reached.
Allows the switching off of

vacuum when desired pres
sure is reached
Detected pressure change

could be used as a signal that
work piece is present
VN−...P } See Fig.4/4 SDE5
VPEV... OVEM−...
VADMI } See Fig.4/3 SDE1
Fig.4/2: Vacuum switches or integrated switches

Fig.4/3: Savings in vacuum generation
Vacuum is automatically switched off when required vac

uum is reached 2 (VADMI−P−LS, OVEM−... )
and automatically switched on again 3 to achieve re

quired vacuum
without need for any external wiring and PLC program

ming
integrated non−return valve prevents purging of the vac

uum (VADMI−P−LS, OVEM−...)
detector registers the increase of suction an switches off

in case of mal function (VADMI−...−P/N−LS, OVEM−...).

Operation cycle to handle a workpiece
Drop off Back to zero position

Evacuation time Transport
Total cycle time
Fig.4/4: Switch−off functionality during return time
Example
Energy cost comparison between VN−05 and VADMI−45. In a
similar problem during 250 days/year and 16 h/day:
Energy costs without switch−off function (VN−...):

37 /a
Energy costs with switch−off function (VADMI−...−LS):

12 /a.

Optical part detection sensors in combination with an air stop

valve help to save compressed air if no workpiece is there to
be succed.
Fig.4/5: Sensors to clarify need of vacuum

4.1.2 Tip 2 Use the correct pressure supply for vacuum generators
Supply pressure affects the vacuum pressure directly.
Vacuum is not generated ac

cording to the higher pres
sure. Check the operating
pressure to achive optimum
vacuum.
VN−...
} See Fig.4/7
Fig.4/6: Vacuum generators

Vacuum depending on supply pressure Faster evacuation time with L type

generator at 0,4 bar vacuum
(L) (L)
(H) (H)
Supply pressure [bar] Supply pressure 6 bar
Fig.4/7: Example of Festo VADM vacuum generators vacuum generators VN−...−H and
VN−...−L
The relation between vacuum ’output’ and pressure ’input’

follows a graph. Different productlines have a specific char
acteristic.
Large flow characteristic (L) is energy saving because
of a linear ratio of pressure and generated vacuum
of a faster evacuation time and as a result the possibility

to switch off the vacuum generation earlier.
See poster 050093

Three selection criteria"

4.1.3 Tip 3 Maintain integrated silencers and filters of vacuum

generators regularly
Peformance of the vacuum genrator can be improved with

better maintenance.
Ensure optimum performance

of application
VAF... In line filter } See Fig.4/10
Fig.4/8: Filter spare parts, silencers

Fig.4/9: Silencer elements to be changed
Fig.4/10: In line filter (VAF−...) to protect vacuum generator

from being clogged
Fig.4/11: Noise reduction with new filter types UO−... main

tenance free because it’s open at the end

4.1.4 Tip 4 Use vacuum pump for applications that require constant
vacuum
Minimum possible air con

sumption

Fig.4/12: Economy function www.festo.com/products/dimensioning software/download

for windows
Caution

For more detailed calculation, refer to Festo’s System guide−

Vacuum Selection Tool.

4.1.5 Tip 5 Place vacuum generator close to application
Nearer to application means faster evacuation time and there

fore less air consumption.
Faster evacuation time Weight of the vacuum generator will be on the moving axis of the
application
VN... } See Fig.4/14 VN−cartridge } See Fig.4/18
Fig.4/13: Light vacuum generators for decentral placement

1 @ andlength of the tube influences the pressure drop

Δp and therefore the vacuum level
2 @ and length of the tube influences the evacuation

time Δt
Fig.4/14: Tubing lengths and diameters
Tubing lengths and diameters have a decisive influence on

vacuum level and evacuation time. Paying attention to these
factors has a positive effect on energy consumption.

Example 1
Service unit: MS4, 1/4 inch connection
QNN = 2000 l/min. flow rate
Load device: Vacuum generator VADMI−200,

QN = 240 l/min., 6 bar, @ 2 mm (Laval nozzle)
Tubing Supply Vacuum level

pressure
Short connection 6.0 bar 89 %
PUN−8 ND (5.7 mm) 2.5 m long 5.8 bar 87 %
PUN−6 ND (4.0 mm) 2.5 m long 4.6 bar 80 %
Fig.4/15: Resisting factors in vacuum generation
ND = Nominal diameter, inner diameter as given in paran

theses.
In this configuration, the air consumption of the suction cup

is only approx. 1/10 of what the service unit can deliver.
The addition of further load devices increases the drop in
vacuum!

Example 2
1st group of bars in Fig.4/17: According to the dimensioning
formula (Fig.4/16), PUN 4 will be adequate for the vacuum
generator VN−07−H (Laval nozzle diameter 0.7 mm). Due to
the increase in volume of 1.4 % (from 1000 cm3 to 1014 cm3)
caused by the 2.5 m long PUN 4 tubing, the evacuation time
rises by 77 % (from 6.2 s to 11 s). The time advantage of
short tubing is even greater at low vacuum levels, see 1st and
2nd bar groups in Fig.4/17.
The influence of the nominal tubing diameter is even greater
in the case of vacuum generators with a low−volume suction
cup.
2 1
Fig.4/16: Calculation of the table diameters with given nozzle size
Formula for the nominal size (mm)

Supply port 1 ≥ 2 x @ venturi nozzle
Vacuum port 2 ≥ 3 x @ venturi nozzle (high vacuum)
Vacuum port 2 ≥ 4 x @ venturi nozzle (large flow)

time 1234 Evacuation time with p1 = 6 bar
Vacuum generators
1 Suction cup volume only 1000 cm3

2 Suction cup volume only 1000 cm3 plus PUN−4; 2.5 m
long (tubing volume 14 cm3)


Fig.4/17: Evacuation time as a function of tubing length with

P1 = 6 bar

Fig.4/18: Mounting of VN−cardridges in a bore hole of your

machine rack

4.1.6 Tip 6 Choose suitable succion cups
Best thightness allows to reduce the input pressure.
Less consumption Surface changes of sucked material during production may be diffi
cult
Fig.4/19: Different succion cups for every purpose

Example
Step 1 Calculating the weight of the workpiece
Step 2 Selecting the succion gripper
Step 3 Calculating the holding and on breakaway forces
Step 4 Selecting the connection diameter in relation to

succion diameter
Step 5 Taking into account the ambient conditions
Fig.4/20: Different shapes depending on surface finish
See poster 053719

Vacuum Handling"
See Poster 053799
Trend, modular vacuum suction
grippers"


Accessories
Chapter 5

5. Accessories
Contents
5. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

5.1.1 Tip 1 Ensure tubings are mounted properly . . . . . . . . . . . . . . . . . . . . . . 5−4
5.1.2 Tip 2 Use push/pull fittings with sealing lip . . . . . . . . . . . . . . . . . . . . . . 5−6
5.1.3 Tip 3 Select correct tubing design suitable to the purpose used for . . . 5−8
5.1.4 Tip 4 Tighten sealing rings for threading connections . . . . . . . . . . . . . . 5−10

5.2.1 Tip 1 Reduce the length of the tubing used . . . . . . . . . . . . . . . . . . . . . . . 5−12
5.2.2 Tip 2 Use multiple distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−15
5.2.3 Tip 3 Ensure that exhaust interfaces are suitable . . . . . . . . . . . . . . . . . . 5−18

5. Accessories
Energy saving on Accessories
Fig.5/1: Saving points on accessories
Saving points at tubing, connectors, sealing rings are as

follows:
1 Tubing (dimensioning, length, bendings)
2 Cutted surface (rectangled, not stressed)
3 Sealing rings and threads (face, tape, material)
KISS − keep it striktly
1. Short (tubings)
2. Smooth (diameter variations)
3. Straight (adapters)
4. Same (size of fittings)

Maintain the connections

5. Accessories
5.1.1 Tip 1 Ensure tubings are mounted properly
Eliminate burrs on tubing, deformation of the tubing and en

sure the orthogonal cut of the tube end.
Less leakages from incorrect

sealing of connectors
ZRS } Pipe and tube cutter ZDS QSO
Fig.5/2: Assembly tools for best results

5. Accessories
cutted with scissors cutted with knife
Fig.5/3: Burrs on tubing the tubing then damages the seal

system
Fig.5/4: Cut end of tubing not orthogonal the tubing is

not guided correctly in the fitting
Fig.5/5: Tools for easy mounting/demounting without de

formation of other connections

5. Accessories
5.1.2 Tip 2 Use push/pull fittings with sealing lip
Sealing surface instead of sealing line.
Reduces leakages by com

pensation of grooves in the
tube
Bigger sealing contact
Under pressure the inner lip is

pressed tightly to the tube
QS−... QS−F−...
QS−B−...
QS... Festo push/pull fittings
Fig.5/6: Push/pull fittings

5. Accessories
sealing lip
Fig.5/7: Washer disc based fitting with sealing lip (QS−...,

QS−B−...
o−ring
Fig.5/8: Washer disc based fitting with o−ring (QS−F−...)
A fitting with a sealing lip offers in comparison to O−ring

sealed fitting a better sealing characteristic.

5. Accessories
5.1.3 Tip 3 Select correct tubing design suitable to the purpose

used for
Tubing life will be extended, leading to less leakage over time.
Ensure longer life and durabil

ity of the tubing used
Festo tube selection software } See Fig.5/10 and Fig.5/11
Fig.5/9: Tools to define suitable tubing types

5. Accessories
Damage Application
Chemical damage Detergents, disinfection agents, cooling agents
Stress cracks Solvents, lubricants, hydrocarbon
Microbial damage Outdoor areas, stacks, channels, areas with

high pollution, wet and warm environment
(cable channel)
Physical damage Outdoor areas, applications with artificial UV−

radiation e. g. disinfection in food industry
Fig.5/10: Symptoms of stressed tubings
Tube type Tubing Chemical Stress cracks Microbial Physical

damage damage damage
PUN−... Polyesterurethan 0 +
PUN−H−... Polyetherurethan + 0 ++ +
PAN−... Polyamide 0 0 0 0
PLN, PEN Polyethylene ++ + ++ +
PFAN−... Perfluoralkoxy− +++ ++ ++ ++

polymer
Fig.5/11: Rough selection criteria for tubings ( = not resistant against, 0 = critical, (++)+ =
(very) resistant against)
Fig.5/12: Chemical, biological, physical dammage of tubings

5. Accessories
5.1.4 Tip 4 Tighten sealing rings for threading connections
Protects better against leakage.
Better sealing means lower

leakages
Minimum relaxing effect over

lifetime due to solid support
ring
OK... } See Fig.5/14
Fig.5/13: Non−relating sealings for threads (cylindric form)

5. Accessories
With the new OK sealing ring Festo has succeeded in

developing a sealing ring which is soft−sealing on
both sides when manually tightened.
In combination with the fixed stop this new sealing
system is compatible with ISO 16030.
Owing to its two products PA and PUR, it is suitable

for use in all pneumatic applications.
Fig.5/14:
Sealing with tape, apart from being slowly installed, can leave
debris on the inside of the elements and can cause obstruc
tions in valves, specially in small holes/ports.
Sealing with liquid is also slowly installed and makes future

dismantling much more difficult.

5. Accessories
5.2 Case 2 Reduction in pressure loss
5.2.1 Tip 1 Reduce the resistance of the tubing used
Correct dimensioning of length and diameter reduces the loss

of energy over distance.
Actuation time is reduced
Volume of air in tubing is re

duced
} See Fig.5/16
Fig.5/15: ProPneu Software for calculation and simultation
Caution

5. Accessories
Straight QS−connectors
Tube length [mm]
Fig.5/16: Flow rate will be reduced over longer length of tubings
Tubings which are filled and exhausted all the time should be
dimensioned smaller than supply tubings under continuous
pressure.
Flow controllers may be avoided by selecting smaller tube
size.

5. Accessories
3 2
1 Supply tubing under constant pressure

2 Tubing for forward stroke (working stroke)
3 Tubing for return stroke
Fig.5/17: Optimized tubing concept for specific needs

5. Accessories
Fig.5/18: Minimal restrictions by using straight tubings.

5. Accessories
5.2.2 Tip 2 Use multiple distributors with adequate counter parts
Pressure loss is lower than it Longer tubings may be necessary

is with single T−distributors
Fig.5/19: Multiple distributors to replace several T−distributors

5. Accessories
Designation Connecting Equivalent length [m]

piece
i
Inner diameter [mm]
9 12 14 18 23 40 50 90 100
Ball valve 0.2 0.2 0.2 0.3 0.3 0.5 0.6 1.0 1.3
Elbow 0.6 0.7 1.0 1.3 1.5 2.5 3.5 4.5 6.5
T−connection 0.7 0.85 1.0 1.5 2.0 3.0 4.0 7.0 10
Reducer from 0.3 0.4 0.45 0.5 0.6 0.9 1.0 2.0 2.5
2d to d
Designation Connecting Equivalent length [m] / Nominal diameter [DN]

piece DN DN DN DN DN DN DN
25 40 50 80 100 125 150
Poppet valve 8 10 15 25 30 50 60
Slide valve 1.2 2 3 4.5 6 8 10
Ball valve 0.3 0.5 0.7 1 1.5 2 2.5
Elbow sharp 1.5 2.5 3.5 5 7 10 15
Elbow smooth 0.3 0.5 0.6 1 1.5 2 2.5
Bow 0.15 0.25 0.3 0.5 0.8 1 1.5
T−connection 2 3 4 7 10 15 20
Reducer from 0.5 0.7 1 2 2.5 3.5 4

2d to d
Fig.5/20: Equivalent length of connection pieces (indicates flow resistance/pressure loss)

5. Accessories
Interfaces and couplings always consists out of a male and a

female part. Tubes and fittings mostly seal better if they come
from the same supplier.
Important is the inside passage of couplings to be free of

turbulences.
Fig.5/21: Air flow (turbulences) in couplings

5. Accessories

5. Accessories
5.2.3 Tip 3 Ensure that exhaust interfaces are suitable
Minimum use of compressed

air
Fig.5/22: Exhausting interfaces

Exhausting interfaces have to be maintained that they will not
be blocked.

5. Accessories
Air savings are possible with adequate solutions:
Blowing air Description Saving potentials

parameters
Blowing time Time, the air blow is Reduction of time

active
Blowing pulse Interruption rate of a Enlarge interruption in

steady blow tervals
Blowing pressure Pressure level in the Use of a regulator

tubing
Blowing force Diameter of nozzle in Saving nozzles

the mouthpiece
Blowing jet number Distribution situation Air fan is often better

at the mouthpiece than single jet
Blowing jet length Distance of mouth Short distances for

piece to the workpiece lower forces
Blowing jet direction Fix or variable orienta Combination with

tion of the mouthpiece semi−rotary drive for
best positioning of jet
Fig.5/23: Realize savings on blowing air

5. Accessories
Fig.5/24: Circuit for strong air pulse with less air consump
tion

Controllers and concepts
Chapter 6

6. Controllers and concepts
Contents
6. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

6.1.1 Tip 1 Decentralise pneumatic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−4
6.1.2 Tip 1 Analyse high frequent operations to find energy waist . . . . . . . . . 6−6
6.2.1 Tip 1 Monitor continuously the energy status . . . . . . . . . . . . . . . . . . . . 6−8
6.3 Case 3 Reduction in electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−10
6.3.1 Tip 1 Select positioning drive according to the specific demands . . . . . 6−10
6.3.2 Tip 2 Use self−locking lead screw drives . . . . . . . . . . . . . . . . . . . . . . . . . 6−12

Energy saving with controllers and concepts
3 1 2
Fig.6/1: Saving points with controllers and concepts
Saving points at controllers and concepts are:
1 High speed motions
2 Stillstand positions
3 Controller distances
1. Stillstand without energy consumptions
2. Clear defined high speed movements
3. Short pneumatic lines, long information lines (electric,

wireless)

6.1.1 Tip 1 Decentralise pneumatic circuits
Minimal tubing volume
Systems/Decentralized concepts
Fig.6/2: Decentral cabinet located near the controlled actuators


6.1.2 Tip 1 Analyse high frequent operations to find energy waist
Operations too quick for Additional space needed but

human eyes become obvious only temporarily needed
by slow motion films
SBO..−M−... FCT−...
(plug in for SBO..−M network)
Fig.6/3: Optical devices to visualize high speed operations


Changes in the status are communicated immediately and

therefore longlasting unfavourable conditions are avoided.
6.2.1 Tip 1 Monitor continuously the energy status
Quickest possible reaction additional weight, additional space to calculate

times
Sensor Controller Software Visualisation
1 SFE−... CPX−FEC−... FST4−... FED−.../VIPWIN

MS6 SFE
MS6−SFE−...
2 FMT−...
3 WEBMonitor
Sensor Controller Software Visualisation
4 SFE−... CECX−... CoDeSys pbF FED−.../VIPWIN

MS6 SFE
MS6−SFE−...
5 FED−CEC−... VIPWIN
Fig.6/4: Todays and upcoming concepts to monitor machine conditions


6.3 Case 3 Reduction in electrical power
6.3.1 Tip 1 Select positioning drive according to the specific demands
Adequate solution Time intensive trading process
Fig.6/5: Positioning Drives Software to find the specific solution

www.festo.com/products/dimensioning software/Download for windows or
www.festo.com/engeneering/selection&dimensioning/software


6.3.2 Tip 2 Use self−locking drives
Self−locking lead screw drives save energy because they can

hold a position without spending extra energy.
Short cables avoid losses of transmitting between motor and

controller.
No additional break necessary Control unit necessary to shut off current during stillstand of axis
DNCE−... DMES−...
Fig.6/6: Electrical axes with self locking lead screws

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Energy_Questions_A5_140808.qxp:Layout 1 14.08.

2008 13:33 Uhr Seite 1

Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leonard Lau

Editors . . . . . . . . . . . . . . . . . . . . . . . . . . . U. Will, S. Lensdorf

Layout . . . . . . . . . . . . . . . . . . Festo AG & Co. KG, Abtl. SV−P

Type setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DUCOM

Order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555 662 . . . . . . . . . . . . . . . . . . . . . . . .

E (Festo AG&Co., D73726 Esslingen, Federal Republic

The copying, distribution and utilization of this document as

Festo P.BE−FESS−01−EN en 0508a I

II Festo P.BE−FESS−01−EN en 0508a

Important user instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

1.1 Case 1  Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 1−4

2.1 Case 1  Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 2−4

Festo P.BE−FESS−01−EN en 0508a III

2.1.6 Tip 6  Use valve terminals with integrated (sandwich) pressure

2.2 Case 2  Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . . 2−18

2.3 Case 3  Reduction of electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−22

3. Air preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

3.1 Case 1  Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 3−4

3.2 Case 2  Reduction in pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10

4. Vacuum application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

4.1 Case 1  Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 4−4

IV Festo P.BE−FESS−01−EN en 0508a

5.1 Case 1  Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . 5−4

5.2 Case 2  Reduction in pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−12

6. Controllers and concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

6.1 Case 1  Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 6−4

Festo P.BE−FESS−01−EN en 0508a V

Important user instructions

In addition, the following pictogram marks passages in the

Electrostatically sensitive components: Incorrect handling

VI Festo P.BE−FESS−01−EN en 0508a

Marking special information

S The bullet denotes activities which can be carried out in

1. Figures denote activities which must be carried out in the

 Hyphens denote general activities.

Festo P.BE−FESS−01−EN en 0508a VII

As a family enterprise Festo feels responsible also for long−

The purpose of this manual is to give prospective customers

This manual for Energy Saving evolved out of necessity due

The result is a collection of tips and tricks that has a clear

Not all tips and tricks may be applicable to your machine or

VIII Festo P.BE−FESS−01−EN en 0508a

"The contents have been divided in six different sections,

 Controllers and concepts

It is important to note that while this manual is not designed

Festo P.BE−FESS−01−EN en 0508a IX

What is Energy Saving?

Energy saving opportunities are present everywhere in pneu

Why Energy Saving is important?

With the raising price of worldwide crude oil prices, energy

There are also environmental concerns in regards to the re

X Festo P.BE−FESS−01−EN en 0508a

How can Energy Saving be applied?

How to use this manual?

To use this manual effectively, start from page 1 and move

Useful Festo software

1. Pneumatic dimensioning  ProPneu

2. Fluidic muscle  Festo MuscleSIM

3. Tubing selection  Tube selector

6. Mass moment of inertia  calculation program

Visit Festo at www.festo.com for more information on

Festo P.BE−FESS−01−EN en 0508a XI

1.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 1−4

2.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 2−4

2.1.6 Tip 6 Use valve terminals with integrated (sandwich) pressure

2.2 Case 2 Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . . 2−18

2.3 Case 3 Reduction of electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−22

3.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 3−4

3.2 Case 2 Reduction in pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10

4.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 4−4

5.1 Case 1 Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . 5−4

5.2 Case 2 Reduction in pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−12

6.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 6−4

Hyphens denote general activities.

Controllers and concepts

1. Pneumatic dimensioning ProPneu

2. Fluidic muscle Festo MuscleSIM

3. Tubing selection Tube selector

6. Mass moment of inertia calculation program

+ = possibility highly given, o = possibility maybe given, = possibility less given

1.1 Case 1 Reduction in compressed air consumption . . . . . . . . . . . . . . . . . . 1−4

1.2 Case 2 Reduction in compressed air leakage . . . . . . . . . . . . . . . . . . . . . . . 1−14

1.3 Case 3 Reduction in friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−22

1.4 Case 4 Reduction in Pressure lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30

1.1.1 Tip 1 Use single acting cylinders

1.1.2 Tip 2 Use clamping modules to hold cylinder in position

1.1.4 Tip 4 Use correct dimensioned cylinders

1.2.1 Tip 1 Use special seals in cylinders