Part A - Exercises: © Festo Didactic GMBH & Co. KG - 541091

Contents
Part A – Exercises
Exercise 1: Realising a diverting device ___________________________________A-3

Exercise 2: Insertion of drinks bottles ___________________________________A-15
Exercise 3: Realising a selection station _________________________________A-23
Exercise 4: Machining of key blanks ____________________________________A-39
Exercise 5: Bending of mounting brackets _______________________________A-49
Exercise 6: Realising a filling system ____________________________________A-57
Exercise 7: Bonding of components _____________________________________A-67
Exercise 8: Selecting modes of operation ________________________________A-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________A-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP FUNCTION ____________________A-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function____________________ A-103
Exercise 12: Eliminating a fault on a machining station ___________________ A-113
© Festo Didactic GmbH & Co. KG • 541091 A-1

Contents
A-2 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device
Training aims • To familiarise yourself with the design and function of valve terminals.
• To be able to use valve terminals in accordance with requirements.
Problem definition Drinks bottles are to be diverted from one conveyor to another using a diverting
device. By pressing a pushbutton the frame of the diverting device is to advance. A
bottle is transferred and conveyed in the opposite direction. By pressing another
pushbutton, the frame is to return into the initial position.
Parameters • A double-acting cylinder is to be used.

• Cylinder control is to be realised indirectly and via a pushbutton.
• In the event of a power failure the cylinder piston rod is to remain in the assumed
position.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Positional sketch
Diverting device for drinks bottles
1. Cylinder 1A1 is in the retracted end position.

2. The 5/2-way double solenoid valve 1V1 is to switch by pressing pushbutton S1
and the cylinder to move into the forward end position.
3. The 5/2-way double solenoid valve is to reverse by pressing pushbutton S2 and
the cylinder to move into the retracted end position.

Name: Date:
Fundamentals: Installation costs Sheet 1 of 5
The configuration, tubing and wiring of the components of an electropneumatic

control system should be selected such as to keep the sum total of equipment,
installation and maintenance costs as low as possible. The following choices are
available as regards wiring:
• Conventional wiring technology, e.g. terminal strips

• Advanced installation concepts, e.g. wiring using multi-pin connectors
The following choices are available in respect of configuration, i.e. number of drives
and tubing requirements:
• Individual mounting of solenoid operated directional control valves

• Block mounting (manifold or valve terminal)

Name: Date:
– Compare the above listed concepts using the example of this control system in
terms of reducing the tubing costs.
Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.
Components Individual mounting Block mounting of Saving when using

of directional control directional control block mounting
valves valves
Tubing
Number of compressed
air distribution units
Amount of tubing for

supply to compressed air
distribution unit
Amount of tubing for

compressed air supply to
control chains
Amount of tubing
between directional
control valves and
cylinders
Silencers
Number of silencers for

control chains

Name: Date:
– Which concept enables you to achieve a reduction in tubing costs? Explain the
reason for your choice.
Note
Reason Individual mounting Block mounting of

of directional control directional control
valves valves

Name: Date:
– Compare the above listed concepts using the example of this control system with
regard to reducing wiring costs
Note
Use the individual valves of TP201 or the MPA valve terminal from TP202 and the
Wiring table
Components Cables Number of Number of

terminals/components terminals/components
Conventional wiring Multi-pin wiring concept
technology
Control cabinet 1 1
Terminal strip 1 in control cabinet Earthing cable
Supply voltage (24 V)
PLC outputs (actuation of solenoid

coils)
PLC inputs (evaluation of proximity

sensors)
Terminal strip 1 in control cabinet, overall
Cable from control cabinet to Cable between terminal strips 1 and

terminal box 2
Cable from terminal strip 2 Proximity sensors (3 wires per

(in terminal box) proximity sensor)
Solenoids
(2 wires per solenoid)
Terminal strip 2, overall
Cable to directional control valves Connection of solenoid coils

and sensors
Connection of sensors

Name: Date:
Fundamentals: Reducing the wiring costs Sheet 5 of 5
– Which concept enables you to achieve a reduction in wiring costs? Explain the
reason for your choice.
Note
Reason Conventional wiring Multi-pin wiring

technology concept

Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3
– Complete the pneumatic circuit diagram for the diverting device.
4 2
5 3
1
Pneumatic circuit diagram with individual valve

Name: Date:
– Complete the pneumatic circuit diagram for the diverting device.
0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit diagram with valve terminal (circuit diagram in DIN A3 format in Part D)

Name: Date:
– Complete the electrical circuit diagram for the diverting device.
+24 V 1 2 3 4
A1 A1
A2 A2
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Electrical circuit diagram

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


Exercise 2: Insertion of drinks bottles
Training aims • To familiarise yourself with the design and function of valve terminals.
• To be able to use valve terminals in accordance with requirements.
Problem definition Crates of drinks are to be individually loaded. The crates are to be moved towards a
loading point via a conveyor, where they are put into the loading position and raised
into a retaining frame.
Parameters • The end positions of the cylinder are to be sensed via limit switches and
proximity sensors.
• The drinks crate is to be detected via a proximity sensor.
6. Check the circuit operation .

Positional sketch
Loading station for drinks bottles
1. Cylinder 1A1 is to advance whereby the drinks crates are brought into the
loading position.
2. Cylinder 2A1 is to advance thereby lifting the drinks crate into the retaining frame
of the loading station.
3. 20 drinks bottles are to be inserted into the crate.
4. Then cylinder 1A1 is to retract, followed by cylinder 2A1.
5. The overall sequence is therefore:
1A1+ 2A1+ 1A1– 2A1–

Exercise 2: Inserting of drinks bottles
Name: Date:
Fundamentals: Valve block mounting Sheet 1 of 2
Due to the wide range of different designs of electromagnetic control systems, a

comparison of individual valves and valve terminals in industrial practice reveals a
number of different advantages and disadvantages.
– Compare the concepts of individually mounted or block mounted directional

control valves as regards the tubing up of spatially separate control systems.
Which concept is of advantage? Explain the reasons for your choice.
Reason Individual mounting Block mounting of

of directional control directional control
valves valves

Name: Date:
Fundamentals: Current reduction with solenoid coils Sheet 2 of 2
The directional control valves from TP201 or the MPA valve terminal from TP202
respectively, are equipped with a current reducer (see technical description of the
individual valve from TP201 or the MPA valve terminal from TP202)
– Describe what is understood by the term “current reduction“ .
Description: “Current reduction“
– Describe the advantages of current reduction.
Description: Advantages as a result of current reduction

Name: Date:
– Complete the pneumatic circuit diagram for the loading station.
1 1 1 1
2 2 2 2
4 2 4 2
5 3 5 3
1 1
Pneumatic circuit diagram for individual valves

Name: Date:
– Complete the pneumatic circuit diagram for the loading station.
1 1 1 1
2 2 2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 2M1 2M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit diagram with valve terminal (circuit diagram to DIN A3 format in Part D)

Exercise 2: Inserting of drinks bottles
Name: Date:
– Complete the electrical circuit diagram for the loading station.
+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13
2B1 2B2 13
2 4 2 4 S1
1B1 1 B2 14
1 1
A1 A1 A1 A1 A1 1M1 2M1 1M2 2M2

K1 K2 K3 K4 K6
A2 A2 A2 A2 A2
0V 12 12 12 12 12 12
11 14 11 14 11 14 11 14 11 14 11 14
22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44

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

Exercise 3: Realising a selection station
Training aims • To be able to solve the problem of signal overlap in a sequence control according
to the group method.
Problem definition Similar workpieces of different lengths are to be transported on a conveyor. If a long
workpiece is detected, a cylinder is to raise the pronged stop plate, whereby the
workpiece is stopped in the feed position and a second cylinder is to push it into the
paternoster. Short workpieces are not stopped and are dropped into a basket.
Parameters • This sequence control results in signal overlap. This problem is to be solved via
the group method.
Project task 1. Answer the question or carry out the exercises regarding the training contents
listed.
2. Draw the displacement-step diagram.
3. Create the appropriate function diagram.
4. Draw the pneumatic and electrical circuit diagrams for the selection device.

Positional sketch
Selection station
1. Cylinder 1A1 is to raise the pronged stop plate if a long workpiece is detected,
whereby the workpiece is stopped in the feed position.
2. Cylinder 2A1 is to push the workpiece into the paternoster.
3. Cylinder 2A1 is then to retract, followed by cylinder 1A1.
4. The overall sequence represented in abbreviated notation is:
1A1+ 2A1+ 2A1– 1A1–

Name: Date:
Fundamentals: Signal overlaps Sheet 1 of 3
A displacement-step diagram is a useful aid for circuit diagram design and helps
with fault finding and the maintenance of machinery.
Sequence
1. Cylinders 1A1 and 2A1 are retracted in the initial position, the limit switch 1B1
and the proximity sensor 2B1 are actuated.
2. The cylinder moves into the forward end position if the pushbutton S1 is pressed
AND the limit switch 1B1 is actuated.
3. The limit switch 1B2 is actuated and the cylinder 2A1 advances. The proximity
sensor 2B2 is actuated in the forward end position.
4. Cylinder 2A1 moves into the retracted end position and actuates the proximity
sensor 2B1.
5. Cylinder 1A1 retracts.
– Draw the displacement-step diagram of the sequence described.
1 2 3 4 5=1
1A1
2A1
Step 1 Step 2 Step 3 Step 4
Displacement-step diagram

Name: Date:
Fundamentals: Signal overlap Sheet 2 of 3
Signal overlap(s) occur(s) due to the power section and operating sequence
described.
– Describe this problem.
Description: Signal overlap(s)

Name: Date:
Fundamentals: Signal overlap Sheet 3 of 3
– Describe how this problem is to be solved.
Description: Solving the problem of signal overlap(s)

Name: Date:
Fundamentals: Group method Sheet 1 of 3
This signal overlap can be prevented by forming groups of movement (creating

control circuits).
1. Form the group(s) for the control sequence described above.

2. Designate the solenoid coils.
3. Designate the signalling elements/memory inputs at the group separation.
Enter which solenoid coil the respective memory output influences.
Note
Signalling elements at the group separation must act on a memory input (e.g. relay
with latching circuit or RS flipflop); the memory output allocated to the memory
input initiates the subsequent movement.
4. Designate the signalling element within the group(s).

Enter which solenoid coil(s) the respective signalling elements influence.
Note
Signalling elements within the group initiate the subsequent movements directly.

Name: Date:
1. Group formation
1A1+ 2A1+ 2A1– 1A1–
2. Designation of solenoid coils
1A1+ 2A1+ 2A1– 1A1–

Name: Date:
3. Designation of signal generators/memory inputs at the group separation, i.e.

allocation of memory outputs/solenoid coils
1A1+ 2A1+ 2A1– 1A1–
4. Designation of signalling elements within the group, i.e.

allocation of signalling elements/solenoid coils
1A1+ 2A1+ 2A1– 1A1–

Name: Date:
Fundamentals: Displacement-step diagram – group formation Sheet 1 of 3
– Create the displacement-step diagram of the cylinder movements described and

form the group.
Note
The control system will be less complex if you link up as many movements as
possible within one group.
1A1+ 1A1– 2A1+ 3A1+ 3A1– 2A1–

1 2 3 4 5 6 7 8
1
1A1
0
1
2A1
0
1
3A1
0

Name: Date:
1A1+ 2A1+ 2A1– 3A1+ 1A1– 3A1–

1 2 3 4 5 6 7 8
1
1A1
0
1
2A1
0
1
3A1
0
3A1– 1A1+ 3A1+ 2A1+ 2A1– 1A1–

1 2 3 4 5 6 7 8
1
1A1
0
1
2A1
0
1
3A1
0

Name: Date:
1A1+ 3A1+ 1A1– 2A1– 3A1– 2A1+

1 2 3 4 5 6 7 8
1
1A1
0
1
2A1
0
1
3A1
0

Name: Date:
Fundamentals: Designing a function diagram Sheet 1 of 1
A function diagram and/or functions chart is of help in several ways. For example to
assist with systematic circuit diagram design or as an auxiliary means for fault
finding and maintenance of machinery.
– Design the function diagram for the selection station.
Note
Combine the signal switching functions, i.e. signal switch-off function in such a way
that one signalling element switches off two interference signals at a time; this
simplifies the circuit diagram.
1 2 3 4 5=1
1
Cylinder 1A1
1
Coil 1M1
0
1
Coil 1M2
0
Cylinder 2A1
1
Coil 2M1
0
1
Coil 2M2
0
1
Supply
voltage
0

Name: Date:
Pneumatic circuit diagram of the selection station.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 2M1 2M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

Name: Date:
– Complete the electrical circuit diagram for the selection station.
Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13
1B2 2B2 13
2 4 2 4 S1
1B1 2B1 14
1 1
A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 1M1 2M1 2M2 1M2
A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12
11 14 11 14 11 14 11 14 11 14 11 14 Group 1 Group 2
22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44
Electrical circuit diagram (circuit diagram in DIN A3 in Part D)

Name: Date:
Completing the equipment list Sheet 1 of 1
an equipment list.
– Complete the equipment list by entering the number of required components in

the table below.
Cylinder, double-acting
One-way flow control valve
5/2-way double solenoid valve (plate J on valve terminal)
Limit switch, electrical
Proximity sensor, electronic
Pushbutton (normally open contact)
Relay
1 Manifold
1 On/off valve with filter regulating valve
1 Compressed air supply
1 Power supply unit 24 V DC
Equipment list


Exercise 4: Machining of key blanks
Training aims • To be able to design a displacement-step diagram for a sequence control.

• To be able to transcribe a function chart to GRAFCET.
• To be able to design a sequence chain using spring-return valves.
Problem definition Key blanks are to be fed towards a machine tool. A handling device is to be used for
this. First, a gripper picks up the key blanks. A lifting cylinder is to lift the key blanks
to the level of the machine tool and a feed cylinder to move the blank into the
machine position.
Parameters • Double-acting cylinders and solenoid valves with spring return are to be used .
Project task 1. Draw the displacement-step diagram.

2. Design the appropriate function diagram.
3. Transcribe the function chart shown to GRAFCET.
4. Draw the pneumatic and electrical circuit diagrams for the feed limiting and
turning station.
6. Check the equipment list.

Positional sketch
Machining of key blanks
1. Lifting cylinder 1A1 is in the lower end position.

2. Pressing of pushbutton S1 is to cause the 5/2-way solenoid valve to reverse and
the lifting cylinder to move into the upper end position.
3. Once the lifting cylinder 1A1 has advanced, the feed cylinder 2A1 is to move into
the forward end position.
4. When cylinder 2A1 reaches the forward end position, cylinder 2A1 is to retract
first and lifting cylinder 1A1 is to subsequently move downwards.
5. The sequence is:
1A1+ 2A1+ 2A1– 1A1–
Note
The gripper is not taken into account in the design.
The machining time (cylinder 2A1 in the forward end position) is not taken into
account.

Name: Date:
Fundamentals: Displacement-step diagram Sheet 1 of 2
1. Cylinders 1A1 and 2A1 are retracted in the initial position and the limit switches
1B1 and 2B1 are actuated.
2. If pusbutton S1 is pressed AND the limit switch 1B1 is actuated, cylinder 1A1
moves into the forward end position and proximity sensor 1B2 is actuated.
3. Cylinder 2A1 advances and proximity sensor 2B2 is actuated in the forward end
position.
4. Cylinder 2A1 returns into the retracted end position and actuates the limit
switch 2B1
Consequently, the overall sequence is:

1A1+ 2A1+ 2A1– 1A1–
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
1M1 2M1
5 3 5 3
1 1
Pneumatic circuit diagram

Name: Date:
Fundamentals: Designing the displacement-step diagram Sheet 2 of 2
A displacement-step diagram is a useful aid for systematic circuit diagram design

and also helps with fault finding or maintenance of machinery.
– Design the displacement-step diagram for the sequence described.
1 2 3 4 5=1
1A1
2A1

Name: Date:
Fundamentals: Designing the function diagram Sheet 1 of 1
A function diagram and/or function chart is useful in several ways. For example to
assist with systematic circuit diagram design or as an auxiliary means for fault
finding or maintenance of machinery.
– Design the function diagram for the exercise definition described.
1 2 3 4 5=1
1
Lifting cylinder 1A1
1
Coil 1M1
0
Feed cylinder 2A1
1
Coil 2M1
0
Function diagram

Name: Date:
Fundamentals: Drawing up GRAFCET Sheet 1 of 2
– Transcribe the function chart shown to GRAFCET.
A4 0
START
&
4.1: 1B1
1
Lifting S Coil 1M1 on 1B2
cylinder
to move up
1.1: 1B2
2
S Coil 2M1 on 2B2
Key to
advance
2.1: 2B2
3
Key to
S Coil 2M1 off 2B1
retract
3.1: 2B1
4
Lifting S Coil 1M1 off 1B1
cylinder to
move down
A1
Function chart

Name: Date:
Fundamentals: Drawing up GRAFCET Sheet 2 of 2
1B1*2B1 “Initial position”
GRAFCET

Name: Date:
Pneumatic circuit diagram of the handling unit.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
1V1 4 2 2V1 4 2 -V- 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
1M1 2M1 -M1 -M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the handling unit.
Signal input Signal processing Signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1B2 2B2 13
2 4 2 4 S1
1B1 2B1 14
1 1
A1 A1 A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12
1A1+ 2A1+
11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
1A1+ 2A1+ 2A1- 1A1-
Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

Name: Date:
an equipment list.

the table below.
5/2-way solenoid valve (plate M on valve terminal)
Relay
1 Manifold
Equipment list

Exercise 5: Bending of mounting brackets
Training aims • To be able to detect signal overlaps in a sequence control.

• To be able to design a sequence chain using double solenoid valves.
Problem definition Mounting brackets are to be bent from sheet metal strips using a pneumatic bending
device. The sheet metal strips are inserted manually into the bending device. The
bending cylinders are to be actuated using double solenoid valves. The operational
reliability of the bending device must be ensured.
Note
Protective equipment required in industrial practice is not taken into account.
Parameters • The advancing and retracting speeds during the bending operation are to be
independently adjustable.
Project task 1. Draw the displacement-step diagram.

2. Draw up the appropriate function diagram and the GRAFCET.

Positional sketch
Bending device for sheet metal
1. The bending cylinders 1A1 and 2A1 are retracted.

2. If the START button S1 is pressed, cylinder 1A1 is to advance.
3. Once the bending cylinder 1A1 reaches the forward end position, bending
cylinder 2A1 is to advance and bend the bracket fully.
4. Bending cylinder 2A1 is then to retract, followed by bending cylinder 1A1.
5. Consequently the motion sequence is:
1A1+ 2A1+ 2A1– 1A1–

Name: Date:
Designing the displacement-step diagram Sheet 1 of 1
1. Cylinders 1A1 and 2A1 are retracted in the initial position and the limit switches
1B1 and 2B1 are actauted.
2. If the START button S1 is pressed AND the limit switch 1B1 is actuated, cylinder
1A1 advances into the forward end position and the proximity sensor 1B2 is
actuated.
3. Cylinder 2A1 advances into the forward end position and the proximity sensor
2B2 is actuated.
4. Cylinder 2A1 moves into the retracted end position and actuates limit switch
2B1.
– Draw the displacement-step diagram of the sequence described.
1 2 3 4 5=1
1A1
2A1

Name: Date:
Designing the function diagram Sheet 1 of 1
– Design the function diagram for the bending device described.
1 2 3 4 5=1
1
Cylinder 1A1
1
Coil 1M1
0
1
Coil 1M2
0
Cylinder 2A1
1
Coil 2M1
0
1
Coil 2M2
0
1
Supply
voltage
0
Function diagram

Name: Date:
Drawing up the GRAFCET Sheet 1 of 1
– Draw up the GRAFCET for the sequence described.
1B1*2B1 “Initial position”
GRAFCET

Name: Date:
Pneumatic circuit diagram of the bending device.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 2M1 2M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram of the bending device.

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34
1B2 2B2 13
2 4 2 4 S1
Start 11 11 11 11 11 11 11 11 21 11 31 31 31 31
1B1 2B1 14
1 1 12 14
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
21 21 21 21 21 41 41 41 31
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 1M1 2M1 2M2 1M2

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14
22 22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
1A1+ 2A1+ 2A1- 1A1- Control

step

Name: Date:
an equipment list.

the table below.
Relay
1 Manifold
Equipment list

Exercise 6: Realising a filling system
Training aims • To familiarise yourself with the mode of operation of different proximity sensors.
• To be able to select proximity sensors in line with parameters.
• To familiarise yourself with logic operations and to be able to realise these.
Problem definition In a filling plant, filled jars are to be sealed with lids. Both jars and lids are fed
independently of one another. Filled jars are to be sealed with lids and incorrectly
filled jars are to be rejected.

Positional sketch
Filling of jam jars
1. The inductive proximity sensor B1 is located at the lid feed.

2. The following are located at the jar feed:
The capacitive proximity sensor B2, which detects whether a jar is present,
The optical proximity sensor B3, which detects whether the filling level in the jar
is correct.
3. Cylinder 1A1 is to seal the correctly filled jar with a lid.
4. Any jars not filled correctly are to be rejected by cylinder 2A1.

Name: Date:
Fundamentals: Logic operations Sheet 1 of 4
The following text information is obtained on the basis of the control function of the
filling system:
a) B1 AND B2 AND B3 = 1M1 (Cylinder 1A1 to advance)

or
b) B1 AND B2 AND (NOT B3) = 2M1 (Cylinder 2A1 to advance)
– Draw up the appropriate boolean equations.
a)
_____________________________________________________________________
b)
_____________________________________________________________________
– Design the appropriate logic symbols.
a) b)
– Prepare the appropriate ladder diagrams.
a) b)

Name: Date:
Fundamentals: Proximity sensors Sheet 2 of 4
Electronic sensors include inductive, optical and capacitive proximity sensors. These
sensors do not switch any moving contacts. Instead the output is connected
electronically either to the supply voltage or to earth (= output voltage 0 V).
– Describe the design and function of an inductive proximity sensor.
Description of design and function Symbol
BN
BK
BU

Name: Date:
Optical proximity sensors deploy optical and electronic means for

object detection. Basically, differentiation is made between three types of optical
proximity sensors:
• Through-beam sensors
• Retro-reflective sensors
• Diffuse sensors
– Describe the design and function of an optical diffuse sensor.
Description of design and function Symbol
BN
BK
BU

Name: Date:
– Describe the design and function of a capacitive proximity sensor.
Description of design and function Symbol/electrical circuit

diagram
BN
BK
BU

Name: Date:
Pneumatic circuit diagram of the filling system.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 2M1 2M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the filling system.

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
13 12 14
1B2 BN 2B2 BN B1 BN B2 BN B3 BN S1 K8
2 4 2 4 START
BK BK BK BK BK 14 11
1B1 2B1
1 1
BU BU BU BU BU
31
S2
STOP
32
A1 A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 1M2 2M1 2M2
A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12
1A1+ 1A1- 2A1+ 2A1-
11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44

Name: Date:
an equipment list.

the table below.
2 Cylinder, double-acting
4 One-way flow control valve
Proximity sensor, inductive
Proximity sensor, capacitive
Proximity sensor, optical
Pushbutton (normally closed contact)
Relay
1 Manifold
Equipment list


Exercise 7: Bonding of components
Training aims • To familiarise yourself with the design and function of a pneumatic-electrical
converter.
• To familiarise yourself with the function and possible applications of a time relay
with switch-on delay.
• To familiarise yourself with the options for sensing pressure and time in
electropneumatic control systems.
Problem definition Components are to be bonded together on the processing station of an automatic
rotary indexing machine. A specific working pressure must be achieved for this
process step. The dwell time of the positioning cylinder must be adjustable to
ensure reliable bonding of the components.
2. Draw the pneumatic and electrical circuit diagrams for the bonding device.

Positional sketch
Processing station on an automatic rotary indexing machine
1. The positioning cylinder 1A1 is retracted and actuates the proximity sensor 1B1.
2. The positioning cylinder is to advance if the START button S1 is actuated.
3. Once the positioning 1A1 is in the forward end position and the preset pressure
of 5 bar (500 kPa) is obtained at pressure sensor 1B3, the set time delay is to
commence at time relay K5.
4. Once the time delay has expired, the positioning cylinder 1A1 is to retract again.

Name: Date:
Fundamentals: Time relays Sheet 1 of 3
Time relays can basically be divided into two groups:

• Time relay with switch-off delay
• Time relay with switch-on delay
– Allocate the appropriate symbol to the description in the table.
A1 A1
1) A2 2) A2
Description Symbol
Time relay with switch-on delay
One or several contacts can be switched by the relay coil of a time relay. Depending
on the function required, relays with normally closed, normally open or changeover
contact(s) are used.
– Describe the design and contact line-up of the relays shown.
Design/contact line-up Symbol
A1
6 8
5
A2
A1 7
8
A2

Name: Date:
Fundamentals: Time relay Sheet 2 of 3
– Represent the signal behaviour of a switch-on delay in the diagram below.

– Designate the set time delay tv.
Voltage at relay coil
Time t
Contact
Closed
open
Time t
– Represent the signal behaviour of a switch-off delay in the diagram below.

– Designate the set time delay tv.
Voltage at relay coil
Time t
Contact
Closed
open
Time t

Name: Date:
Fundamentals: Pressure sensor Sheet 3 of 3
The bonding device is operated within a pressure range of 4 to 6 bar (400 kPa to
600 kPa). Once a switching pressure SPMAX of 5 bar (500 kPa) is obtained, the set
time delay is to start.
Changing the switching pressure
1. Press the EDIT button twice (selection of switching output is omitted ??.)
2. Press the UP/DOWN button until the desired switching function is obtained, i.e. in this case the
threshold value comparator.
3.Press EDIT button
4. Press the UP/DOWN button until the desired lower switching pressure [SP] is set, i.e. in this case 4
bar (400 kPa).
5. Press the EDIT button
6. Press the UP/DOWN button until the desired hysteresis [HY] is set.
7. Press the EDIT button
8. Press the UP/DOWN button until the desired switching characteristic is set, in this case [NO].
9. Press the EDIT button in order to change to RUN mode
Notes
Information regarding the technical data of the pressure sensor can be found in
chapter D and on the CD-ROM provided.

Name: Date:
Pneumatic circuit diagram of bonding device.
1A1
1B1 1B2
1V2 1 1 1V3
1B3
p
2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the bonding device.

+24 V 1 2 3 4 5 6 7 8 9 10
1B1 BN 1B2 BN 1B3 BN

13
BK BK BK
p S1
14
BU BU BU
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 1M1 1M2
A2 A2 A2 A2 A2
0V 12 12 12 12 12
1A1+ 1A1-
11 14 11 14 11 14 11 14 11 14
22 22 22 22 22
21 24 21 24 21 24 21 24 21 24
32 32 32 32 32
31 34 31 34 31 34 31 34 31 34
42 42 42 42 42
41 44 41 44 41 44 41 44 41 44

Name: Date:
an equipment list.

the table below.
1 5/2-way double solenoid valve (plate J on valve terminal)
Pressure sensor
Relay
1 Relay (switch-on delay)
1 Manifold
Equipment list

Exercise 8: Selecting modes of operation
Training aims • To familiarise yourself with modes of circuit operation and to be able to design
circuits with which single cycle and continuous cycle modes can be realised..
• To familiarise yourself with the function of an electrical preselect counter and to
be able to use this in circuits.
Problem definition 10 bars of chocolate at a time are to be fed towards a manual workstation via an
ejecting device, where these 10 bars are inserted in a cardboard box for despatch.
The process is to be started manually each time.
Parameters • The diverting device is to operate in automatic mode (individual

cycle/continuous cycle).
• The operating pressure should be between 4 bar and 5 bar (400 kPa and
500 kPa) and must be monitored.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals.
2. Draw the pneumatic and electrical circuit diagrams for the ejecting device.

Positional sketch
Packaging of chocolate bars
1. The individual cycle and continuous cycle are to be selected by pressing

pushbutton S3 for continuous cycle or S4 for individual cycle.
2. The sequence is to be started by pressing the START button S1.
3. The sequence is to be stopped by pressing pushbutton S2 (stop at cycle end).
4. The ejecting cylinder 1A1 is to remain in the retracted end position once it has
completed 10 advancing/retracting movements.

Name: Date:
Fundamentals: Preselect counter Sheet 1 of 4
– Describe the function of the component shown.
Symbol
A1 1 R1
A2 R2
4 2
Description: Component
– Answer the questions regarding the function of the preselect counter in question.
How is the preselected value set?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
How can the preselected value be reset?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
– Designate and describe the switching functions of the pressure sensor in

question.
Description: Switching functions
The operating pressure of the ejecting device is to be reduced from 6 bar (600 kPa)
to 4 bar (400 kPa). The pressure sensor is to send a signal and stop the system if
pressure drops below this value. The switching pressure setting in the pressure
sensor is to be changed accordingly.
– Describe how you proceed.
Description: Change of switching function

Name: Date:
The ejecting device is operated within a pressure range of 4 bar to 6 bar (400 kPa to
600 kPa). Now the maximum switching pressure SPMAX is to be reduced to a value of
5 bar (500 kPa). The system is to stop if pressure increases beyond this value.
– Describe how you proceed.
Description: Changing the switching function

Name: Date:
The range of hysteresis can be changed on the pressure sensor used.
– Describe what is understood by the term “hysteresis“.
Description: Hysteresis

Name: Date:
Pneumatic circuit diagram of the ejecting device.
1A1
1V2 1 1 1V3
2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
1B3 12/14 12/14 12/14 12/14 12/14 12/14
p 1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the ejecting device.
+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14
13 12 14 13 22 24 12 14 22 24 22 24
1B1 BN 1B2 BN 1B3 BN
S3 S1
Continuous START
14 11 14 21 BK BK BK 11 21 21
On
p
12 14
BU BU BU
11
31 31
S4 S2
Continuous STOP AT
32 32
Off CYCLE END
0
A1 A1 A1 A1 A1 A1 R1
K1 K2 K3 K4 K5 P6 1M1 1M2
A2 A2 A2 A2 A2 A2 R2
0V 12 12 12 12 12 12
11 14 11 14 11 14 11 14 11 14 11 14
22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44

Name: Date:
an equipment list.
– Complete the equipment list by entering the required quantity of components in

the table below.
Pressure sensor
Preselect counter, electrical
Pushbutton (normally closed contact)
Relay
1 Manifold
Equipment list


Exercise 9:
Machining of key blanks and the use of an EMERGENCY-STOP function
Training aims • To be able to develop and design the EMERGENCY-STOP function for a control
system with spring-return valves.
Problem definition Key blanks are to be fed towards a machine tool. A handling device is to be used for
this. First, the key blanks are to be picked up by a gripper. Then a lifting cylinder is to
lift the key blanks to the level of the machine tool and a feed cylinder to move the
blank into the machining position.
Parameters • The sequence is:

1A1+ 2A1+ 2A1– 1A1–
• Double-acting cylinders and a solenoid valve with spring-return are to be used.
• EMERGENCY-STOP condition:
The feed cylinder and the lifting cylinder are to move into the retracted end
position immediately if the EMERGENCY-STOP is actuated.
Note
The gripper would not open if the EMERGENCY-STOP were actuated.
2. Draw the pneumatic and electrical circuit diagrams for the feed limiting and
turning station including the use of the EMERGENCY-STOP function.

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Positional sketch
1. The lifting cylinder 1A1 is in the retracted end position.

2. The 5/2-way solenoid valve 1M1 is to reverse when pushbutton S1 is pressed
and the lifting cylinder to move into the forward end position.
3. The feed cylinder 2A1 is to move into the forward end position once the lifting
cylinder 1A1 is advanced.
4. Cylinder 2A1 is to retract first when cylinder 2A1 reaches the forward end
position; and the lifting cylinder 1A1 to then move down.
Note
The gripper is not taken into account in the design.
The machining time (cylinder 2A1 in forward end position) is not taken into account.

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP FUNCTION
Name: Date:
Fundamentals Sheet 1 of 4
An EMERGENCY-STOP device is a configuration of components which are intended to

avert or minimise any arising or existing danger to persons and damage to
machinery or materials.
– Identify the parts of a machine to which an EMERGENCY-STOP (ES)device could

apply.
System Machine section Component

section ES device
Control system Signals, displays, warnings
Actuating components
Control devices, i.e. command devices
Data storage and data processing
Sensors
Non-separating protective devices
Power/control elements
Plant section
Drive components
Separating devices, brakes
Power transmission components, power components
Separating protective devices

Exercise 9: Machining key blanks and the use of an EMERGENCY-STOP function
Name: Date:
Apart from considering the equipment section (e.g. electrics, mechanics,

pneumatics), it is also necessary to take into account the aspect of human reaction
in the case of an EMERGENCY-STOP in order to obtain optimal safety.
– List the general requirements to be met by an EMERGENCY-STOP.
General requirements to be met by an EMERGENCY-STOP

Name: Date:
Apart from the electrics and associated mechanics, the equipment section of
electropneumatics also includes pneumatics.
– Name the main EMERGENCY-STOP conditions, i.e. functions required in practice

from a drive cylinder.
EMERGENCY-STOP conditions

Name: Date:
According to EN 418, the EMERGENCY-STOP function must either act as a category 0

or category 1 STOP.
– Describe the difference between these categories.
Stop category 0 Stop category 1
The EMERGENCY-STOP command unit has to operate according to the principle of

forced actuation.
– Describe this principle.
Description: Principle of forced actuation

Name: Date:
Pneumatic circuit diagram for the handling device.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
1V1 4 2 2V1 4 2 -V- 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
1M1 2M1 -M1 -M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the handling device.
Signal input
+24 V 1 2 3 4 5 6 7 8 9
Signal processing Signal output

10 11 12 13 14 15 16 17 18 19
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
2B2 BN 13
1B2 BN K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
2 4 2 4 S1
BK BK 11 11 11 11 11 11 11 11 31 31
1B1 2B1 START 14
1 1 12 14
BU BU
K1
11
22 24 22 24 22 24 22 24 32 34 32 34
K9 K6 K7 K8 K9 K8
21 21 21 21 31 31
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1
K10 K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+
11 14 11 14 .10 11 14 .12 11 14 .16 11 14 .14 11 14 .10 11 14 .11 11 14 .13 11 14 .15 11 14 .17
22 22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 21 24 .12 21 24 .14 21 24 .16 21 24 .10
32 32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 31 34 .18 31 34 .19 31 34 .19 31 34 .18
42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
1A1+ 2A1+ 2A1- 1A1-

Name: Date:
Checking the equipment list Sheet 1 of 1
an equipment list.
– Check the equipment list. Are the required components entered in the table
below?
2 5/2-way solenoid valve (plate M on valve terminal)
2 Limit switch, electrical
2 Proximity sensor, electronic
1 Pushbutton (normally open contact)
1 Mushroom actuator (normally closed contact)
9 Relay
1 Manifold
Equipment list


Exercise 10:
Bending of mounting brackets and the use of an EMERGENCY-STOP function
Training aims • To be able to develop and design the EMERGENCY-STOP function for a control
system with double solenoid valves.
• To be able to develop and design a specified motion sequence including an
EMERGENCY-STOP.
Problem definition Mounting brackets made of sheet metal strips are to be bent using a pneumatic
bending device. Sheet metal strips are to be inserted manually. The bending
cylinders are to be actuated via double solenoid valves. The operational reliability of
the bending device must be ensured.
Note
Protective devices required in practice are not taken into account.
Parameters • The sequence selected is:

1A1+ 2A1+ 2A1– 1A1–
• Double-acting cylinders and double solenoid valves are to be used.
• EMERGENCY-STOP condition:
The actuators are to move out of the danger area in a controlled manner if the
EMERGENCY-STOP is actuated: Cylinder 2A1 is to retract first. Cylinder 1A1 is to
retract only when cylinder 2A1 reaches its retracted end position.
Project task 1. Answer the questions or carry out the additional exercices.
2. Draw the pneumatic and electrical circuit diagrams for the bracket bending
device with EMERGENCY-STOP function.
7. Describe the behaviour of the circuit during EMERGENCY-STOP.

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Positional sketch
Bending device for sheet metal
1. Bending cylinders 1A1 and 2A1 are retracted.

2. Cylinder 1A1 is to advance if pushbutton S1 is actuated.
3. When bending cylinder 1A1 reaches the forward end position, bending cylinder
2A1 is to advance and fully bend the bracket.
4. Bending cylinder 2A1 is to then retract, followed by bending cylinder 1A1.

Name: Date:
Additional exercise Sheet 1 of 2
A double-acting cylinder is to be exhausted during EMERGENCY-STOP. The circuit is

to be realised with indirect actuation using a spring-return solenoid valve and an
upstream double solenoid valve.
In the event of an EMERGENCY-STOP the air supply is to be shut off and the air
supply of the cylinder exhausted. No movement is to occur if the EMERGENCY-STOP
is released. The upstream valve is to switch to air flow only if a pushbutton (RESET-
ES) is pressed in order to enable a re-start.
• Design the electrical circuit diagram for this EMERGENCY-STOP condition.

• Simulate the electropneumatic circuit diagram and check its correct functioning.
• Compile an equipment list.
• Carry out the pneumatic and electrical circuit assembly.
• Check the circuit operation .
• Describe the behaviour of the circuit during EMERGENCY-STOP.
1A1
1B1 1B2
1V2 4 2
1M3
5 3
1
1V1 4 2
1M1 1M2
5 3
1

Name: Date:
Additional exercise Sheet 2 of 2
– Complete the electrical circuit diagram for the EMERGENCY-STOP condition

described.
+24 V 1 2 3 4 5 6 7 8 13
21
ES
EMERGENCY- 22
STOP 9 10 11 12
12 14 12 14 12 22 24 12 14
1B2 BN 13 13
1B1 BN
S1 ACKNOW-
BK BK START LEDGE 11 11 21 11
14 14
EMERGENCY-
STOP 12 14
BU BU
11
12 14
11
A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 1M3 1M2 1M1
A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12
1A1+
11 14 11 14 11 14 11 14 11 14 11 14 1A1–
22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44

Name: Date:
Pneumatic circuit diagram of bending device.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2
S M M J J
14 14 14 12 14 12
-M1 -M1 1M1 1M2 2M1 2M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the bending device.

+24 V 1 2 3 4 5 6 7 8 9 23 25
21 12 14 22 24 32 34
ES K11
EMERGENCY- 22 11 21 31
STOP 10 11 14 15 16 17 18 19 20 21 22 24
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34
2B2 BN 13
1B2 BN K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9
2 4 2 4 S1
BK BK 11 11 11 11 11 11 11 11 21 11 31 31 31 31
1B1 2B1 START 14
1 1 12 14
BU BU
K1
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
21 21 21 21 21 41 41 41 31
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 1M1 2M1 2M2 1M2

K11 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 .9 11 14 .10 11 14 .12 11 14 .16 11 14 .14 11 14 .10 11 14 .11 11 14 .13 11 14 .15 11 14 .17 11 14 .19
22 22 22 22 22 22 22 22 22 22 22
21 24 21 24 .18 21 24 21 24 21 24 21 24 21 24 .12 21 24 .14 21 24 .16 21 24 .18 21 24 .10
32 32 32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 31 34 .20 31 34 .21 31 34 .22 31 34 .24 31 34 .24
42 42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 .20 41 44 .21 41 44 .22 41 44
1A1+ 2A1+ 2A1- 1A1- Control

step

Name: Date:
Check the equipment list Sheet 1 of 1
an equipment list.
below?
2 Limit switch, electrical
11 Relay
1 Manifold
Equipment list


Exercise 11:
Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Training aims • To be able to design the EMERGENCY-STOP condition „cylinder remains it its
current position during EMERGENCY-STOP“.
• To familiarise yourself with the design and mode of operation of a 5/3-way
solenoid valve.
• To be able to replace a 5/3-way solenoid valve with a 3/2-way solenoid valve.
• To be able to integrate the mode of operation „reset“ into a control system.
Problem definition During production, bars of chocolate are to be conveyed by means of a handling
device. An EMERGENCY-STOP function is to be developed for the linear drive.
Parameters • EMERGENCY-STOP condition:

The linear drive is to remain in its current position if the EMERGENCY-STOP is
actuated.
• Set:
Set must only be possible in manual mode.
Project task 1. Answer, i.e. solve the additional exercise.

2. Answer the questions or carry out the exercises regarding the fundamentals of
3. Draw the pneumatic and electrical circuit diagrams for the linear drive of the
handling device including an EMERGENCY-STOP function.
8. Describe the behaviour of the circuit during EMERGENCY-STOP.

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Positional sketch
Handling device for chocolate bars
1. The mode of operation „automatic“ or „manual“ is to be selected by pressing the

pushbuttons AUTO or MAN.
2. In manual mode, the linear drive 1A1 is to move into the lefthand end position by
pressing the RESET pushbutton.
3. The selection between individual cycle and continuous cycle is to be effected by
pressing pushbuttons S3 (continuous cycle) or S4 (individual cycle).
4. The sequence is to be started by pressing the START pushbutton S1.
5. The sequence is to be stopped via the pushbutton S2 (stop at cycle end).
Note
The linear drive is replaced by a double-acting cylinder.

Name: Date:
Fundamentals: Flow control valves and non-return valves Sheet 1 of 3
Non-return valves and flow control valves are used in order to shut off or control the
flow rate.
– Describe the design and function of the valves shown.
Symbol 1 Symbol 2 Symbol 3
1 2 2
1 1/3
1 21
Description: Design/function

Name: Date:
Fundamentals: 5/3-way solenoid valve Sheet 2 of 3
A valve symbol provides information regarding the function of a valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.
– Describe the mode of operation of the directional control valve represented.
4 2
14 12
(1M1) (1M2)
5 3
1
Description: Mode of operation of a directional control valve

Name: Date:
Fundamentals: 5/3-way solenoid valve Sheet 3 of 3
Directional control valves with three switching positions offer further possibilities for
cylinder actuation thanks to the additional mid-position. Differentiation is made
between three mid-positions, i.e. closed, pressurised or exhausted.
The behaviour of a cylinder changes depending on the different mid-positions.
– Describe the effect of different mid-positions on the behaviour of a double-acting

cylinder if a 5/3-way solenoid valve is switched in mid-position.
Description: Effect of mid-position on drive cylinder behaviour

Name: Date:
Pneumatic circuit diagram of handling device with EMERGENCY-STOP function.
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3

Name: Date:
The equipment set does not include a 5/3-way solenoid valve.
– How can you replace this solenoid valve with a suitable circuit? Complete the
pneumatic circuit diagram.
1A1
1B1 1B2
0V1
1V1 4 2 1V2 4 2 -V- 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
1M1 1M2 1M1 2M1 1M1 2M1
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Name: Date:
– Complete the electrical circuit diagram for the handling device.
Signal input
+24 V 1 2 3 4 5 6
21 12 14
ES K1
EMERGENCY- 22 Signal processing Signal output
11
STOP 7 8 9 10 11 12 13 14 15 16 17 18 19 20
13 12 14 13 13 12 14 13 22 24 22 24 12 14 12 14 12 14 32 34 22 24
1B1 1B2
AUTO K4 RESET CONTINUOUS K6 S1 K6 K7 K8 K3 K9 K8 K9
ON START
14 11 14 14 11 14 21 21 11 11 11 31 21
12 14 12 14
K7 K2
11 11
31 31 31
MAN CONTINUOUS STOP AT
OFF CYCLE END
32 32 32 32 34 22 24
K3 K8
32 34
31 21
K4
31
A1 A1 A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 1M2
A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12
11 14 .6 11 14 .14 11 14 .16 11 14 .8 11 14 11 14 .11 11 14 .13 11 14 .15 11 14 .17
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 .14 21 24 .9 21 24 21 24 .13 21 24 .14 21 24 .16 21 24 .19
32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 .10 31 34 31 34 31 34 31 34 .18 31 34
42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
Notes
Altogether 4 pushbutton and 2 control switches are available in the equipment sets
of TP201 and TP202. You will require either a third electrical signal input or can
proceed as follows:
1. Dispense with the STOP AT CYCLE END pushbutton.

2. Use a control switch for the MANUAl pushbutton.
3. Use a control switch for the RESET pushbutton.

Name: Date:
Checking the equipment list Sheet 1 of 1
an equipment list.
below?
2 Non-return valve, piloted
2 5/2-way solenoid valve (plate M in valve terminal)
3 Pushbutton (Normally closed contact)
9 Relay
1 Manifold
Equipment list


Exercise 12: Eliminating a fault on a machining station
Training aims • To be able to identify and eliminate faults in complex electropneumatic control
systems.
Problem definition A machining station for key blanks stops during continuous operation. A fault has
occurred and is to be eliminated. The system is then to be re-started.
Project task 1. Describe the behaviour of the circuit. Compare this with the correct behaviour of
the circuit. Use the function diagram to assist you with this.
2. Localise the potential error causes with the help of the pneumatic and electrical
circuit diagrams.
3. Find the fault in the circuit and eliminate this.
4. Re-start the circuit.

Positional sketch
START
1 2 3 4 5=1
(1M1)
1
1B2
1A1
0
(1M1) 1B1
2B2 (2M1)
1
2A1
2B1
0
(2M1)

Name: Date:
Fault finding in complex electropneumatic control system Sheet 1 of 4
The following fault occurs in the circuit illustrated below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and
remain in the forward end position.
– Describe the potential causes of a fault.
1A1 2A1
1B2 2B2
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
0V1
1V1 4 2 2V1 4 2 -V- 4 2 -V- 4 2
S M M J J
14 14 14 12 14 12
1M1 2M1 -M1 -M2 -M1 -M2
3/5 3/5 3/5 3/5 3/5 3/5

82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1
Pneumatic circuit (circuit diagram in DIN A3 format in Part D)

Name: Date:
Fault finding in complex electropneumatic circuits Sheet 2 of 4

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
1B2 BN 2B2 BN 13
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
2 4 2 4 S1
BK BK START 11 11 11 11 11 11 11 11 31 31
1B1 2B1 14
1 1 12 14
BU BU
K1
11
32 34 22 24 22 24 22 24 22 24 32 34
K9 K6 K7 K8 K9 K8
31 21 21 21 21 31
A1 A1 A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12
1A1+ 2A1+
11 14 .8 11 14 .10 11 14 .14 11 14 .12 11 14 .8 11 14 .9 11 14 .11 11 14 .13 11 14 .15
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 .10 21 24 .12 21 24 .14 21 24 .16
32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .16 31 34 .17 31 34 .17 31 34 .8
42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
1A1+ 2A1+ 2A1- 1A1-
List of potential error causes

Name: Date:
A cable break occurs at the points marked in the circuit illustrated below.
– Describe how a cable break at these respective points affects the functioning of
the circuit.

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
1B2 BN 2B2 BN 13
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
2 4 2 4 S1
BK BK START 11 11 11 11 11 11 11 11 31 31
1B1 2B1 14
x x
1 1 12 14
BU BU
K1
11
x 22
K9
24 22
K6
24 22
K7
24 22
K8
24 32
K9
34 32
K8
34
x
21 21 21 21 31 31
A1 A1 A1 A1 A1 A1 A1 A1 A1
x
K1 K2 K3 K4 K5 K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2 A2 A2 A2 A2 A2
0V 12 12 12 12 12 12 12 12 12
1A1+ 2A1+
11 14 .8 11 14 .10 11 14 .14 11 14 .12 11 14 .8 11 14 .9 11 14 .11 11 14 .13 11 14 .15
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 21 24 .10 21 24 .12 21 24 .14 21 24 .16
32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .16 31 34 .17 31 34 .17 31 34 .8
42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44
1A1+ 2A1+ 2A1- 1A1-
Electrical circuit diagram (Circuit diagram in DIN A3 format in Part D)

Name: Date:
Fault Effect of fault
Cable break in signal line of

limit switch 2B1
(current path 4)
Cable break in supply line of

changeover contact K6
Connection 11
(current path 9)
Cable break in earthing in

earth wire of relay K7
(current path 10)

Connection 11
(current path 13)

Connection 21 to relay K9
Connection A1
(current path14)

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

Name: Date:
Fault finding: Nominal/Actual comparison Sheet 2 of 9
Determine the ACTUAL status of the system with the help of the following
documentation:
• Positional sketch with problem description
• Graphic representation
– If the correct function is not the case (NOMINAL/ACTUAL comparison), clearly

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

Name: Date:
Fault finding: Description of fault Sheet 3 of 9
In the ‘NOMINAL/ACTUAL comparison’ worksheet, you have marked the point where
the fault occurs in the diagram.
– Describe the sequence up to the where the station, i.e. system, stops.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Fault finding: Error definition – pneumatics Sheet 4 of 9
Once you have established the ACTUAL status of the system, consider what the
cause of the fault could be.
In which pneumatic tubing connection could the error be located?
– Enter all the possibilities. Indicate the components at the start and end of the
tubing connection in order to ensure a clear identification.
Potential fault Tubing connection

No. Start End
Potential faults

Name: Date:
Fault finding: Error definition – electrics Sheet 5 of 9
Once the ACTUAL status has been established, consider what the causes of the error
could be.
• In which current path could the error be located?

• What is the function of the current path?
– Enter all the possibilities.
Potential error Current path Function of current path

No. No.
Potential errors

Name: Date:
Fault finding: Localisation of faults – pneumatics Sheet 6 of 9
Investigate the potential causes of pneumatic faults you have found.
• Use the same fault numbering you have used in the worksheet ‘Error definition –
pneuamtics.
• Document the procedure used to check the tubing connections.
– Enter the result of your investigation.
Measuring and test protocol
Potential fault Tubing connection Investigation Result

No. Start End

Name: Date:
Fault finding: Localisation of faults – electrics Sheet 7 of 9
Investigate the potential causes of faults you have found.
• Use the same numbering of faults you have used in the worksheet ‘Error
definition – electrics’.
• Document the procedure used to check the line connection.
– Enter the result of your investigation.
Potential fault Current path No. Measuring points Investigation Result

No.

Name: Date:
Fault finding: Error elimination Sheet 8 of 9
Once you have localised the error location, you need to document the procedure
followed to eliminate the fault on this worksheet.
– Describe each of the steps in detail.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Note
Go back to the first worksheet and repeat the fault finding if the system does not
fulfil the required function.
Ask for new worksheets to do so.

Name: Date:
Fault finding: Re-start Sheet 9 of 9
– Re-start the system according to the DESIRED status once you have identified,
localised and eliminated the fault.
– R-set the specified DESIRED TIMES.
– Document the procedure you have followed in note form
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


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Exercise 1: Realising a diverting device ___________________________________A-3

© Festo Didactic GmbH & Co. KG • 541091 A-1

A-2 © Festo Didactic GmbH & Co. KG • 541091

Parameters • A double-acting cylinder is to be used.

© Festo Didactic GmbH & Co. KG • 541091 A-3

Diverting device for drinks bottles

1. Cylinder 1A1 is in the retracted end position.

A-4 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device

Fundamentals: Installation costs Sheet 1 of 5

The configuration, tubing and wiring of the components of an electropneumatic

• Conventional wiring technology, e.g. terminal strips

• Individual mounting of solenoid operated directional control valves

© Festo Didactic GmbH & Co. KG • 541091 A-5

Exercise 1: Realising a diverting device

Fundamentals: Installation costs Sheet 2 of 5

Components Individual mounting Block mounting of Saving when using

Amount of tubing for

Amount of tubing for

Number of silencers for

A-6 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device

Fundamentals: Installation costs Sheet 3 of 5

Reason Individual mounting Block mounting of

© Festo Didactic GmbH & Co. KG • 541091 A-7

Exercise 1: Realising a diverting device

Fundamentals: Installation costs Sheet 4 of 5

Components Cables Number of Number of

Terminal strip 1 in control cabinet Earthing cable

Supply voltage (24 V)

PLC outputs (actuation of solenoid

PLC inputs (evaluation of proximity

Terminal strip 1 in control cabinet, overall

Cable from control cabinet to Cable between terminal strips 1 and

Cable from terminal strip 2 Proximity sensors (3 wires per

Terminal strip 2, overall

Cable to directional control valves Connection of solenoid coils

A-8 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device

Fundamentals: Reducing the wiring costs Sheet 5 of 5

Reason Conventional wiring Multi-pin wiring

© Festo Didactic GmbH & Co. KG • 541091 A-9

Exercise 1: Realising a diverting device

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

– Complete the pneumatic circuit diagram for the diverting device.

Pneumatic circuit diagram with individual valve

A-10 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– Complete the pneumatic circuit diagram for the diverting device.

3/5 3/5 3/5 3/5 3/5 3/5

© Festo Didactic GmbH & Co. KG • 541091 A-11

Exercise 1: Realising a diverting device

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– Complete the electrical circuit diagram for the diverting device.

Electrical circuit diagram

A-12 © Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device

Compiling the equipment list Sheet 1 of 1

© Festo Didactic GmbH & Co. KG • 541091 A-13

A-14 © Festo Didactic GmbH & Co. KG • 541091

© Festo Didactic GmbH & Co. KG • 541091 A-15