Festo worldwide

Pneumatics
Basic level
Argentina Estonia Japan Singapore
Festo S.A. Festo OY AB Eesti Filiaal Festo K.K. Festo Pte. Ltd.
Edison 2392 Laki 11B 1-26-10 Hayabuchi, Tsuzuki-ku 6 Kian Teck Way
(B1640 HRV) Martinez 12915 Tallinn Yokohama 224-0025 Singapore 628754
Prov. Buenos Aires Tel. ++372 666 15 60, Fax ++372 666 15 61 Tel. ++81 (0)45/593 56 10, Fax 593 56 78 Tel. ++65/62 64 01 52, Fax 62 61 10 26
Tel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82 E-mail: info_ee@festo.com E-mail: info_jp@festo.com E-mail: info_sg@festo.com
E-mail: info@ar.festo.com
Finland Korea South Slovakia Workbook
Australia Festo OY Festo Korea Co., Ltd. Festo spol. s r.o.
Festo Pty. Ltd. Mkituvantie 9, P.O. Box 86 470-1 Gasan-dong, Geumcheon-gu Gavlovicov ul. 1 TP 101
Head Office (Melbourne) 01511 Vantaa Seoul #153-803 83103 Bratislava 3
179-187 Browns Road, P.O. Box 261 Tel. ++358 (09)/87 06 51, Fax 87 06 52 00 Tel. ++82 (0)2/850 71 14, Fax 864 70 40 Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11
Noble Park Vic. 3174 E-mail: info_fi@festo.com E-mail: info_kr@festo.com E-mail: info_sk@festo.com
Call Toll Free 1300 88 96 96
Fax Toll Free 1300 88 95 95 France Latvia Slovenia
Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87 Festo Eurl Festo SIA Festo d.o.o. Ljubljana
E-mail: info_au@festo.com.au Deglava 60 IC Trzin, Blatnica 8
Numro Indigo Tel. 0820/204640, Fax 204641
1035 Riga 1236 Trzin
ZA des Maisons Rouges
Austria Tel. ++371 67/57 78 64, Fax 57 79 46 Tel. ++386 (0)1/530 21 00, Fax 530 21 25
8 rue du Clos Sainte Catherine
Festo Gesellschaft m.b.H. E-mail: info_lv@festo.com E-mail: info_si@festo.com
94367 Bry-sur-Marne cedex
Linzer Strae 227 Tel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01
1140 Wien Lithuania South Africa
E-mail: info_fr@festo.com Festo UAB Festo (Pty) Ltd.
Tel. ++43 (0)1/9 10 75-0, Fax 9 10 75-250
E-mail: automation@festo.at Karaliaus Mindago pr. 22 22-26 Electron Avenue, P.O. Box 255
Germany 3000 Kaunas Isando 1600
Festo Didactic GmbH & Co. KG Tel. ++370 (8)7/32 13 14, Fax 32 13 15 Tel. ++27 (0)11/971 55 00, Fax 974 21 57
Belarus
Postfach 10 07 10
IP Festo
73707 Esslingen
E-mail: info_lt@festo.com E-mail: info_za@festo.com With CD-ROM
Minsk, 220035
Rechbergstrae 3 Malaysia Spain
Mascherov Prospekt, 78
73734 Esslingen Festo Sdn.Berhad Festo Pneumatic, S.A.
Belarus
Tel. ++49 (0)711/3467-0 10 Persiaran Industri Tel. 901243660 Fax 902243660
Tel. ++375 (0)17/204 85 58, Fax 204 85 59
E-mail: info_by@festo.com Fax ++49 (0)711/347-54 88500 Bandar Sri Damansara, Wilayah Persekutuan Avenida Granvia, 159
E-mail: did@de.festo.com 52200 Kuala Lumpur Distrito econmico Granvia L'H
Belgium Tel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11 ES-08908 Hospitalet de Llobregat, Barcelona
Festo Belgium sa/nv Greece E-mail: info_my@festo.com Tel. ++ 3493/261 64 00, Fax 261 64 20
Rue Colonel Bourg 101 Festo Ltd. E-mail: info_es@festo.com
1030 Bruxelles/Brussel 40 Hamosternas Ave. Mexico
Tel. ++32 (0)2/702 32 11, Fax 702 32 09 11853 Athens Festo Pneumatic, S.A. Sweden
E-mail: info_be@festo.com Tel. ++30 210/341 29 00, Fax 341 29 05 Av. Ceyln 3 Festo AB
E-mail: info_gr@festo.com Col. Tequesquinahuac Stillmansgatan 1, P.O. Box 21038
Brazil 54020 Tlalnepantla, Edo. de Mxico 20021 Malm
Festo Automao Ltda. Hong Kong Tel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55 Tel. ++46 (0)40/38 38 40, Fax 38 38 10
Rua Guiseppe Crespi, 76 Festo Ltd. E-mail: festo.mexico@mx.festo.com E-mail: info_se@festo.com
KM 12,5 - Via Anchieta Unit C&D, 7/F, Leroy Plaza
04183-080 So Paulo SP-Brazl 15 Cheung Shun Street Netherlands Switzerland
Tel. ++55 (0)11/50 13 16 00, Fax 50 13 18 68 Cheung Sha Wan, Kowloon Festo B.V. Festo AG
Hong Kong Schieweg 62 Moosmattstrasse 24
E-mail: info_br@festo.com 1A1
2627 AN Delft 8953 Dietikon ZH 1B1
Tel. ++ 852/27 43 83 79, Fax 27 86 21 73
E-mail: info_hk@festo.com Tel. ++31 (0)15/251 88 99, Fax 261 10 20 Tel. ++41 (0)44/744 55 44, Fax 744 55 00
Bulgaria
E-mail: info@festo.nl E-mail: info_ch@festo.com
Festo EOOD
1592 Sofia Hungary 1Z1 1Z2
New Zealand Taiwan
9, Christophor Kolumb Blvd. Festo Kft.
Festo Limited Festo Co., Ltd.
Tel. ++359 (0)2/960 07 12, Fax 960 07 13 Csillaghegyi t 32-34.
MT. Wellington Head Office
E-mail: info_bg@festo.com 1037 Budapest
Auckland NZ 24450, No. 9, Kung 8th Road 1V3 1V4
Tel. ++36 1/436 51 11, Fax 436 51 01 1 1
Tel. ++64 (0)9/574 10 94, Fax 574 10 99 Linkou 2nd Industrial Zone
E-mail: info_hu@festo.com E-mail: info_nz@festo.com Linkou Hsiang, Taipei Hsien, Taiwan, R.O.C.
Canada
Tel. ++886 (0)2 26 01 92 81,
Festo Inc. India Nigeria Fax ++886 (0)2 26 01 92 86-7
5300 Explorer Drive Festo Controls Private Ltd. Festo Automation Ltd. E-mail: festotw@festo.com
Mississauga, Ontario L4W 5G4 237B, 2 2
Motorways Centre, First Floor, Block C
Tel. ++1 (0)905/624 90 00, Fax 624 90 01 Bommasandra Industrial Area, Alausa, Ikeja, Thailand
E-mail: info_ca@festo.com 1V2 4 2
Bangalore Hosur Highway, Lagos, NIGERIA Festo Ltd.
Bangalore 560 099 Tel. ++234 (0)1/794 78 20, Fax 555 78 94 67/1 Moo 6 Phaholyothin Road 14 12
Chile Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58 E-mail: info@ng-festo.com Klong 1, Klong Luang,
Festo S.A. E-mail: info_in@festo.com Pathumthani 12120 5 3
1V1 2
Mapocho 1901 Norway Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33 1
6500151 Santiago de Chile 1 1
Indonesia Festo AS E-mail: info_th@festo.com
Tel. ++56 (0)2/690 28 00, Fax 695 75 90 PT. Festo Ole Deviks vei 2
E-mail: info.chile@cl.festo.com JL. Sultan Iskandar Muda No.68 0666 Oslo, Norway Turkey
Arteri Pondok Indah Tel. ++47 22 72 89 50, Fax ++47 22 72 89 51 Festo San. ve Tic. A.S. 1 3
China Jakarta 12240 E-mail: info_no@festo.com Tuzla Mermerciler Organize
Festo (China) Ltd. 1S1 2 1B1 2 1S2 2
Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98 Sanayi Blgesi, 6/18 TR
1156 Yunqiao Road E-mail: info_id@festo.com Peru 34956 Tuzla - Istanbul/TR
Jinqiao Export Processing Zone Festo S.R.L. Tel. ++90 (0)216/585 00 85, Fax 585 00 50
Pudong, Iran Calle Amador Merino Reyna #480, San Isidro E-mail: info_tr@festo.com 1 3 1 3 1 3
2
201206 Shanghai, PRC Lima, Per
Festo Pneumatic S.K.
Tel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00 Tel. ++51 (0)1/222 15 84, Fax 222 15 95 Ukraine
# 2, 6th street, 16th avenue,
E-mail: info_cn@festo.com Festo Ukraina
Tehran 1581975411
Philippines Borisoglebskaja 11
Workbook TP 101

Km 8, Special Karaj Road, P.O.Box 15815-1485

Colombia Festo Inc. Kiev 04070
Tehran 1389793761
Festo Ltda. KM 18, West Service Road Tel. ++380 (0)44/239 24 33, Fax 463 70 96
Tel. ++98 (0)21 44 52 24 09,
Avenida El Dorado No. 98-43 South Superhighway E-mail: info_ua@festo.com
Fax ++98 (0)21 44 52 24 08
Bogot 1700 Paranaque City, Metro Manila
Tel. ++57 (0)1/404 80 88, Fax 404 81 01 E-mail: Mailroom@festo.ir
Tel. ++63 (0)2/776 68 88, Fax 823 42 19 United Kingdom
E-mail: festo@festo.com.co E-mail: info_ph@festo.com Festo Limited
Ireland
Applied Automation Centre, Caswell Road
Croatia Festo Limited
Poland Brackmills Trading Estate
Festo d.o.o. Unit 5 Sandyford Park
Festo Sp. z o.o. Northampton NN4 7PY
Nova Cesta 181 Sandyford Industrial Estate
Janki k/Warszawy, ul. Mszczonowska 7 Tel. ++44 (0)1604/66 70 00, Fax 66 70 01
10000 Zagreb Dublin 18
05090 Raszyn E-mail: info_gb@festo.com
Tel. ++385 (0)1/619 19 69, Fax 619 18 18 Tel. ++ 353(0)1/295 49 55, Fax 295 56 80 Tel. ++48 (0)22/711 41 00, Fax 711 41 02
E-mail: info_hr@festo.com E-mail: info_ie@festo.com E-mail: info_pl@festo.com United States
Pneumatics, Basic level

Festo Corporation (New York)

Czech Republic Israel Romania Call Toll-free 800/993 3786
Festo, s.r.o. Festo Pneumatic Israel Ltd. Festo S.R.L. Fax Toll-free 800/963 3786
Modansk 543/76 P.O. Box 1076, Ha'atzma'ut Road 48 St. Constantin 17 395 Moreland Road, P.O.Box 18023
147 00 Praha 4 Yehud 56100 010217 Bucuresti Hauppauge, N.Y. 11788
Tel. ++420 261 09 96 11, Fax 241 77 33 84 Tel. ++972 (0)3/632 22 66, Fax 632 22 77 Tel. ++40 (0)21/310 29 83, Fax 310 24 09 Tel. ++ 1(0)314/770 01 12, Fax 770 16 84
E-mail: info_cz@festo.com E-mail: info_il@festo.com E-mail: info_ro@festo.com E-mail: info_us@festo.com

Denmark Italy Russia Venezuela

Festo A/S Festo S.p.A Festo-RF OOO Festo C.A.
Islevdalvej 180 Via Enrico Fermi 36/38 Michurinskiy prosp., 49 Av. 23, Esquina calle 71, No. 22-62
2610 Rdovre 20090 Assago (MI) 119607 Moskow Maracaibo, Edo. Zulia Festo Didactic
Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10 Tel. ++39 02/45 78 81, Fax 488 06 20 Tel. ++7 495/737 34 00, Fax 737 34 01 Tel. ++58 (0)261/759 09 44, Fax 759 04 55
E-mail: info_dk@festo.com E-mail: info_it@festo.com E-mail: info_ru@festo.com E-mail: festo@festo.com.ve 541088 EN
Use for intended purpose

The training system from Festo Didactic has been developed and produced exclusively for training and
further education in the field of automation and technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.

Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment in situations which serve any purpose
other than training and/or further education, unless such damages have been caused by Festo Didactic due
to malicious intent or gross negligence.

Order no. 541088

Status: 10/2009
Authors: W. Haring, M. Metzger, R.-C. Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 12/2009

Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2009

Internet: www.festo-didactic.com
E-mail: did@de.festo.com

The reproduction, distribution and utilisation of this document, as well as the communication of its contents
to others without explicit authorisation, is prohibited. Offenders will be held liable for compensation of
damages. All rights reserved, in particular the right to file patent, utility model and registered design
applications. Portions of this documentation may be duplicated by an authorised user exclusively for
training purposes.
Table of contents

Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Technology module for pneumatics (TP100) ____________________________________________________X
Learning objectives for the basic level (TP101) _________________________________________________ XI
Overview of learning objectives per exercise __________________________________________________ XII
Equipment set for the basic level (TP101) ____________________________________________________ XIV
Allocation of equipment per exercise _______________________________________________________ XVIII
Practical tools for the trainer _______________________________________________________________ XIX
Structure of the exercises _________________________________________________________________ XIX
Designations of the components____________________________________________________________ XIX
CD ROM contents ________________________________________________________________________ XX
Equipment set for the advanced level (TP102) ________________________________________________ XXII
Learning objectives for the advanced level (TP102)____________________________________________ XXIII

Solutions

Exercise 1: Pressing cheeses _________________________________________________________________1

Exercise 2: Opening a fodder silo _____________________________________________________________9
Exercise 3: Clamping boards to a saw bench __________________________________________________ 15
Exercise 4: Sorting packages _______________________________________________________________ 21
Exercise 5: Stopping milk bottles ___________________________________________________________ 31
Exercise 6: Opening and closing a pipeline ___________________________________________________ 37
Exercise 7: Shutting off a pipeline ___________________________________________________________ 45
Exercise 8: Actuating a shut-off device _______________________________________________________ 51
Exercise 9: Expanding the control system for pressing cheeses ___________________________________ 59
Exercise 10: Clamping a workpiece __________________________________________________________ 65
Exercise 11: Loading wire baskets __________________________________________________________ 73
Exercise 12: Actuating a sliding door ________________________________________________________ 79
Exercise 13: Feeding wooden boards ________________________________________________________ 87
Exercise 14: Compacting beverage cans ______________________________________________________ 93
Exercise 15: Packaging of brochures ________________________________________________________ 99
Exercise 16: Mounting locking pins_________________________________________________________ 105
Exercise 17: Labelling paint pots___________________________________________________________ 111
Exercise 18: Cleaning workpieces __________________________________________________________ 117
Exercise 19: Pressing labels into place ______________________________________________________ 123

Festo Didactic GmbH & Co. KG 541088 III

IV Festo Didactic GmbH & Co. KG 541088
Preface

Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The training packages are therefore broken down as follows:
Basic modules impart basic, interdisciplinary, technological knowledge.
Technology modules address the important topics of open and closed-loop control technology.
Function modules explain the fundamental functions of automated systems.
Application modules enable training and further education that is aligned with real-life practice.

The technology modules deal with various technologies including pneumatics, electro-pneumatics,
programmable logic control systems, automation using a personal computer, hydraulics, electrohydraulics,
proportional hydraulics, sensor technology, electric drives and applications technology (handling).

Festo Didactic GmbH & Co. KG 541088 V

 The modular design of the training system makes it possible to focus on applications above and beyond
those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.

All training modules have the same structure:

Hardware
Teachware
Software
Seminars

The hardware is comprised of industrial components and systems that are specially designed for training
purposes.

The structure of the teachware corresponds to that of the training hardware. It includes:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, supplementary instructions and solutions)
Transparencies and videos (for dynamic instruction)

The working materials for TP101 consist of 19 exercises and a workbook. Each exercise has its own set of
ready-to-use worksheets. The solutions are included in the workbook, which also has the worksheets and a CD
ROM. The exercises can be purchased without the workbook and are used as consumables. They can thus be
easily made available to trainees. Data sheets for the hardware components are made available along with the
training module and on the CD ROM.

The teaching and learning media are available in several languages. Theyre intended for use in classroom
instruction, but are also suitable for self-study.

Where software is concerned, computer training programs and programming software are made available
for programmable logic controllers.

A wide range of seminars covering the contents of the technology module round off the programme for
training and further education.

VI Festo Didactic GmbH & Co. KG 541088

Introduction

This workbook is part of the training system for automation and technology from Festo Didactic GmbH & Co.
KG. The system provides a solid basis for practical training and further education. The TP100 technology
module only includes pneumatic control systems.

The TP101 basic level is suitable for basic training in the field of pneumatic control technology. It covers the
fundamentals of pneumatics as well as the function and use of pneumatic equipment. The equipment can be
used to set up simple pneumatic control systems.

The TP102 advanced level comprises vocational training in the field of pneumatic control technology. The
equipment can be used to set up extensive combinatory circuits with linking of the input and output signals
as well as control systems with stepper modules.

A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the
control systems. The profile plate has 14 parallel T-slots at 50 mm intervals. A portable compressor with
silencer (230 V, max. 8 bar = 800 kPa) can be used for compressed air supply.

Working pressure should not exceed 6 bar (600 kPa).

Ideal control sequence reliability can be achieved by operating the control system at a working pressure of 5
bar (500 kPa) without oil.

All the control systems for the 19 exercises are set up using the equipment set for the TP101 basic level. The
theoretical fundamentals for understanding this series of exercises are included in the textbook:

Pneumatics, basic level

Data sheets for the individual components are also available (cylinders, valves, measuring instruments etc.).

Festo Didactic GmbH & Co. KG 541088 VII

 Work instructions and safety precautions

General
Trainees should only work with the control systems under the supervision of a trainer.
Observe specifications included in the data sheets for the individual components and in particular all
safety instructions!

Mechanical
Mount all the components securely onto the profile plate.
Limit switches must not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Only reach into the set-up when its at a complete standstill.

Electrical
Electrical connections must only be established and interrupted in the absence of voltage!
Only use connector cables with safety plugs for electrical connections.
Only use low-voltage (max. 24 V DC).

Pneumatics
Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
Do not switch on the compressed air until all of the tubing connections have been completed and
secured.
Do not disconnect tubing while under pressure.
Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
Danger of accident due to tubing slipping off!
Use shortest possible tubing connections.
Wear safety glasses.
In the event that tubing slips off:
Switch compressed air supply off immediately.
Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
Switch compressed air supply off before dismantling the circuit.
Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.

VIII Festo Didactic GmbH & Co. KG 541088

The mounting boards for the components are equipped with mounting variant A, B or C:

Variant A, snap-in system

Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the
components into the slot on the profile plate. Release the component from the slot by actuating the blue
lever.

Variant B, bolt-on system

Components with medium load capacity (e.g. actuators). These are clamped onto the profile plate using
T-head bolts. The blue knurled nut is used for clamping and loosening.

Variant C, screw system

For components with high load capacity and components that are seldom removed from the profile plate (for
example on-off valve with filter regulator). These components are secured with socket head screws and
T-head bolts.

Observe specifications in the data sheets regarding the individual components.

A stopwatch is required in order to evaluate the control systems once they have been set up. The stopwatch is
used to:
Adjust the one-way flow control valves so that the cylinder stroke times comply with the specified
values
Adjust time delay valves

Festo Didactic GmbH & Co. KG 541088 IX

 Technology module for pneumatics (TP100)

The TP100 technology module consists of a multitude of training materials and seminars. The subject matter
is focused entirely on pneumatic control systems. Individual components included in the TP100 technology
packet can also be included in any of the other modules.

Important components of the TP100

Permanent workstation with Festo Didactic profile plate
Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)
Equipment sets or individual components (e.g. cylinders, directional control valves, preset counters,
stepper modules, logic components, pneumatic proximity switches)
Optional training materials (e.g. optical displays, 5/3-way valve, pulling/pushing load)
Practical training models
Complete laboratory set-ups

Training documentation

Textbooks TP101 basic level

Fundamentals of pneumatic control technology
Maintenance of pneumatic equipment and systems
Pneumatics/electropneumatics

Workbooks TP101 basic level

TP102 advanced level

Optional teachware Set of transparencies

Magnetic symbols, drawing template
FluidSIM pneumatic simulation software
WBT Pneumatics
Set of cutaway models with storage case

Seminars

P100 Basic pneumatics for machine operators

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance and troubleshooting for pneumatic and electropneumatic systems

P-OP Tracking down wastage economic use of pneumatics

P-NEU Pneumatic refresher and update

IW-PEP Repair and maintenance in the field of control technology pneumatic and electropneumatic systems

P-AL Pneumatics for further education

P-AZUBI Pneumatics and electropneumatics for trainees

Please refer to the current seminar planner for locations, dates and prices.

Youll find further training materials in our catalogue and on the Internet. The training system for automation
and technology is continuously updated and expanded. Transparencies, videos, CD ROMs and DVDs, as well
as textbooks, are offered in several languages.

X Festo Didactic GmbH & Co. KG 541088

Learning objectives for the basic level (TP101)

Become familiar with the set-up and mode of operation of a single-acting cylinder.
Become familiar with the set-up and mode of operation of a 3/2-way valve.
Be able to recognise and sketch the various types of actuation for directional control valves.
Be able to explain and set up direct actuation.
Be able to analyse and evaluate circuits.
Become familiar with the set-up and mode of operation of a double-acting cylinder.
Become familiar with the set-up and mode of operation of a 5/2-way valve.
Be able to explain and set up indirect actuation.
Become familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.
Become familiar with the difference between a signalling element and a control element.
Be able to measure pressure in pneumatic control systems.
Be able to differentiate between the various types of flow control and use them in accordance with
specifications.
Be able to adjust cylinder advancing and retracting speeds.
Become familiar with one type of signal storage in pneumatic control systems.
Be able to explain and implement AND/OR/NOT logic operations.
Be able to explain and set up latching circuits.
Become familiar with one option for end-position sensing in cylinders.
Be able to combine logic operations.
Become familiar with the set-up and mode of operation of a magnetic proximity switch.
Be able to differentiate between 5/2-way valves and to select and use them in accordance with
specifications.
Be able to further develop existing circuits.
Become familiar with the set-up and mode of operation of a pressure sequence valve.
Be able to set up pressure-dependent control systems.
Become familiar with the set-up and mode of operation of a pressure regulator.
Be able to analyse existing circuits and optimise them in accordance with specifications.
Become familiar with the set-up and mode of operation of a time delay valve.
Be able to set up circuits with oscillating motion.
Be able to use time delay valves in accordance with specific constraints.
Be able to analyse and set up circuits with two cylinders.

Festo Didactic GmbH & Co. KG 541088 XI

 Overview of learning objectives per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Learning Objective

Become familiar with the set-up

and mode of operation of a
single-acting cylinder.

Become familiar with the set-up

and mode of operation of a 3/2-
way valve.

Be able to recognise and sketch

the various types of actuation for
directional control valves.

Be able to explain and set up

direct actuation.

Be able to analyse and evaluate

circuits.

Become familiar with the set-up

and mode of operation of a
double-acting cylinder.

Become familiar with the set-up

and mode of operation of a
5/2-way valve.

Be able to explain and set up

indirect actuation.

Become familiar with the

difference between a signalling
element and a control element.

Be able to measure pressure in

pneumatic control systems.

Be able to differentiate between

the various types of flow control

and use them in accordance with
specifications.

Be able to adjust cylinder

advancing and retracting speeds.

XII Festo Didactic GmbH & Co. KG 541088

 Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Learning Objective

Become familiar with one type of

signal storage in pneumatic
control systems.

Be able to explain and implement

AND/OR/NOT logic operations.

Be able to explain and set up

latching circuits.

Become familiar with one option

for end-position sensing in
cylinders.

Be able to combine logic

operations.

Become familiar with the set-up

and mode of operation of a
magnetic proximity switch.

Be able to differentiate between

5/2-way valves and to select and

use them in accordance with
specifications.

Be able to further develop

existing circuits.

Become familiar with the set-up

and mode of operation of a
pressure sequence valve.

Be able to set up pressure-

dependent control systems.

Become familiar with the set-up

and mode of operation of a
pressure regulator.

Become familiar with the set-up

and mode of operation of a time
delay valve.

Be able to set up circuits with

oscillating motion.

Be able to use time delay valves

in accordance with specific
constraints.

Be able to analyse and set up

circuits with two cylinders.

Festo Didactic GmbH & Co. KG 541088 XIII

 Equipment set for the basic level (TP101)

The equipment set has been put together for basic training in the field of pneumatic control technology. It
includes all the components that are necessary for mastering the specific learning objectives and can be
supplemented with any other equipment sets. A profile plate and a source of compressed air are also
required in order to set up functional control systems.

Equipment set for the basic level (TP101)

Quantity Designation Order no.

2 3/2-way roller lever valve, normally closed 152866

1 3/2-way valve with pushbutton, normally open 152861

2 3/2-way valve with pushbutton, normally closed 152860

1 3/2-way valve with selector switch, normally closed 152863

1 3/2-way valve, pneumatically actuated at one end 539768

3 5/2-way double pilot valve, pneumatically actuated at both ends 539769

1 5/2-way valve with selector switch 152862

1 5/2-way valve, pneumatically actuated at one end 538694

1 Double-acting cylinder 152888

2 One-way flow control valve 193967

2 Pressure gauge 152865

1 Pressure regulator with pressure gauge 539756

1 Pressure sequence valve 152884

1 Single-acting cylinder 152887

1 On-off valve with filter regulator 540691

2 Plastic tubing, 4 x 0.75, silver, 10 m 151496

2 Pneumatic proximity switch with cylinder mounting 539775

1 Pneumatic timer, normally closed 540694

1 Quick exhaust valve 539772

10 Push-in sleeve 153251

10 Push-in T-connector 153128

1 Distributor block 152896

1 Shuttle valve (OR) 539771

2 Dual-pressure valve (AND) 539770

XIV Festo Didactic GmbH & Co. KG 541088

Equipment set symbols

Designation Symbol

3/2-way valve with pushbutton, normally closed 2

1 3

3/2-way valve with pushbutton, normally open

5/2-way valve with selector switch 4 2

5 3
1

3/2-way valve with selector switch

Pressure gauge

3/2-way roller lever valve, normally closed 2

1 3

Pneumatic proximity switch 2

1 3

3/2-way valve, pneumatically actuated at one end 2

12

1 3

5/2-way valve, pneumatically actuated at one end 4 2

14

5 1 3

5/2-way double pilot valve, pneumatically actuated at both 4 2

ends
14 12

5 1 3

Festo Didactic GmbH & Co. KG 541088 XV

 Designation Symbol

Shuttle valve

1 1

Dual-pressure valve

2
1 1

Pneumatic timer, normally closed

2

1 3

Quick exhaust valve

1
3

One-way flow control valve

1 2

Pressure sequence valve

2

12 1 3

Single-acting cylinder

Double-acting cylinder

XVI Festo Didactic GmbH & Co. KG 541088

Designation Symbol

On-off valve with filter regulator

2
3
Pressure regulator with pressure gauge

1 3

Distributor block

Connectors

Festo Didactic GmbH & Co. KG 541088 XVII

 Allocation of equipment per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Equipment

Cylinder, single-acting 1 1 1 1 1 1

Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1 1 1 1 1

One-way flow control valve 2 2 1 2 2 2 2 2 2 2 1 2 2

Quick exhaust valve 1 1

Pressure gauge 2 2 1 2 1

3/2-way valve, pushbutton, 1 2 1 2 2 1 2 2 1 1 1 1

normally closed

3/2-way valve, pushbutton, 1 1

normally open

3/2-way valve, selector 1 1 2 1

switch, normally closed

3/2-way roller lever valve, 1 1 1

normally closed

Pneumatic proximity switch 2 2 2 1 2 2 2 2

3/2-way pneumatic valve 1 1

3/2-way pneumatic double 1 1

pilot valve

5/2-way valve, selector 1 1 1

switch

5/2-way pneumatic valve 1 1 1 1

5/2-way pneumatic double 1 1 1 1 1 1 1 1

pilot valve

Shuttle valve 1 1 1 1 1

Dual-pressure valve 1 2 2 1 1 2 1 1

Pressure sequence valve 1 1 1

Pressure regulator with 1 2 1 1

pressure gauge

Time delay valve, normally 1 1

closed

Distributor block 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

On-off valve with filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

regulator

XVIII Festo Didactic GmbH & Co. KG 541088

Practical tools for the trainer

Learning objectives
The basic learning objectives for the exercises in this module are the systematic sketching of circuit diagrams
as well as the practical set-up of a control system on the profile plate. This direct interaction involving both
theory and practice ensures faster, long-term learning. Each exercise has its own individual learning objectives;
the specific learning objectives are documented in the matrix.

Required time
The time required for the exercises depends on the learners previous knowledge of the subject matter. For
training a skilled labourer in metalworking or electrical installation: approx. 2 weeks. For training a
technician or engineer: approx. 1 week.

Equipment sets
The exercises and the equipment sets matched each other. For all 19 exercises youll only need the
components included in the equipment set for TP101 basic level.

Each exercise in the basic level can be set up on a profile plate.

Structure of the exercises

All 19 exercises have the same structure and are broken down into:
Title
Learning objectives
Presentation of the problem
Parameters
Project assignment
Layout
Worksheets

The solutions for all the 19 exercises are included in the trainers manual.

Festo Didactic GmbH & Co. KG 541088 XIX

 Designations of the components

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

Cylinders: 1A1, 2A1, 2A2 ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
Sensors: 1B1, 1B2 ...
Signal inputs: 1S1, 1S2 ...
Accessories: 0Z1, 0Z2, 1Z1 ...

CD ROM contents

The CD ROM provides you with additional media. The worksheets and solutions have been saved as PDF
files on the CD ROM that is included with the trainers manual.

The CD ROM contains the following folders:

Operating instructions
Data sheets
Demo
Festo catalogue
FluidSIM circuit diagrams
Industrial applications
Presentations
Product information
Videos

Operating instructions
Operating instructions for the various components included in the technology module are available. These
instructions are helpful when using and commissioning the equipment.

Data sheets
The data sheets for the components included in the technology module are supplied along with the
equipment set and are available as PDF files.

FluidSIM demo version

A demo version of the FluidSIM pneumatics software package is included on the CD ROM. Even this demo
version is suitable for testing control systems developed by the user.

XX Festo Didactic GmbH & Co. KG 541088

Festo catalogue
The relevant pages from the Festo catalogue will be provided with selected components. The
representations and descriptions of the components are intended to demonstrate how the components are
presented in an industrial catalogue. Additional information regarding the components is also included.

FluidSIM circuit diagrams

The FluidSIM circuit diagrams for all 19 exercises included in the technology module are contained in this
directory.

Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks. Project presentations can also be supplemented with these illustrations.

Presentations
Contains short presentations of the components included in the technology module. These can be used, for
example, to create project presentations.

Product information
This directory contains product information and data sheets from Festo for the components included in the
technology module. This is intended to demonstrate which information and data are available for industrial
components.

Videos
Several videos of industrial applications complete the media provided with the technology module. Short
clips demonstrate the applications in their actual industrial environments.

Festo Didactic GmbH & Co. KG 541088 XXI

 Equipment set for the advanced level (TP102)

The equipment set for the advanced level has been put together for further training in the field of pneumatic
control technology. The two equipment sets (TP101 and TP102) include components that are necessary for
mastering the predefined learning objectives and can be supplemented as required with other equipment
sets from the training system for automation and technology.

Equipment set for the advanced level (TP102)

Quantity Designation Order no.

1 3/2-way roller lever valve with idle return, normally closed 152867

2 3/2-way valve with pushbutton, normally closed 152860

1 3/2-way valve with mushroom actuator (red), normally open 152864

4 3/2-way valve, pneumatically actuated at one end 539768

2 5/2-way double pilot valve, pneumatically actuated at both ends 539769

2 Double-acting cylinder 152888

2 One-way flow control valve 193967

2 Plastic tubing, 4 x 0.75, silver, 10 m 151496

1 Pneumatic timer, normally open 539759

2 Non-return valve, piloted non-return function 540715

1 Back pressure limit valve 152868

10 Push-in sleeve 153251

1 Stepper module 152886

20 Push-in T-connector 153128

1 Pneumatic preset counter 152877

1 Shuttle valve (OR) 539771

1 Shuttle valve, 3-way (OR) 152882

1 Dual-pressure valve, 3-way (AND) 152883

XXII Festo Didactic GmbH & Co. KG 541088

Learning objectives for the advanced level (TP102)

Detect end-positions without limit switches

Understand and set up flip-flop circuits (flip-flop, double pilot valve)
Convert a 3/2 and/or a 5/2-way valve
Evaluate, use and adjust various sensors
Explain the function of a back pressure end stop
Explain the function of stepper modules
Develop basic sequence control systems (continuous cycle)
Implement a sequence control system with the following operating modes: automatic/manual, start and
reset
Implement an OR operation for feedback signals
Set and coordinate delays
Be able to abort delay times with an OR operation
Implement a sequence control system with idle step (3 steps)
Describe and set up variable step repetition within a motion sequence using a preset counter
Develop an input circuit with self-latching loop including the following functions: automatic/manual,
start, stop (at end of cycle) and reset
Evaluate and use sensors for material sensing
Actuate the final control element with two steps via a shuttle valve (double cylinder stroke)
Use a proximity switch within the stroke sub-range in order to reverse cylinder motion
Development of an input circuit for a sequence control system with secure pilot air, as well as start,
emergency stop and reset functions
Stop the cylinder within the sub-stroke range (positioning) by pressurising at both ends (preloading)
Adjust proximity switches in the end positions and within the sub-stroke range
Combined use of quick exhaust valve and pressure regulator with pressure gauge
Set up an inverted timer signal
Implement a control system with guide features in combination with sequence control

Festo Didactic GmbH & Co. KG 541088 XXIII

XXIV Festo Didactic GmbH & Co. KG 541088
Exercise 1: Pressing cheeses

Learning objectives
After completing this exercise youll:
Be familiar with the set-up and mode of operation of a single-acting cylinder.
Youll be able to calculate the piston force of a single-acting cylinder.
Be familiar with the set-up and mode of operation of a normally closed 3/2-way valve.
Be able to recognise and sketch the various types of actuation for directional control valves.
Be able to explain and set up direct actuation.

Presentation of the problem

Presses are used to press cheeses into moulds during the production process. Develop a control system
with which this process can be executed

Layout

Cheese production

Festo Didactic GmbH & Co. KG 541088 1

Exercise 1: Pressing cheeses

Parameters
Use a double-acting cylinder.
Pneumatically control the cylinder using a manually actuated valve.

Project assignment
1. Describe the mode of operation of a single-acting cylinder.
2. Describe the mode of operation of a normally closed 3/2-way valve.
3. Complete the pneumatic circuit diagram for the pressing tool.
4. Set up the control system.
5. Double-check the control system configuration.
6. Describe the mode of operation of the control system.
7. Create an equipment list.

Procedure
1. The cheeses are placed into the tool manually.
2. When the pushbutton is activated, the cylinder advances and presses the cover onto the tool.
3. The pushbutton is pressed and held until the pressing operation has been completed.
4. When the pushbutton is released, the cylinder is retracted and the tool can be accessed.
5. The cheese can be removed.

Safety note
Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately
deactivate compressed air supply if the tubing slips off.

2 Festo Didactic GmbH & Co. KG 541088

 Exercise 1: Pressing cheeses

Set-up and mode of operation of a single-acting cylinder

1 2 3 4 5

8 7 6

Circuit symbol and schematic diagram of a single-acting cylinder

Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two representations coincide with each other.

The two representations coincide with each other.

Describe the set-up and mode of operation of a single-acting cylinder.

The compressed air flows into the cylinders piston chamber. Pressure is built up in the chamber and
force is applied to the surface of the piston as a result. If this force exceeds static friction, the piston is
advanced. Pressure is not built up to full operating pressure until the piston is fully advanced.
When this pressure drops, the integrated return spring forces the piston back into its initial position.
Spring force is not great enough to move heavy loads attached to the piston rod. Hence single-acting
cylinders only perform work in a single direction.

Match up each component with the corresponding number from the above drawing.

Component Designation

3 Cylinder barrel

1 End cap

6 Bearing cap

5 Piston rod

8 Piston

7 Spring return

2 Supply port

4 Exhaust port

Table of component designations

Festo Didactic GmbH & Co. KG 541088 3

Exercise 1: Pressing cheeses

Calculate the piston force of a single-acting cylinder

Theoretical piston force is calculated using the following formula:

Fth = Ap
Fth = theoretical piston force (N)
A = effective piston surface (sq. metres)
D2
= ( )
4
p = working pressure (Pa)
D = cylinder diameter (m)

Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when
calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa),
it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.

The following applies to the effective piston force of single-acting cylinders:

Feff = A p (FR + FF)

Feff = effective piston force (N)
FR = friction force (approx. 10% of Fth ) (N)
FF = return spring force (N)

Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure
of 6 bar (600 kPa).

0.022 3.14
A= ( ) = 0.000314
4

Feff = 0.9 A p FF

Feff = 0.9 (0.000314) 600,000 13.5

Feff = 169.56 13.6 = 155.96 N

Note
The required data is included in the data sheet for the cylinder.

The piston diameter of the used cylinder is 20 mm and spring return force is 13.6 N.

4 Festo Didactic GmbH & Co. KG 541088

 Exercise 1: Pressing cheeses

Mode of operation of a normally closed 3/2-way valve

Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.

3
2 1

1 3

Circuit symbol and schematic representation of a normally closed 3/2-way valve

Describe the mode of operation of the 3/2-way valve.

A 3/2-way valve has 3 ports and 2 switching positions. Its represented in the normal position.
Normally closed means that compressed air cannot flow through the valve. When the pushbutton is
actuated the valve is opened, thus allowing air to flow and the piston of a connected cylinder is
advanced.

Festo Didactic GmbH & Co. KG 541088 5

Exercise 1: Pressing cheeses

Complete the pneumatic circuit diagram

Complete the pneumatic circuit diagram for the control system and enter the port designations.

1A1

1S1 2

1 3

0Z2

0Z1
1

2
3

Pneumatic circuit diagram

6 Festo Didactic GmbH & Co. KG 541088

 Exercise 1: Pressing cheeses

Sequence description

Set up the control system and describe its working sequence.

Initial position
Valve 1S1 is closed in its initial position. The piston rod of cylinder 1A1 is retracted.

Step 1-2
When the pushbutton on 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber of
cylinder 1A1 and the piston rod is advanced.

Step 2-3
When the pushbutton is released, valve 1S1 is exhausted and cylinder 1A1 returns to its initial position
due to force applied by the return spring.

Festo Didactic GmbH & Co. KG 541088 7

Exercise 1: Pressing cheeses

Create an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.

Create an equipment list by entering the required components and their quantities in the table below.

Quantity Designation

1 Cylinder, single-acting

1 3/2-way valve with pushbutton, normally open

1 Distributor block

1 On-off valve with filter regulator

1 Compressed air source

Equipment list

8 Festo Didactic GmbH & Co. KG 541088