Electropneumatics

Advanced Level

Workbook TP 202

CD-ROM included

Festo Didactic
541091 en
Intended use

The Festo Didactic Learning system has been developed and produced solely for
vocational and further training in the field of automation and technology. The
training company and/or instructor need to ensure that trainees observe the safety
precautions specified in this workbook.
Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,
the training company and/or other parties, which may occur during the
use/application of this equipment set other than in a training situation and unless
such damages are caused with intention or through gross negligence on the part of
Festo Didactic.

Order No.: 541091

Status: 04/2005
Authors: M. Pany, S. Scharf
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 10/2005

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005
Internet: www.festo-didactic.com
e-mail: [email protected]

The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Parts of this documentation may be copied by the authorised user exclusively for
training purposes.

2 © Festo Didactic GmbH & Co. KG • 541091

Contents

Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology packages for electropneumatics (TP200) _______________________ 11
Training aims of Advanced Level (TP202) _________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Advanced Level (TP202) _________________________________ 17
Allocation of equipment and exercises ___________________________________ 21
Methodological help for the trainer ______________________________________ 23
Methodological structure of the exercises_________________________________ 25
Designation of equipment _____________________________________________ 26
Contents of the CD-ROM _______________________________________________ 27
Equipment set – Basic Level (TP201) _____________________________________ 29
Training aims – Basic Level (TP201)______________________________________ 30

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 3

Contents

Part B – Fundamentals

Part C – Solutions

Exercise 1: Realising a diverting device ___________________________________C-3

Exercise 2: Insertion of drinks bottles ___________________________________C-13
Exercise 3: Realising a selection station _________________________________C-21
Exercise 4: Machining of key blanks ____________________________________C-37
Exercise 5: Bending of mounting brackets________________________________C-47
Exercise 6: Realising a filling system ____________________________________C-57
Exercise 7: Bonding of components _____________________________________C-67
Exercise 8: Selecting modes of operation ________________________________C-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________C-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP function______________________C-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function_____________________C-107
Exercise 12: Eliminating a fault on a machining station ____________________C-117

Part D – Appendix

Organiser _________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets
Circuit diagrams

4 © Festo Didactic GmbH & Co. KG • 541091

Preface

Festo Didactic’s Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured
into the following training packages:
• Basic packages to provide technology-spanning basic knowledge
• Technology packages to address the major subjects of open and closed-loop
technology
• Function packages to explain the basic functions of automated systems
• Application packages to facilitate vocational and further training based on actual
industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal
computer, hydraulics, electrohydraulics, proportional hydraulics and handling
technology.

© Festo Didactic GmbH & Co. KG • 541091 5

Preface

The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.

All the training packages are of identical structure:

• Hardware
• Teachware
• Software
• Seminars

The hardware consists of didactically designed industrial components and systems.

The didactic, methodological design of the teachware is harmonised with the
training hardware and comprises:
• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, additional information, solutions and data
sheets)
• Overhead transparencies and videos (to create an interesting and lively training
environment)

Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.

6 © Festo Didactic GmbH & Co. KG • 541091

Introduction

This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package TP200 is
comprised exclusively of electropneumatic control systems.

Basic Level TP201 is suitable for basic training in electropneumatic control

technology and provides knowledge regarding the physical fundamentals of
electropneumatics and the function and use of electropneumatic equipment. The
equipment set enables you to construct simple electropneumatic control systems.

Advanced Level TP202 focuses on further training in electropneumatic control

technology. The two equipment sets enable you to construct complex combinational
circuits with logic operations of input and output signals and program controls

Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-
circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is
used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar
(800 kPa) can be used for compressed air supply.

Working pressure must not exceed a maximum of p = 6 bar (600 kPa).

Optimum operational reliability is achieved if the control system is operated

unlubricated at a working pressure of p = 5 bar = 500 kPa.

The equipment set of Basic Level TP201 is used to construct complete control
systems for all of the 12 problem definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook

• Electropneumatics

Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices, etc.).

© Festo Didactic GmbH & Co. KG • 541091 7

Introduction

8 © Festo Didactic GmbH & Co. KG • 541091

Notes on safety and operation

The following advice should be observed in the interest of your own safety:

• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately.
• Do not switch on compressed air until tubing is securely connected.
• Caution!
Cylinders may advance automatically as soon as the compressed air is switched
on.
• Do not operate an electrical limit switch manually during fault finding (use a
tool).
• Observe general safety regulations. (DIN 58126 and VDE 100).
• With electrical limit switches you need to distinguish between two designs
– Actuation from the left
– Actuation from the right.
• At high piston speeds, limit switches must be approached only in the designated
direction of the trip cam of the cylinder. Limit switches must not be actuated from
the front.
• Do not exceed the permissible working pressure (see data sheets).
• Only use extra-low voltage ≤ 24V.
• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use
cables with jack plugs for the electrical connections.
• Pneumatic circuit assembly:
Connect devices using the silver-metallic plastic tubing of 4 mm outer diameter,
the tubing is plugged into the push-in fitting up to the stop; no need for securing!
• Releasing of push-in fitting:
The tubing can be released by pressing down the releasing ring (disconnection
under pressure is not possible!)
• Switch off compressed air supply and power supply prior to dismantling the
circuit.

© Festo Didactic GmbH & Co. KG • 541091 9

Notes on safety and operation

• The mounting plates of the devices are equipped with mounting variants A to D:
Variant A, latching system
For lightweight non-loadable devices (e.g. directional control valves). Simply clip
the device into the slot in the profile plate. Devices can be released by pressing
the blue lever.
Variant B, rotary system
Medium weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head bolts. Clamping and releasing is
effected by means of the blue knurled nut.
Variant C, screw system
For heavy loadable devices rarely removed from the profile plate (e.g. On/off
valves with filter regulating valve). These components are mounted by means of
socket head screws and T-head bolts.
Variant D, plug-in system
Lightweight non-loadable devices with locking pins (e.g. indicating devices).
These devices are attached by means of plug-in adapters.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.

10 © Festo Didactic GmbH & Co. KG • 541091

Technology package for electropneumatics (TP200)

The technology package TP200 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively electropneumatic
control systems. Individual components from the technology package TP200 may
also form a component part of other packages.

Important elements of • Fixed workstation with Festo Didactic profile plate

TP200 • Compressor (230 V, 0.55 kW, maximum 8 bar (800 kPa)
• Equipment sets or individual components
• Optional training aids
• Practical training models
• Complete laboratory setups

Training documentation

Textbooks Basic Level TP201

Fundamentals of pneumatic control technology
Maintenance of pneumatic devices and systems

Workbooks Basic Level TP201

Advanced Level TP202

Optional Teachware Sets of overhead transparencies and overhead projector

Magnetic symbols, drawing template
WBT Fluid Studio Electropneumatics
Cutaway model sets 1 + 2 with storage case
®
Simulation software FluidSIM Pneumatic

© Festo Didactic GmbH & Co. KG • 541091 11

Technology package for electropneumatics (TP200)

Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic

control circuits

EP-AL Electropneumatics for vocational training

Details of venues, dates and prices can be found in the current seminar planner.

Information regarding further training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually
updated and expanded. The sets of overhead transparencies, films, CD-ROMs and
DVDs as well as technical books are available in several languages.

12 © Festo Didactic GmbH & Co. KG • 541091

Training aims of Advanced Level (TP202)

• To familiarise yourself with the design and function of valve terminals.

• To be able to use valve terminals in accordance with requirements.
• 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 solve the problem of signal overlaps in a sequence control
according to the group method.
• To be able to detect signal overlaps in a sequence control.
• To be able to design a sequence chain using spring-return valves.
• To be able to design a sequence chain using double solenoid valves.
• 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.
• To familiarise yourself with the design and function of a pneumatic-electrical
converter.
• To familiarise yourself with the options for sensing pressure and time in electro-
pneumatic control systems.
• To familiarise yourself with the function and possible applications of a time relay
with switch-on delay.
• 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.
• To be able to develop and design the EMERGENCY-STOP function for a control
system with spring-return valves.
• To be able to develop and design the EMERGENCY-STOP function for a control
system with double solenoid valves.
• To be able to design a specified motion sequence with EMERGENCY-STOP.
• To be able to design the EMERGENCY-STOP condition „Cylinder remains in its
current position during EMERGENCY-STOP“.
• To familiarise yourself with the design and mode of operation of a 5/3-way valve.
• To be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.
• To be able to integrate the mode of operation „resetset“.
• To be able to identify and eliminate faults in complex electropneumatic control
systems.

© Festo Didactic GmbH & Co. KG • 541091 13

Training aims of Advanced Level (TP202)

14 © Festo Didactic GmbH & Co. KG • 541091

Allocation of training aims and exercises

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Training aims

To familiarise yourself with the design • •

and function of valve terminals.
To be able to use valve terminals in • •
accordance with requirements.
To be able to solve the problem of •
signal overlap in a sequence control
according to the group method.

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 •

with spring-return valves.

To be able to detect signal overlaps in •

a sequence control.

To be able to design a sequence chain •

using double solenoid valves.

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.

To familiarise yourself with the •

options for sensing pressure and time
in electro-pneumatic control systems.

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.

© Festo Didactic GmbH & Co. KG • 541091 15

Allocation of training aims and exercises

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Training aim

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.

To be able to develop and design the •

EMERGENCY-STOP function for a
control system with spring-return
valves.

To be able to develop the •

EMERGENCY-STOP function for a
control system using double solenoid
valves.

To be able to develop and design a •

specified motion sequence with
EMERGENCY-STOP.

To be able to design the EMERGENCY- •

STOP condition „Cylinder remains in
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 3/2 way solenoid
valves.

To be able to integrate the mode of •

operation „reset“.

To be able to identify and eliminate •

faults in complex electropneumatic
control systems.

16 © Festo Didactic GmbH & Co. KG • 541091

 Equipment set – Advanced Level (TP202)

The equipment set for the advanced level has been compiled for further training in
electro-pneumatic control technology. The two equipment sets (TP201 and TP202)
contain all the components required to meet the specified training aims and can be
expanded as desired with other equipment sets of the Learning System for
Automation and Technology.

Equipment set – Advanced Description Order No. Quantity

Level (TP202
EMERGENCY-STOP button 183347 1
Order No.: 540713)
Non-return valve, piloted 540715 2

Preselect counter, electrical 162355 1

Proximity sensor, capacitive 178575 1

Proximity sensor, inductive 178574 1

Relays, 3-off 162241 2

Signal input plate, electrical 162242 1

Time relay, 2-off 162243 1

Valve terminal with 4 valve slices (MMJJ) 540696 1

© Festo Didactic GmbH & Co. KG • 541091 17

Equipment set – Advanced Level (TP202)

Equipment set symbols Description Symbol

Relay, 3-off
12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

Signal input plate, electrical

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

18 © Festo Didactic GmbH & Co. KG • 541091

Equipment set – Advanced Level (TP202)

Description Symbol

Time relay, 2-off

17 27 35 45
A1

with switch-on delay

A2
18 28 36 46

17 27 35 45
A1

with switch-off delay

A2
18 28 36 46

Preselect counter, electrical

A1 1 R1

A2 R2
4 2

Proximity sensor, inductive

Proximity sensor, capacitive

EMERGENCY-STOP button 13 21

14 22

Non-return valve, piloted

2

1 21

© Festo Didactic GmbH & Co. KG • 541091 19

Equipment set – Advanced Level (TP202)

20 © Festo Didactic GmbH & Co. KG • 541091

Allocation of equipment and exercises

Equipment set TP202

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Equipment

Proximity sensor, inductive 1

Proximity sensor, capacitive 1

EMERGENCY-STOP button 1 1 1

Relay 2 6 6 6 6 6 4 5 6 6 6 6

Pushbutton, electrical, normally open 2 1 1 1 1 1 1 2 1 3 1

Pushbutton, electrical, normally 1

closed

Non-return valve, piloted 2

Valve terminal with 4 valve slices 1 1 1 1 1 1 1 1 1 1 1 1

(MMJJ)

Preselect counter, electrical 1

Time relay, 2-off 1

Equipment set TP201

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Equipment

Cylinder, double-acting 1 2 2 2 2 2 1 1 2 2 1 2

One-way flow control valve 2 4 4 4 4 4 2 2 4 4 2 4

Pressure sensor 1 1

Limit switch, electrical 2 2 2 2 2 2 2 2

Proximity sensor, electronic 2 2 2 2 2 2 2 2 2 2 2

Proximity sensor, optical 1 1

Pushbutton, electrical, normally 2 3

closed contact

Relay 3 4 2 4 5 3 3

Manifold 1 1 1 1 1 1 1 1 1 1 1 1

On/off valve with filter regulating 1 1 1 1 1 1 1 1 1 1 1 1

valve

Power supply unit 24V DC 1 1 1 1 1 1 1 1 1 1 1 1

© Festo Didactic GmbH & Co. KG • 541091 21

Allocation of equipment and exercises

22 © Festo Didactic GmbH & Co. KG • 541091

Methodological help for the trainer

• Training aims
The overall aim of this collection of exercises is the systematic design of circuit
diagrams and practical assembly of a control system on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
The detailed training aims are documented in the table. Actual individual training
aims are allocated to each problem and major training aims are shown in
brackets.
• Time required
The time required to work through a problem depends on the trainee’s prior
knowledge. Skilled workers in the engineering and electrical fields require
approximately 2 weeks. Technicians or engineers require approximately 1 week.
• Components of the equipment set
The book of exercises and equipment set are harmonised. You will require the
components of the equipment set for Basic Level TP 201 and Advanced Level
TP202. Each of the Advanced Level exercises can be assembled on a profile plate.
For exercise 11 you will require an additional electrical input or will need to
assemble the circuit in a different form.
• Representation
Abbreviated notation and motion diagrams are used for the represention of
motion sequences and switching statuses.

© Festo Didactic GmbH & Co. KG • 541091 23

Methodological help for the trainer

24 © Festo Didactic GmbH & Co. KG • 541091

Methodological structure of the exercises

All 12 exercises in Part A are of identical methodological structure.

The exercises are divided into:

• Title
• Training aims
• Problem definition
• Parameters
as well as
• Project task
• Positional sketch
• Worksheets

The proposed solutions in Part C are divided into:

• Circuit diagram
• Solution description
as well as
• Circuit design
• Equipment list

© Festo Didactic GmbH & Co. KG • 541091 25

Designation of equipment

The designation of components in a circuit is effected in accordance with the

DIN-ISO 1219-2 standard. All components of a circuit have the same main code
number. Letters are assigned depending on components. Several components
within a circuit are numbered consecutively. The designation of multiple pressure
ports is P and these are consecutively numbered separately.

Drives: 1A1, 2A1, 2A2, ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...
Sensors: 1B1, 1B2, ...
Signal input: 1S1, 1S2, ...
Accessories: 0Z1, 0Z2, 1Z1, ...
Pressure ports: P1, P2, ...

26 © Festo Didactic GmbH & Co. KG • 541091

Contents of the CD-ROM

The CD-ROM supplied provides you with additional media. The contents of Part A –
Exercises, and Part C – Solutions, are stored in the form of pdf files.

The structure of the CD-ROM is as follows:

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

Operating instructions Operating instructions are available for the various pieces of equipment of the
technology package to assist you in the use and commissioning of the equipment.

Data sheets The data sheets for the equipment of the technology package are available in the
form of pdf files.

Demo A demo version of the software package FluidSIM® Pneumatic is stored on the CD-
ROM. This version is suitable for the testing of the control system developed.

Festo catalogue Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of
equipment. The representation and description of equipment in this form is intended
to illustrate how such equipment is represented in an industrial catalogue. You will
also find additional information here regarding the equipment.

FluidSIM® circuit diagrams FluidSIM® circuit diagrams are stored in this directory for all 12 exercises in the
technology package.

For the introduction to logic programming, all FluidSIM® circuit diagrams are also
stored in a variant with logic control in addition to the circuit diagrams with relay
control.

© Festo Didactic GmbH & Co. KG • 541091 27

Contents of the CD-ROM

Industrial applications Photos and pictures are provided of industrial applications to enable you to
illustrate your own problem definitions. These can also be added to project
presentations.

Presentations Brief presentations are stored in this directory regarding the equipment for this
technology package. These presentations can for instance be used to create project
presentations.

Product information This directory provides you with the product information and data sheets of Festo
AG & Co. KG regarding the equipment of the technology package and is intended to
explain what information and data are provided for an industrial component.

Videos A number of videos of industrial applications complete the media for the training
package. Short sequences are shown of practice-related applications.

28 © Festo Didactic GmbH & Co. KG • 541091

Equipment set – Basic Level (TP201)

This equipment set has been compiled for basic training in electropneumatic control
technology. It comprises all the components required for the training aims specified
and can be expanded in any way with other equipment sets. In addition you will also
need a profile plate, electrical power supply unit and compressed air supply to
assemble a fully functional control system.

Equipment set – Basic: Description Order No. Quantity

Level (TP201
2 x 3/2-way way solenoid valve, normally open 539776 1
Order No.: 540712)
5/2-way double solenoid valve 539778 2

5/2-way solenoid valve 539777 1

Blanking plug 153267 10

One-way flow control valve 539773 4

Pressure sensor 539757 1

On/off valve with filter regulating valve 540691 1

Limit switch, electrical, actuation from the left 183322 1

Limit switch, electrical, actuation from the right 183322 1

Plastic tubing 4 x 0.75, 10 m 151496 2

Proximity sensor, electronic 540695 2

Proximity sensor, optical 178577 1

Relay, 3-off 162241 2

Signal input plate, electrical 162242 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Manifold 152896 1

Cylinder, double-acting 152888 2

Cylinder, single-acting 152887 1

© Festo Didactic GmbH & Co. KG • 541091 29

Training aims of Basic Level (TP201)

• To familiarise yourself with the design and mode of operation of a

single-acting cylinder.
• To familiarise yourself with the design and mode of operation of a
double-acting cylinder.
• To be able to calculate piston forces according to specified values.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To familiarise yourself with the design and mode of operation of a double
solenoid valve.
• To be able to select solenoid valves according to requirements.
• To be able to identify and draw the various types of actuation of directional
control valves.
• To be able to convert solenoid valves.
• To be able to explain and design an example of direct actuation.
• To be able to explain and design an example of indirect actuation.
• To familiarise yourself with logic functions and to design these.
• To familiarise yourself with different types of end position control and to be able
to select a suitable type.
• To be able to calculate electrical characteristic values.
• To familiarise yourself with latching circuits with different characteristics.
• To be able to explain and design an electrical latching circuit with dominant
switch-off signal.
• To be able to design a pressure-dependent control system.
• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
• To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
• To be able to realise a sequence control using two cylinders.
• To be able to identify and eliminate errors in simple electropneuamtic control
systems.

30 © 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.

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

Exercise 1: Realising a diverting device

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.

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

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)

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 2 of 5

– 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

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 3 of 5

– Which concept enables you to achieve a reduction in tubing costs? Explain the
reason for your choice.

Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Reason Individual mounting Block mounting of

of directional control directional control
valves valves

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 4 of 5

– 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
respective technical descriptions.

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

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

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
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Reason Conventional wiring Multi-pin wiring

technology concept

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

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

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– 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)

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– 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

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

Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

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

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

Exercise 1: Realising a diverting device

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

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.

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 .

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

Exercise 2: Insertion of drinks bottles

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–

A-16 © Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles

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

© Festo Didactic GmbH & Co. KG • 541091 A-17

Exercise 2: Insertion of drinks bottles

Exercise 2: Insertion of drinks bottles

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

A-18 © Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles

Exercise 2: Insertion of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

– 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

© Festo Didactic GmbH & Co. KG • 541091 A-19

Exercise 2: Insertion of drinks bottles

Exercise 2: Insertion of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– 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)

A-20 © Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles

Exercise 2: Inserting of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– 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

Electrical circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-21

Exercise 2: Insertion of drinks bottles

Exercise 2: Insertion of drinks bottles

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

A-22 © Festo Didactic GmbH & Co. KG • 541091

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.
5. Simulate the electropneumatic circuit diagram and check its correct functioning.
6. Compile an equipment list.
7. Carry out the pneumatic and electrical circuit assembly.
8. Check the circuit operation.

© Festo Didactic GmbH & Co. KG • 541091 A-23

Exercise 3: Realising a selection station

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–

A-24 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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

© Festo Didactic GmbH & Co. KG • 541091 A-25

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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)

A-26 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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)

© Festo Didactic GmbH & Co. KG • 541091 A-27

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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.

A-28 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Group method Sheet 2 of 3

1. Group formation

1A1+ 2A1+ 2A1– 1A1–

2. Designation of solenoid coils

1A1+ 2A1+ 2A1– 1A1–

© Festo Didactic GmbH & Co. KG • 541091 A-29

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Group method Sheet 3 of 3

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–

A-30 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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

© Festo Didactic GmbH & Co. KG • 541091 A-31

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Displacement-step diagram – group formation Sheet 2 of 3

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

A-32 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Displacement-step diagram – group formation Sheet 3 of 3

1A1+ 3A1+ 1A1– 2A1– 3A1– 2A1+

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

© Festo Didactic GmbH & Co. KG • 541091 A-33

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

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

A-34 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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)

© Festo Didactic GmbH & Co. KG • 541091 A-35

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– 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)

A-36 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station

Exercise 3: Realising a selection station

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

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

© Festo Didactic GmbH & Co. KG • 541091 A-37

Exercise 3: Realising a selection station

A-38 © Festo Didactic GmbH & Co. KG • 541091

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.
5. Simulate the electropneumatic circuit diagram and check its correct functioning.
6. Check the equipment list.
7. Carry out the pneumatic and electrical circuit assembly.
8. Check the circuit operation .

© Festo Didactic GmbH & Co. KG • 541091 A-39

Exercise 4: Machining of key blanks

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.

A-40 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

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
5. Cylinder 1A1 retracts.

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

© Festo Didactic GmbH & Co. KG • 541091 A-41

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

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

Step 1 Step 2 Step 3 Step 4

Displacement-step diagram

A-42 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

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

© Festo Didactic GmbH & Co. KG • 541091 A-43

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

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

A-44 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

Name: Date:

Fundamentals: Drawing up GRAFCET Sheet 2 of 2

1B1*2B1 “Initial position”

GRAFCET

© Festo Didactic GmbH & Co. KG • 541091 A-45

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

A-46 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

– 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)

© Festo Didactic GmbH & Co. KG • 541091 A-47

Exercise 4: Machining of key blanks

Exercise 4: Machining of key blanks

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

Cylinder, double-acting

One-way flow control valve

5/2-way solenoid valve (plate M 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

A-48 © Festo Didactic GmbH & Co. KG • 541091

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.
3. Draw the pneumatic and electrical circuit diagrams.
4. Simulate the electropneumatic circuit diagram and check its correct functioning.
5. Compile an equipment list.
6. Carry out the pneumatic and electrical circuit assembly.
7. Check the circuit operation.

© Festo Didactic GmbH & Co. KG • 541091 A-49

Exercise 5: Bending of mounting brackets

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–

A-50 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

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.
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

© Festo Didactic GmbH & Co. KG • 541091 A-51

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

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

A-52 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

Name: Date:

Drawing up the GRAFCET Sheet 1 of 1

– Draw up the GRAFCET for the sequence described.

1B1*2B1 “Initial position”

GRAFCET

© Festo Didactic GmbH & Co. KG • 541091 A-53

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

A-54 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram of the bending device.

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 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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 A-55

Exercise 5: Bending of mounting brackets

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

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

A-56 © Festo Didactic GmbH & Co. KG • 541091

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.

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 .

© Festo Didactic GmbH & Co. KG • 541091 A-57

Exercise 6: Realising a filling system

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.

A-58 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

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)

© Festo Didactic GmbH & Co. KG • 541091 A-59

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

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

A-60 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

Name: Date:

Fundamentals: Proximity sensors Sheet 3 of 4

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

© Festo Didactic GmbH & Co. KG • 541091 A-61

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

Name: Date:

Fundamentals: Proximity sensors Sheet 4 of 4

– Describe the design and function of a capacitive proximity sensor.

Description of design and function Symbol/electrical circuit

diagram

BN

BK

BU

A-62 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-63

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the filling system.

Signal input Signal processing and signal output

+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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

A-64 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system

Exercise 6: Realising a filling system

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

5/2-way double solenoid valve (plate J on valve terminal)

Limit switch, electrical

Proximity sensor, electronic

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Pushbutton (normally open contact)

Pushbutton (normally closed 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

© Festo Didactic GmbH & Co. KG • 541091 A-65

Exercise 6: Realising a filling system

A-66 © Festo Didactic GmbH & Co. KG • 541091

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.

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 for the bonding device.
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 .

© Festo Didactic GmbH & Co. KG • 541091 A-67

Exercise 7: Bonding of components

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.

A-68 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components

Exercise 7: Bonding of components

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

© Festo Didactic GmbH & Co. KG • 541091 A-69

Exercise 7: Bonding of components

Exercise 7: Bonding of components

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

A-70 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components

Exercise 7: Bonding of components

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.

© Festo Didactic GmbH & Co. KG • 541091 A-71

Exercise 7: Bonding of components

Exercise 7: Bonding of components

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

A-72 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components

Exercise 7: Bonding of components

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the bonding device.

Signal input Signal processing and signal output

+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

Electrical circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-73

Exercise 7: Bonding of components

Exercise 7: Bonding of components

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (plate J on valve terminal)

Proximity sensor, electronic

Pressure sensor

Pushbutton (normally open contact)

Relay

1 Relay (switch-on delay)

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

A-74 © Festo Didactic GmbH & Co. KG • 541091

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.
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 .

© Festo Didactic GmbH & Co. KG • 541091 A-75

Exercise 8: Selecting modes of operation

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.

A-76 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

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?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

© Festo Didactic GmbH & Co. KG • 541091 A-77

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 2 of 4

– 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

A-78 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 3 of 4

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

© Festo Didactic GmbH & Co. KG • 541091 A-79

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 4 of 4

The range of hysteresis can be changed on the pressure sensor used.

– Describe what is understood by the term “hysteresis“.

Description: Hysteresis

A-80 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 A-81

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– 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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

A-82 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation

Exercise 8: Selecting modes of operation

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Complete the equipment list by entering the required quantity of components in

the table below.

Quantity Description

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (plate J on valve terminal)

Proximity sensor, electronic

Pressure sensor

Preselect counter, electrical

Pushbutton (normally open contact)

Pushbutton (normally closed 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

© Festo Didactic GmbH & Co. KG • 541091 A-83

Exercise 8: Selecting modes of operation

A-84 © Festo Didactic GmbH & Co. KG • 541091

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.

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 for the feed limiting and
turning station including the use of the EMERGENCY-STOP function.
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 .

© Festo Didactic GmbH & Co. KG • 541091 A-85

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Positional sketch

Machining of key blanks

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.

A-86 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

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

© Festo Didactic GmbH & Co. KG • 541091 A-87

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 2 of 4

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

A-88 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 3 of 4

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

© Festo Didactic GmbH & Co. KG • 541091 A-89

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 4 of 4

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

A-90 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-91

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– 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-

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

A-92 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Checking the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Check the equipment list. Are the required components entered in the table
below?

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

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

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 A-93

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

A-94 © Festo Didactic GmbH & Co. KG • 541091

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.
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 .
7. Describe the behaviour of the circuit during EMERGENCY-STOP.

© Festo Didactic GmbH & Co. KG • 541091 A-95

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.

A-96 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-97

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

A-98 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 A-99

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the bending device.

Signal input Signal processing Signal output

+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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

A-100 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Check the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Check the equipment list. Are the required components entered in the table
below?

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

1 Mushroom actuator (normally closed contact)

11 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 A-101

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

A-102 © Festo Didactic GmbH & Co. KG • 541091

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
the training contents listed.
3. Draw the pneumatic and electrical circuit diagrams for the linear drive of the
handling device including an EMERGENCY-STOP function.
4. Simulate the electropneumatic circuit diagram and check its correct functioning.
5. Compile an equipment list.
6. Carry out the pneumatic and electrical circuit assembly.
7. Check the circuit operation .
8. Describe the behaviour of the circuit during EMERGENCY-STOP.

© Festo Didactic GmbH & Co. KG • 541091 A-103

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.

A-104 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

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

© Festo Didactic GmbH & Co. KG • 541091 A-105

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP 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

A-106 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

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

© Festo Didactic GmbH & Co. KG • 541091 A-107

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

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

Pneumatic circuit diagram

A-108 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 A-109

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– 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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

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.

A-110 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Checking the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

– Check the equipment list. Are the required components entered in the table
below?

Quantity Description

1 Cylinder, double-acting

2 Non-return valve, piloted

2 One-way flow control valve

2 5/2-way solenoid valve (plate M in valve terminal)

2 Proximity sensor, electronic

4 Pushbutton (normally open contact)

3 Pushbutton (Normally closed contact)

1 Mushroom actuator (normally closed contact)

9 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 A-111

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

A-112 © Festo Didactic GmbH & Co. KG • 541091

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.

© Festo Didactic GmbH & Co. KG • 541091 A-113

Exercise 12: Eliminating a fault on a machining station

Positional sketch

Machining of key blanks

START

1 2 3 4 5=1
(1M1)
1
1B2
1A1

0
(1M1) 1B1

2B2 (2M1)
1

2A1
2B1
0
(2M1)
Step 1 Step 2 Step 3 Step 4

Displacement-step diagram

A-114 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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)

© Festo Didactic GmbH & Co. KG • 541091 A-115

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 2 of 4

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

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-

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

List of potential error causes

A-116 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 3 of 4

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.

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

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)

© Festo Didactic GmbH & Co. KG • 541091 A-117

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 4 of 4

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)

Cable break in supply line of

changeover contact K8
Connection 11
(current path 13)

Cable break in supply line of

changeover contact K8
Connection 21 to relay K9
Connection A1
(current path14)

A-118 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

Displacement-step diagram

© Festo Didactic GmbH & Co. KG • 541091 A-119

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

Displacement-step diagram

A-120 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

© Festo Didactic GmbH & Co. KG • 541091 A-121

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

A-122 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

© Festo Didactic GmbH & Co. KG • 541091 A-123

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

Measuring and test protocol

A-124 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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.

Measuring and test protocol

Potential fault Current path No. Measuring points Investigation Result

No.

Measuring and test protocol

© Festo Didactic GmbH & Co. KG • 541091 A-125

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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.

A-126 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station

Exercise 12: Eliminating a fault on a machining station

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

© Festo Didactic GmbH & Co. KG • 541091 A-127

Exercise 12: Eliminating a fault on a machining station

A-128 © Festo Didactic GmbH & Co. KG • 541091

Part B – Fundamentals

The theoretical fundamentals for the electropneumatics training package are

summarised in the textbook:

Electropneumatics, Basic Level

This textbook represents an impressive synthesis of years of experience gained in
Festo Didactic courses and the requirements of company and college training. It
explains basic equipment and modern installation-saving components that require
little maintenance. A comprehensive description of methods of representation
showing motion sequences and operating states makes complex circuits easy to
understand. A detailed example provides students with the necessary knowledge for
the planning and realisation of an electropneumatic circuit.

G. Prede, D. Scholz, edition 2001,

296 pages, bound
Order No.: 091181

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

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

Part C – Solutions

Exercise 1: Realising a diverting device __________________________________C-3

Exercise 2: Insertion of drinks bottles ___________________________________C-13
Exercise 3: Realising a selection station _________________________________C-21
Exercise 4: Machining of key blanks ____________________________________C-37
Exercise 5: Bending of mounting brackets________________________________C-47
Exercise 6: Realising a filling system ____________________________________C-57
Exercise 7: Bonding of components _____________________________________C-67
Exercise 8: Selecting modes of operation ________________________________C-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________C-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP function______________________C-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function_____________________C-107
Exercise 12: Eliminating a fault on a machining station ____________________C-117

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

Contents

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

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 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)

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 2 of 5

– 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 1 0 1
air distribution units

Amount of tubing for 1 0 1

supply to compressed air
distribution unit

Amount of tubing for 3 1 2

compressed air supply to
control chains

Amount of tubing 6 6 -
between directional
control valves and
cylinders

Silencers

Number of silencers for 6 1 5

control chains

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 3 of 5

– Which concept enables you to achieve a reduction in tubing costs? Explain the
reason for your choice.

Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
relevant technical descriptions.

Reason Individual mounting Block mounting of

of directioal control directional control
valves valves

If the directional control valves of the control X

chains are jointly mounted on a manifold or valve
terminal, one length of tubing is sufficient for the
compressed air supply to all control chains and one
silencer assumes the conduction of all exhaust air.
Compared to individual mounting, this method
saves numerous tubing connections and silencers
as well as a compressed air distribution unit. This
correspondingly reduces the amount of tubing
work involved.

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 4 of 5

– 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 and the respective
technical descriptions.

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 1 2

Supply voltage (24 V) 1 2

PLC outputs (actuation of solenoid 6 6

coils)

PLC inputs (evaluation of proximity 6 6

sensors)

Terminal strip 1 in control cabinet, overall 14 16

Cable from control cabinet to Cable between terminal strips 1 Cable tree or one cable with Cable tree or one cable with
terminal box and 2 14 wires 8 wires

Terminal strip 2 Proximity sensors (3 wires per 18 18

(in terminal box) proximity sensor)

Solenoids 12 -
(2 wires per solenoid)

Terminal strip 2, overall 30 18

Cable to directional control valves Connection of solenoid coils 6 cables with 2 wires each -
and sensors
Connection of sensors 6 cables with 3 cables each 6 cables with 3 cables each

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

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
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Reason Conventional wiring Multi-pin wiring

technology concept

All the valves of the control system are to be X

configured on the MPA valve terminal (using MP
connection. When connecting the valve terminal via
a multi-pin connector, a large number of terminals
from terminal strip 2 and the cables to the solenoid
coils are dispensed with compared to conventional
wiring. This reduces the wiring costs and simplifies
maintenance and fault finding.

Note
The use of the MPA valve terminal with a CPX terminal (CPX fieldbus node,
CPX-EA-module) would further reduce the wiring costs.

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

– Complete the pneumatic circuit diagram for the diverting device.

1A1

1V2 1 1 1V3

2 2

1V1 4 2

1M1 1M2
5 3
1

Pneumatic circuit diagram with individual valve

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– Complete the pneumatic circuit diagram from the diverting 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
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)

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– Complete the electrical circuit diagram from the diverting device.

Signal input Signal processing and signal output

+24 V 1 2 3 4

13 13 12 14 12 14
S1 S2 K1 K2
14 14 11 11

A1 A1
K1 K2 1M1 1M2
A2 A2

0V 12 12
11 14 .3 11 14 .4
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44

Electrical circuit diagram

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Process description Sheet 1 of 1

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

Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes relay K1 to pick up and
the changeover contact K1 in current path 3 to close.
The circuit of solenoid coil 1M1 is closed. This causes the 5/2-way double solenoid
valve 1V1 to reverse.
The piston end of cylinder 1A1 is pressurised whilst the piston rod end is exhausted.
The piston rod of cylinder 1A1 advances.

As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay

K1 drops out and the changeover contact K1 in current path 3 opens.
The circuit of solenoid coil 1M1 is open.

Steps 2-3
Actuation of pushbutton S2 (normally open contact) causes relay K2 to pick up and
the changeover contact K2 in current path 4 to close.
The circuit of the solenoid coil 1M2 is closed. This causes the 5/2-way double
solenoid valve 1V1 to switch into the initial position again.
The piston rod end of cylinder 1A1 is pressurised whilst the piston end is exhausted.
The piston rod of cylinder 1A1 moves into the retracted end position.

As soon as pushbutton S2 (normally open contact) is no longer actuated relay K2

drops out and changeover contact K2 opens.
The circuit of solenoid coil 1M2 is open.

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

Exercise 1: Realising a diverting device
Solutions

Exercise 1: Realising a diverting device

Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from a 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

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (plate J on valve terminal)

2 Pushbutton (normally open contact)

2 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

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

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Fundamentals: Valve block assembly Sheet 1 of 2

Due to the wide range of different designs of electromagnetic control systems, a

comparison of individual valves and valve terminals used in industrial practice
reveals a number of 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 reason for your choice.

Reaso Individual mounting Block mounting of

of directional control directional control
valves valves

Despite the indisputable advantages (reduced X

wiring and tubing costs), valve block assembly
leads to undesirable secondary effects in the case
of cylinder drives located far apart:

• Long tubing is required between directional

control valves and cylinders.
This involves long signal running times (approx.
30 ms for 10 m tubing length). Cylinder reaction
is delayed. Operation of the electropneumatic
control system is correspondingly slower.

• The large tubing volume between valve and

cylinder leads to increased compressed air
consumption.

• The resulting overall assembly is very complex.

Replacement of tubing is time-consuming.

Directional control valves should therefore only be

block mounted if the allocated drive cylinders are
relatively closely together or if the above listed
disadvantages can be tolerated.

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

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

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 descriptions of the individual valves from TP201 or the MPA valve
terminal from TP202)

– Describe what is understood by the term“current reduction“.

Description: “Current reduction“

After the high current phase (switching operation, switch-on time 20ms), the nominal current is
reduced electronically by the valve solenoid coil to the point where the pre-stage (pilot actuation of
the solenoid valve) against the reset spring force is still just retained in the actuated position. This
distinctly reduces the electrical power consumption during this phase.
The nominal pull current (up to 20 ms) is 80 mA at 24 V DC; the nominal current with current reduction
(after 20 ms switch-on time) is only 20 mA. Since the holding phase is considerably longer than the
switching phase, the operation of the solenoid coil requires considerably less electrical power.

– Describe the advantages gained as a result of current reduction.

Description: Advantages gained as a result of current reduction

• Directional control valves, i.e. MPA valve terminals have lower power consumption.

• Depending on the application, the power pack for the voltage supply of the directional control
valves, i.e. the MPA valve terminal, can be more economically configured.

• Reduced current flow through the valve solenoid coil means less waste heat. This is of particular
advantage in the case of a large number of parallel configured valve coils (subject of heating of coil
windings due to waste heat, burn out of coil wire).

• The valve solenoid coils are subject to reduced power dissipation.

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

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

– Complete the pneumatic circuit diagram for the loading station.

1A1 2A1
1B1 2B2
1B1 1B2

1V2 1 1 1V3 2V2 1 1 2V3

2 2 2 2

1V1 4 2 2V1 4 2

1M1 1M2 2M1 2M2

5 3 5 3
1 1

Pneumatic circuit diagram with individual valves

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

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– Complete the pneumatic circuit diagram for the loading station.

1A1 2A1
1B1 2B2
1B1 1B2

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 with valve terminal (circuit diagram in DIN A3 format in Part D)

C-16 © Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– Complete the electrical circuit diagram for the loading station.

Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13

12 14 12 14 12 14 22 24
2B1 BN 2B2 BN 1B3 13
BN K1 K2 K4 K1
2 4 2 4 S1
BK BK BK 11 11 11 21
1B1 1 B2 14
1 1 12 14
BU BU BU
K3
11

12 14
K5
11

12 14
K6
11
A1 A1 A1 A1 A1 A1 1M1 2M1 1M2 2M2
K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2

0V 12 12 12 12 12 12
11 14 .10 11 14 .11 11 14 .10 11 14 .12 11 14 .10 11 14 .10
22 22 22 22 22 22
21 24 .13 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

© Festo Didactic GmbH & Co. KG • 541091 C-17

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Process description Sheet 1 of 2

Sequence
CyIinders 1A1 and 2A1 are in the retracted end position in the initial position. Limit
switch 1B1 is actuated, relay K1 is energised and closes the changeover contact K1
in current path 10. Proximity sensor 2B1 is actuated, relay K3 is energised and
closes the changeover contact K3 in current path 10.

The optical proximity sensor 1B3 has detected a drinks crate, relay K5 is energised
and closes the changeover contact K5 in current path 10.

Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes relay K6 to pick up.
Changeover contact K6 closes in current path 10. The circuit of the solenoid coil 1M1
of the 5/2-way double solenoid valve 1V1 is closed. This causes the double solenoid
valve 1V1 to reverse and cylinder 1A1 to advance.

As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K6

drops out and changeover contact K6 opens. The circuit of solenoid coil 1M1 is
open.

Steps 2-3
When cylinder 1A1 reaches the forward end position, the limit switch 1B2 (normally
open contact) switches and the relay K2 picks up. The changeover contact K2 in
current path 11 closes. The circuit of the solenoid coil 2M1 of the 5/2-way double
solenoid valve 2V1 is closed. The double solenoid valve 2V1 reverses. Cylinder 2A1
advances.

C-18 © Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Process description Sheet 2 of 2

Steps 3-4
Proximity sensor 2B2 (normally open contact) is actuated when cylinder 2A1 reaches
the forward end position and the relay K4 picks up. The changeover contact K4 in
current path 12 closes. The circuit of solenoid coil 1M2 is closed. This causes the
double solenoid valve 1V1 to return into the initial position the cylinder 1A1 to move
into the retracted end position.

Steps 4-5
Limit switch 1B1 switches when cylinder 1A1 reaches the retracted end position and
relay K1 picks up. The changeover contact K1 in current path 13 closes. The circuit of
solenoid coil 2M2 is closed. This causes the double solenoid valve 2V1 to return into
the initial position and cylinder 2A1 to move into the retracted end position.

© Festo Didactic GmbH & Co. KG • 541091 C-19

Exercise 2: Insertion of drinks bottles
Solutions

Exercise 2: Insertion of drinks bottles

Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from a 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

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Proximity sensor, optical

1 Pushbutton (normally open contact)

6 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

C-20 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Signal overlap Sheet 1 of 3

Sequence
1. Cylinders 1A1 and 2A1 are retracted in the initial position; the limit switch 1B1
and proximity sensor 2B1 are actuated.
2. If pushbutton S1 AND limit switch 1B1 are actuated, cylinder 1A1 moves into the
forward end position.
3. Limit switch 1B2 is actuated and cylinder 2A1 advances. In the forward end
position, proximity sensor 2B2 is actuated.
4. Cylinder 2A1 moves into the retracted end position and actuates
proximity sensor 2B1.
5. Cylinder 1A1 retracts.

1A1 2A1
1B1 2B2
1B1 1B2

1V2 1 1 1V3 2V2 1 1 2V3

2 2 2 2

1V1 4 2 2V1 4 2

1M1 1M2 2M1 2M2

5 3 5 3
1 1

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 C-21

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Signal overlap Sheet 2 of 3

– Design the displacement-step diagram for the problem definition described.

START

1 2 3 4 5=1
(1M2)
1
1B2
1A1

0
(1M1) 1B1

2B2 (2M2)
1

2A1
2B1
0
(2M1)
Step 1 Step 2 Step 3 Step 4

Displacement-step diagram

C-22 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Signal overlap Sheet 3 of 3

Signal overlap(s) occur(s) owing to the power section and operating sequence
described above.

– Describe this problem.

Description: Overlap(s)

Signal overlaps are caused as a result of simultaneous signals at the control inputs of a bistable
control element. The interfering signal is to be cleared. If power is removed from the relevant
signalling element, the interfering signal is simultaneously switched off, which leads to signal overlap:
From the displacement-step diagram it can be seen that the signalling element 2B1 in the retracted
end position at cylinder 2A1 causes the return stroke movement of cylinder 1A1 (see operating status
4). 2B1 is actuated in the start status (initial status) and consequently supplies a continuous signal
(logic 1) to reset input 1M2. A start signal (logic 1) to 1M1 will therefore generate a signal overlap at
control signal 1V1 of cylinder 1A1. The sequence can therefore not be started in this way. In operating
status 2, the signalling element 1B2 triggers the movement 2A1+ as the solenoid coil 2M1 is switched
on. However, as 1B2 stays actuated through to operating status 4, 2M1 receives a continuous signal
(logic 1). The signalling element 2B2 is then to initiate the motion 1A1- by switching on solenoid coil
2M2. This causes the machine to stop since the control element 2V1 remains in the position shown
and cylinder 2A1 consequently remains in the forward position.

– Describe how this problem is to be solved.

Description: Solution to signal overlap(s)

The interfering signal must be cleared.If power is removed from the corresponding signalling element,
the interfering signal is also switched off. These switching functions can be selected such that the
applied signals (logic 1) are switched off (set to logic 0 gesetzt), if they disturb the correct sequence,
or at an earlier time. It is useful to combine these signal switch-off functions such that one signalling
element simultaneously switches off two interfering signals. This measure renders the circuit diagram
more simple, clearly arranged and requires fewer switching functions. By forming groups of movement
(control circuit formation), it is possible to determine the right point for these signal interruptions.

© Festo Didactic GmbH & Co. KG • 541091 C-23

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Group method Sheet 1 of 3

This signal overlap can be prevented by forming groups of movement (control circuit
formation).

1. Form the groups 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(s) the respective memory output influences.
4. Designate the signalling elements within the group(s)..
Enter which solenoid coil(s) the respective signalling elements influence.

1. Group formation
Describe the operating sequence by means of abbreviated notation. Configure the
groups of movement (control circuits). Define the groups of movement by means of
separating lines. Put a group separating line at cycle start and cycle end.

Group 1 Group 2

1A1+ 2A1+ 2A1– 1A1–

Combine as many groups as possible into one group. This makes the control system
less complex. Each drive (= movement) must only be designated once in a group.

C-24 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Group method Sheet 2 of 3

2. Designation of solenoid coils

Enter the solenoid coils.

Group 1 Group 2

1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–

Determine the control memory (control unit). The signalling element at the group
separation must act on a memory input. The memory output allocated to the
memory input initiates the following subsequent movement.

3. Description of signalling elements/memory input at group separation, i.e.

allocation of memory outputs/solenoid coils

Group 1 Group 2

1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–

START 2B2
+ 1B1

Memory Memory

© Festo Didactic GmbH & Co. KG • 541091 C-25

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Group method Sheet 3 of 3

4. Designation of signalling elements within the group, i.e. allocation of

signalling elements/solenoid coils
A signalling element within a group directly initiates the subsequent movement.

Group 1 Group 2

1B2 2B1

1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–

START 2B2
+ 1B1

Memory Memory

C-26 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Displacement-step diagram – group formation Sheet 1 of 3

– Create the displacement-step diagram for the cylinder movements described and
form groups.

Note
The control system will be less complex if you combine 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

1A1+ 1A1– 2A1+ 3A1+ 3A1– 2A1–

Group 1 Group 2 Group 3

© Festo Didactic GmbH & Co. KG • 541091 C-27

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Displacement-step diagram – group formation Sheet 2 of 3

1A1+ 2A1+ 2A1– 3A1+ 1A1– 3A1–

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

2A1
0
1
3A1
0

1A1+ 2A1+ 3A1+ 1A1– 3A1–

Group 1 Group 2 Group 3

1A1+ 2A1+ 2A1– 3A1+ 1A1– 3A1–

Group 1 Group 2 Group 3

3A1– 1A1+ 3A1+ 2A1+ 2A1– 1A1–

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

2A1
0
1
3A1
0

3A1– 1A1+ 2A1+ 2A1– 1A1–

Group 1 Group 2 Group 3

3A1– 1A1+ 3A1+ 2A1+ 2A1– 1A1–

Group 1 Group 2 Group 3

C-28 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Fundamentals: Displacement-step diagram – group formation Sheet 3 of 3

1A1+ 3A1+ 1A1– 2A1– 3A1– 2A1+

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

2A1
0
1

3A1
0

1A1+ 3A1+ 2A1– 3A1– 2A1+

Group 1 Group 2 Group 3

1A1+ 3A1+ 1A1– 2A1– 3A1– 2A1+

Group 1 Group 2 Group 3

© Festo Didactic GmbH & Co. KG • 541091 C-29

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Designing the function diagram Sheet 1 of 1

– Design the function diagram for the selection station.

Note
Link the signal switching functions, i.e. signal switch-off function such that one
signal switches off two interfering signals at a time; this simplifies the circuit
diagram.

START

1 2 3 4 5=1
1
1B2
Cylinder 1A1

0
1B1
1
Coil 1M1
0

1
Coil 1M2
0
2B2
1

Cylinder 2A1

0
2B1
1
Coil 2M1
0

1
Coil 2M2
0

1
Supply
voltage
0

Function diagram

C-30 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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)

© Festo Didactic GmbH & Co. KG • 541091 C-31

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Completing the pneumatic and electrical circuit diagram Sheet 2 of 2

– 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

12 14 12 14 22 24 32 34
1B2 BN 2B2 BN 13
K1 K6 K6 K6
2 4 2 4 S1
BK BK START 11 11 21 31
1B1 2B1 14
1 1 12 14
BU BU
K3
11

12 14 12 14 22 24
K5 K2 K3
11 11 21

12 14
K4
11
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 .8 11 14 .11 11 14 .8 11 14 .8 11 14 .8 11 14 .9 Group 1 Group 2
22 22 22 22 22 22
21 24 21 24 21 24 .13 21 24 21 24 21 24 .10
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .12
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 format in Part D)

C-32 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Process description Sheet 1 of 2

Sequence
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position.
In the electrical circuit diagram, the limit switches and proximity sensors 1B1 and
1B2 at cylinder 1A1 and 2B1 and 2B2 at cylinder 2A1 are linked to relays K1, K2, K3
and K4.

Group 1
If the START button S1 is actuated (normally open contact actuated, relay K5 picks
up) AND cylinder 1A1 is in the retracted end position (1B1 normally open contact
actuated, relay K1 energised) AND cylinder 2A1 is in the retracted end position (2B1
normally open contact actuated, relay K3 energised, 2B2 normally open contact
unactuated, relay K4 drops out), then relay K6 in current path 8 picks up and the
self-latching loop (changeover contact K6 in current path 9) is activated.

At the same time, changeover contact K6 in current path 10 closes and switches
group 1 to active. Similarly, changeover contact K6 in current path 12
simultaneously opens and switches group 2 to inactive; the circuits of solenoid coils
1M2 and 2M2 are open.

If the changeover contact K6 in current path 10 is closed, the circuit of the solenoid
coil 1M1 of the double solenoid valve 1V1 is closed. The double solenoid valve 1V1
reverses and cylinder 1A1 advances.

Proximity sensor 1B2 (normally open contact actuated) switches when cylinder 1A1
reaches the forward end position and the relay K2 picks up. The changeover contact
K2 in current path 11 closes. The circuit of the solenoid coil 2M1 of double solenoid
valve 2V1 is closed. The valve reverses and cylinder 2A1 advances.

© Festo Didactic GmbH & Co. KG • 541091 C-33

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Process description Sheet 2 of 2

Group 2
Proximity sensor 2B2 (normally open contact actuated) switches when cylinder 2A1
has reached the forward end position and the relay K4 picks up. The changeover
contact K4 in current path 8 opens and cancels the self-latching loop of relay K6.

Changeover contact K6 in current path 10 opens at the same time and switches
group 1 to inactive; the circuits of solenoid coils 1M1 and 2M1 are open. Similarly,
changeover contact K6 in current path 12 simultaneously closes and switches
group 2 to active. The circuit of the solenoid coil 2M2 of double solenoid valve 2V1 is
closed. Double solenoid valve 2V1 reverses and cylinder 2A1 retracts again.

Limit switch 2B1 (normally open contact actuated) switches when cylinder 2A1
reaches the retracted end position and relay K3 picks up. The changeover contact K3
in current path 13 closes. The circuit of the solenoid coil 1M2 of double solenoid
valve 1V1 is closed. The valve 1V1 reverses and cylinder 1A1 retracts again.

C-34 © Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station
Solutions

Exercise 3: Realising a selection station

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

6 Relay

1 Manifold

1 ON/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-35

Exercise 3: Realising a selection station
Solutions

C-36 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Fundamentals: Designing the displacement-step diagram Sheet 1 of 1

– Design the displacement-step diagram for the problem definition described.

START

1 2 3 4 5=1
(1M1)
1
1B2
1A1

0
(1M1) 1B1

2B2 (2M1)
1

2A1
2B1
0
(2M1)
Step 1 Step 2 Step 3 Step 4

Displacement-step diagram

© Festo Didactic GmbH & Co. KG • 541091 C-37

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Fundamentals: Designing the function diagram Sheet 1 of 1

– Design the function diagram for the problem definition described.

START

1 2 3 4 5=1
1
1B2
Lifting cylinder 1A1

0
1B1
1
Coil 1M1
0

1
2B2

Feed cylinder 2A1

0
2B1
1
Coil 2M1
0

Function diagram

C-38 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

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

© Festo Didactic GmbH & Co. KG • 541091 C-39

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Fundamentals: Draw up GRAFCET Sheet 2 of 2

1B1*2B1 “Initial position”

S1*1B1 “Start condition”

2 1M1:= 1 “Lifting cylinder to move up”

1B2 “Lifting cylinder up”

3 2M1:= 1 “Key to advance”

2B2 “Key advanced”

4 2M1:= 0 “Key to retract”

2B1 “Key retracted”

5 1M1:= 0 “Lifting cylinder to move down ”

1B1 “Lifting cylinder down”

GRAFCET

C-40 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-41

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the handling device.

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

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-

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

C-42 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Process description Sheet 1 of 2

With this sequence chain, individual steps are set in succession and held via latching
circuits. Once all the steps are set, the last step clears the first step, the first step
clears the second step, etc. until all latching circuits are cleared.

Sequence
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position. The
limit switches 1B1 and 2B1 and proximity sensors 1B2 and 2B2 are linked to relays
K1, K2 and K4 in the electrical circuit diagram.

Steps 1-2
If cylinder 1A1 is in the retracted end position (1B1 normally open contact actuated,
relay K1 energised) AND START pushbutton S1 is activated (relay K5 picks up), relay
K6 in current path 8 picks up and the latching circuit (changeover contact K6 in
current path 9) is activated.
Changeover contact K6 in current path 10 closes at the same time and prepares
step 2.
Similarly, changeover contact K6 in current path 16 simultaneously closes. The
current path of solenoid coil 1M1 is closed. Solenoid valve 1V1 reverses and cylinder
1A1 advances.

Steps 2-3
When cylinder 1A1 has reached the forward end position (1B2 normally open contact
actuated, relay K2 picks up) AND step 1 is set (relay K6 energised), the relay K7 in
current path 10 picks up and the self-latching loop (changeover contact K7 in current
path 11) is activated. Changeover contact K7 in current path 12 closes at the same
time and prepares step 3.
Similarly, changeover contact K7 in current path 17 simultaneously closes. The
circuit of the solenoid coil 2M1 is closed. Solenoid valve 2V1 reverses and cylinder
2A1 advances.

© Festo Didactic GmbH & Co. KG • 541091 C-43

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Process description Sheet 2 of 2

Steps 3-4
When cylinder 2A1 has reached the forward end position (2B2 normally open contact
actuated, relay K4 picks up) AND step 2 is set (relay K7 energised), relay K8 in
current path 12 picks up and the self-latching loop (changeover contact K8 in current
path 13) is activated.
At the same time, the changeover contact K8 in current path 14 closes and prepares
step 4.
Similarly, changeover contact K8 in current path 17 simultaneously opens. The
circuit of solenoid coil 2M1 is open. Solenoid valve 2V1 switches back via spring
return and cylinder 2A1 retracts.

Steps 4-5
When cylinder 2A1 has reached the retracted end position (2B1 normally open
contact activated, relay K3 picks up) AND step 3 is set (relay K8 energised,) relay K9
in current path 14 picks up and the self-latching loop (changeover contact K9 in
current path 15) is activated.
Similarly, changeover contact K9 in current path 16 simultaneously opens. The
circuit of the solenoid coil 1M1 is open. The solenoid valve 1V1 switches back via the
spring return. Cylinder 1A1 retracts.
Similarly, changeover contact K9 in current path 8 simultaneously opens and clears
the self-latching loop of relay K6 (step 1). This causes changeover contact K6 in
current path 10 to open and clears the self-latching loop of relay K7 (step 2).
Changeover contact K7 in current path 12 opens and clears the self-latching loop of
relay K8 (step 3), changeover contact K8 in current path 14 opens and clears the
self-latching loop of relay K9 (step 4).
Consequently all steps are cleared..

C-44 © Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks
Solutions

Exercise 4: Machining of key blanks

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way solenoid valve (plate M on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

9 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-45

Exercise 4: Machining of key blanks
Solutions

C-46 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Designing the displacement-step diagram Sheet 1 of 1

1. Cylinders 1A1 and 2A1 are retracted in the initial position and limit switches 1B1
and 2B1 are actuated.
1. Cylinder 1A1 moves into the forward end position if START button S1 is actuated
AND limit switch 1B1 is actuated and proximity sensor 1B2 is actuated.
2. Cylinder 2A1 advances and proximity sensor 2B2 is actuated in the forward end
position.
3. Cylinder 2A1 moves into the retracted end position and actuates limit switch
2B1.
4. Cylinder 1A1 moves into the retracted end position.

– Design the displacement-step diagram of the sequence described.

START

1 2 3 4 5=1
(1M2)
1
1B2
1A1

0
(1M1) 1B1

2B2 (2M2)
1

2A1
2B1
0
(2M1)
Step 1 Step 2 Step 3 Step 4

Displacement-step diagram

© Festo Didactic GmbH & Co. KG • 541091 C-47

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Designing the function diagram Sheet 1 of 1

– Design the function diagram for the bending device.

START

1 2 3 4 5=1
1
1B2
Cylinder 1A1

0
1B1
1
Coil 1M1
0

1
Coil 1M2
0
2B2
1

Cylinder 2A1

0
2B1
1
Coil 2M1
0

1
Coil 2M2
0

1
Supply
voltage
0

Function diagram

Note
The signal switch-off functions are combined such that 1 signalling element switches
off two interfering signals simultaneously. Consequently, the START button switches
the two solenoid coils 1M2 and 2M2 to a 0 signal and proximity sensor 2B2 switches
solenoid coils 1M1 and 2M1.

C-48 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Drawing up GRAFCET Sheet 1 of 1

– Draw up the GRAFCET for the sequence described.

1B1*2B1 “Initial position”

S1*1B1 “Start condition”

2 1M1:= 1 1M2:= 0 “Bending cylinder 1A1 to advance”

1B2 “Bending cylinder 1A1 advanced”

3 2M1:= 1 2M2:= 0 “Bending cylinder 2A1 to advance”

2B2 “Bending cylinder 2A1 advanced”

4 2M1:= 0 2M2:= 1 “Bending cylinder 2A1 to retract”

2B1 “Bending cylinder 2A1 retracted”

5 1M1:= 0 1M2:= 1 “Bending cylinder 1A1 to retract”

1B1 “Bending cylinder 1A1 retracted ”

GRAFCET

© Festo Didactic GmbH & Co. KG • 541091 C-49

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

C-50 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram of the bending device.

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 18 19 20 21

12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 22 24 32 34 42 44 42 44 42 44
1B2 BN 2B2 BN 13
K1 K6 K2 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9
2 4 2 4 S1
BK BK Start 11 11 11 11 11 11 11 11 21 21 31 41 41 41
1B1 2B1 14
1 1 12 14
BU BU
K5
11

12 14 22 24 22 24 22 24 22 24 32 34 32 34 32 34 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
11 21 21 21 21 31 31 31 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 .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 11 14 .8
22 22 22 22 22 22 22 22 22 22
21 24 .16 21 24 21 24 21 24 21 24 21 24 .10 21 24 .12 21 24 .14 21 24 .16 21 24 .17
32 32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .18 31 34 .18 31 34 .19 31 34 .20 31 34 .21
42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 .19 41 44 .20 41 44 .21 41 44

1A1+ 2A1+ 2A1- 1A1- Control

step

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-51

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Process description Sheet 1 of 3

With this sequence chain, the individual steps are set in succession and held via
latching circuits. Once all the steps are set, the last step clears the first step again,
the first step clears the second step, etc., until all latching circuits are cleared.

An additional control step (step 5) needs to be introduced for the circuit using
double solenoid valves so that the sequence chain is cleared.

Sequence
Cylinders 1A1 and 2A1 are in the initial position in the retracted end position. The
limit switches 1B1 and 2B1 as well as the proximity sensors 1B2 and 2B2 are linked
to relays K1, K2, K3 and K4 in the electrical circuit diagram.

Steps 1-2
If cylinder 1A1 is in the retracted end position (1B1 normally open contact actuated,
relay K1 energised) AND START button S1 is actuated (relay K5 picks up), then relay
K6 picks up and the self-latching loop (changeover contact K6 in current path 9) is
activated.
The changeover contact K6 in current path 10 closes at the same time and prepares
step 2.
Similarly, changeover contact K6 in current path 18 closes simultaneously. The
circuit of solenoid coil 1M1 is closed. Double solenoid valve 1V1 reverses and
cylinder 1A1 advances.

C-52 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Process description Sheet 2 of 3

Steps 2-3
When cylinder 1A1 has reached the forward end position (1B2 normally open contact
actuated, relay K2 energised) AND step 1 is set (relay K6 energised), then relay K7
picks up and the self-latching loop (changeover K7 in current path 11) is activated.
Changeover contact K7 in current path 12 closes at the same time and prepares
step 3.
Changeover contact K7 in current path 20 also opens at the same time. The circuit of
solenoid coil 1M1 is open.
Changeover contact K7 in current path 21 also closes simultaneously. The circuit of
solenoid coil 2M1 is closed. The double solenoid valve 1V2 reverses and cylinder
2A1 advances.

Steps 3-4
When cylinder 2A1 has reached the forward end position (2B2 normally open contact
actuated, relay K4 energised) AND step 2 is set (relay K7 energised), then relay K8
picks up and the self-latching loop (changeover contact K8 in current path 13) is
activated.
Changeover contact K8 in current path 13 closes simultaneously and prepares
step 4.
Similarly, changeover contact K8 in current path 19 opens simultaneously. The
circuit of solenoid coil 2M1 is open.
Likewise, changeover contact K8 in current path 20 closes simultaneously. The
circuit of solenoid coil 2M2 is closed. The double solenoid coil 2V1 switches back
and cylinder 2A1 retracts.

© Festo Didactic GmbH & Co. KG • 541091 C-53

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Process description Sheet 3 of 3

Steps 4-5
When cylinder 2A1 has reached the retracted end position (2B1 normally open
contact actuated, relay K3 energised) AND step 3 is set (relay K8 energised), then
relay K9 picks up and the self-latching loop (changeover contact K9 in current path
15) is activated.
Changeover contact K9 in current path 16 closes at the same time and prepares
step 5.
Similarly, changeover contact in current path 20 opens simultaneously. The circuit of
solenoid coil 2M2 is open.
Also, changeover contact K9 in current path 21 closes simultaneously. The circuit of
solenoid coil 1M2 is closed. The double solenoid valve 1V1 switches back and
cylinder 1A1 retracts.

Step 5-6 (control step)

When cylinder 1A1 has reached the retracted end position (1B1 normally open
contact actuated, relay K1 energised) AND step 4 is set (relay K9 energised), then
relay K10 picks up and the self-latching loop (changeover contact K10 in current
path 17) is activated.
Changeover contact K10 in current path 21 opens at the same time. The circuit of
solenoid coil 1M2 is open.
Similarly, changeover contact K10 in current path 8 opens simultaneously and clears
the self-latching loop of relay K6 (step 1). This causes changeover contact K6 in
current path 10 to open and clears the self-latching loop of relay K7 (step 2). The
changeover contact K7 in current path 12 opens and clears the self-latching loop of
relay K8 (step 3). The changeover contact K8 in current path 14 opens and clears the
self-latching loop of relay K9 (step 4). The changeover contact K9 in current path 16
opens and clears the self-latching loop of relay K10 (step 5).
Consequently, all steps are cleared.

C-54 © Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets
Solutions

Exercise 5: Bending of mounting brackets

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

10 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-55

Exercise 5: Bending of mounting brackets
Solutions

C-56 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

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)

i.e.
b) B1 AND B2 AND (NOT B3) = 2M1 (Cylinder 2A1 to advance)

– Draw up the appropriate boolean equations.

a) B1 ∧ B2 ∧ B3 = 1M1
_
b) B1 ∧ B2 ∧ B3 = 2M1

– Design the appropriate logic symbols.

a) b)

B1 & 1M1 B1 & 2M1

B2 B2
B3 B3

– Prepare the appropriate ladder diagrams.

a) b)
B1 B2 B3 1M1 B1 B2 B3 2M1

© Festo Didactic GmbH & Co. KG • 541091 C-57

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

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 0V).

– Describe the design and function of an inductive proximity sensor.

Description: Design and function Symbol

An inductive proximity sensor consists of an electrical resonant

circuit (1), a flip-flop (2) and an amplifier (3). BN
When voltage is applied at the connections, the resonant circuit
BK
generates a high frequency magnetic alternating field, which
emerges at the front of the sensor. If an electrical conductor is
introduced into this alternating field, the resonant circuit is BU
attenuated.
The downstream electronics, consisting of a flip-flop and
amplifier, evaluates the behaviour of the resonant circuit and
actuates the output. Inductive proximity sensors detect all
electrically conducting materials and apart from metal also
graphite.

C-58 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Fundamentals: Proximity sensors Sheet 3 of 4

– Describe the design and function of an optical diffuse sensor.

Description: Design and function Symbol

Both the emitter and receiver of a diffuse sensor are arranged in

parallel in one component. If the light impinges on a reflecting object, BN
then it is deflected to the receiver and the output of the sensor
BK
switches. Owing to its operational principle, a diffuse sensor can only
be used if the workpiece or machine component to be sensed is highly
reflective (e.g. metallic surface, light colours). BU

© Festo Didactic GmbH & Co. KG • 541091 C-59

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Fundamentals: Proximity sensors Sheet 4 of 4

– Describe the design and function of a capacitive proximity sensor.

Description: Design and function Symbol

A capacitive proximity sensor consists of a capacitor and an

electrical resistor, which in combination form an RC resonant BN
circuit as well as an electronic circuit for the evaluation of the
BK
oscillation. An electrostatic field builds up between the active and
the earth electrode of the capacitor and a stray field is created at
the front of the sensor (active sensor surface). The capacitor BU
capacity changes if an object is introduced into this stray field,
The resonant circuit is attenuated and the downstream electronics
actuate the output. Capacitive proximity sensors react not only to
materials of high electrical conductivity (e.g. metals), but also to
all insulators with high dielectric constants, e.g. plastics, glass,
ceramics, fluids and wood. Conducting materials located in the
stray field of the active sensor surface form a counter electrode.
Non-conducting materials increase the capacitor capacity in
relation to material type (relative permittivity). Greater sensing
distances can be achieved with conducting objects than with non-
conducting materials.

C-60 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Pneumatic circuit diagram of 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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 C-61

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the filling system.

Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

13 12 14 12 14 12 14 12 14 22 24 12 14
1B2 BN 2B2 BN B1 BN B2 BN B3 BN S1 K8 K1 K9 K2 K9 K4
2 4 2 4 START
BK BK BK BK BK 14 11 11 11 11 21 11
1B1 2B1
1 1 12 14 12 14 22 24
BU BU BU BU BU
K3 K5 K5
11 11 21

31 22 24 12 14 22 24
S2 K8 K6 K6
STOP
32 21 11 21

12 14 22 24
K7 K7
11 21
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 .15 11 14 .17 11 14 .15 11 14 .19 11 14 .16 11 14 .16 11 14 .16 11 14 .14 11 14 .16
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 .18 21 24 .18 21 24 .18 21 24 .15 21 24 .18
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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

C-62 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Process description Sheet 1 of 2

Logic
1B1 AND 2B1 AND B1 AND B2 AND B3 = 1A1 advance
1B2 = 1A1 return

1B1 AND 2B1 AND B1 AND B2 AND (NOT B3) = 2A1 advance
2B2 = 2A1 return

Sequence
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position. Limit
switches 1B1 and 1B2 are actuated (1B1 normally open contact actuated, relay K1
energised and 2B1 normally open contact actuated, relay K3 energised). The
changeover contacts K1 and K3 in current path 15 close.

Correctly filled jar

Changeover contacts K5, K6 and K7 in current path 16 close if a lid is available (B1
normally open contact, relay K5 energised), and a jar is available (B2 normally open
contact actuated, relay K6 energised) and filled (B3 normally open contact actuated,
relay K7 energised).
Relay K8 picks up and the self-latching loop (changeover contact K8 in current path
14) is activated if the START button S1 is pressed.
At the same time the changeover contact K8 in current path 15 closes. Relay K9
picks up. The changeover contact K9 in current path 16 closes. The circuit of
solenoid coil 1M1 is closed. Double solenoid valve 1V1 switches and cylinder 1A1
advances.

Limit switch 1B1 (normally open contact) is no longer actuated if cylinder 1A1 moves
out of the retracted end position. Changeover contact K1 in current path 15 opens
and relay K9 is de-energised. The circuit of solenoid coil 1M1 is open. As soon as
cylinder 1A1 reaches the forward end position (1B2 normally open contact, K2 picks
up), changeover contact K2 in current path 17 closes. The circuit of solenoid coil
1M2 is closed. Double solenoid coil 1V1 switches back and cylinder 1A1 retracts
again.

This sequence is repeated until pushbutton S2 is pressed or a change occurs in the

output signals of proximity sensors B1, B2 or B3.

© Festo Didactic GmbH & Co. KG • 541091 C-63

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Process description Sheet 2 of 2

Jars not filled

The changeover contacts of K5 and K6 in current path 18 close if a lid is available (B1
normally open contact actuated, relay K5 energised), a glass is available (B2
normally open contact actuated, relay K6 energised), but not filled (B3 normally
open contact not actuated, relay K7 de-energised). The changeover contact of K7 in
current path 18 remains open.
If the START button S1 is pressed, relay K8 picks up and the self-latching loop
(changeover contact K8 in current path 14) is activated.
At the same time, changeover contact K8 in current path 15 closes. Relay K9 picks
up and the changeover contact K9 in current path 18 closes. The circuit of the
solenoid coil 2M1 is closed. The double solenoid valve 2V1 reverses and cylinder
2A1 advances.

Limit switch 2B1(normally open contact) is no longer actuated if cylinder 2A1 moves
out of the retracted end position. The changeover contact K3 in current path 15
opens and relay K9 is de-energised. The circuit of solenoid coil 2M1 is open. As soon
as cylinder 2A1 reaches the forward end position (2B2 normally open contact
actuated, relay K4 picks up), changeover contact K4 in current path 19 closes. The
circuit of solenoid coil 2M2 is closed. Double solenoid valve 2V1 switches back and
cylinder 2A1 retracts again.

This sequence is repeated until pushbutton S2 is pressed or a change occurs in the

output signals of proximity sensors B1, B2 or B3.

C-64 © Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system
Solutions

Exercise 6: Realising a filling system

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Proximity sensor, inductive

1 Proximity sensor, capacitive

1 Proximity sensor, optical

1 Pushbutton (normally open contact)

1 Pushbutton (normally closed contact)

9 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-65

Exercise 6: Realising a filling system
Solutions

C-66 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Fundamentals: Time relays Sheet 1 of 3

Time relays can basically be divided into two groups:

• Time relay with dropout delay
• Time relay with pickup delay

– Allocate the appropriate symbol to the description in the table.

A1 A1

1) A2 2) A2

Description Symbol

Time relay with pickup delay

A1

(Symbol 1) A2

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

Time relays with pick-up delay with one

changeover contact, A1
6 8
contact allocation either in the form of normally
closed contact (delayed opening) or normally open
5
contact (delayed closing). A2

Time relay with drop out delay with normally open

contact, contacts open with time delay A1 7

8
A2

© Festo Didactic GmbH & Co. KG • 541091 C-67

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Fundamentals: Time relay Sheet 2 of 3

– Represent the signal behaviour of a pickup delay in the diagram below (pickup
delay).
– Designate the set time delay tv.

Voltage at relay coil

Time t
Contact

Closed

Open
tV Time t

– Represent the signal behaviour of a dropout delay in the diagram below.

– Designate the set time delay tv.

Voltage at relay coil

Time t
Contact

Closed

Open
tV Time t

C-68 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Fundamentals: Pressure sensor Sheet 3 of 3

The bonding device is operated within a pressure range of 4 bar to 6 bar (400 kPa to
600 kPa). Once a switching pressure SPMAX of 5 bar (500 kPa) is reached, the set
time delay is to start.

Changing the switching pressure

1. Press the EDIT button 2x (selection of switch output is omitted.)

2. Press the UP/DDOWN button until the desired switching function is obtained, i.e. in this case the
threshold value comparator.

3.Press the EDIT button

4. Press the UP/DOWN button until the desired minimuml 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.

© Festo Didactic GmbH & Co. KG • 541091 C-69

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

C-70 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Completing the electrical circuit diagram for the bonding device.

Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10

1B1 BN 1B2 BN 1B3 BN

13 12 14 12 14 17
BK BK BK
p S1 K2 K1 K5
START
14 11 11 18
BU BU BU
12 14 12 14
K3 K4
11 11

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 .9 11 14 .8 11 14 .8 11 14 .9 11 14 .10
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

Electrical circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 C-71

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Process description Sheet 1 of 1

Sequence
Cylinder 1A1 is in the retracted end position in the initial position. Proximity sensor
1B1 is actuated.

Steps 1-2
The circuit of solenoid coil 1M1 is closed if cylinder 1A1 is in the retracted end
position (1B1 actuated, relay K1 energised) AND the START button S1 is actuated
(Relay K4 picks up, changeover contact K4 in current path 9 closes). Double solenoid
valve 1V1 reverses and cylinder 1A1 advances.

If cylinder 1A1 moves out of the retracted end position, proximity sensor 1B1 is no
longer actuated. Changeover contact K1 in current path 9 opens and the circuit of
solenoid coil 1M1 is open.

Steps 2-3
When the cylinder has reached the forward end position, proximity sensor 1B2 is
actuated and relay K2 picks up. Changeover contact K2 in current path 8 closes.
Relay 3 switches if the set pressure is obtained at pressure sensor 1B3. The
changeover contact K3 in current path 8 closes. The circuit of the time-delay relay K5
is closed. When the set time has expired, the changeover contact K5 in current path
10 closes. The circuit of solenoid coil 1M2 is closed. Double solenoid valve 1V1
switches back. Cylinder 1A1 returns into the retracted end position again.

Proximity sensor 1B2 is no longer actuated if cylinder 1A1 moves out of the forward
end position. Changeover contact K2 in current path 8 opens and the circuit of
solenoid coil 1M2 is open.

C-72 © Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components
Solutions

Exercise 7: Bonding of components

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the required number of components in

the table below.

Quantity Description

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (plate J on valve terminal)

2 Proximity sensor, electronic

1 Pressure sensor

1 Pushbutton (normally open contact)

4 Relay

1 Relay (with pickup delay)

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-73

Exercise 7: Bonding of components
Solutions

C-74 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Predetermining counter Sheet 1 of 4

– Describe the component illustrated.

Symbol

A1 1 R1

A2 R2
4 2

Description: Component

Electrical predeterming counter with a set of changeover contacts

– Answer the questions regarding the function of the predeterming counter used.

How is the preselected value set?

The electrical preselect counter is set by pressing the white enabling button and
simultaneously entering the preselect value. The preselected figure is displayed in
the display window. Correction of the preselected value is also possible during
operation.

Question: How can the predetermining counter be reset?

The predetermining counter is reset manually using the black reset button or
electrically using a reset pulse via connections R1 and R2. The set preselected value
is retained when the counter is reset. Incoming counting pulses during the reset
time are not processed.

© Festo Didactic GmbH & Co. KG • 541091 C-75

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 2 of 4

– Designate and describe the switching function of the pressure sensor used.

Description: Switching functions

Switching function of threshold value comparator: Monitoring of a set switching pressure (threshold
value). Depending on the selected switching characteristic, a contact is closed or opened when the
selected value is reached.

Switching function of window comparator: Monitoring of a defined pressure range. Depending on the
selected switching characteric, a contact is closed or opened when the minimum switching pressure is
reached and opened and closed again when the maximum switching pressure is reached.

The operating pressure of the ejecting device is to be reduced from 6 bar (600 kpa)
to 4 bar (400 kPa). If pressure falls below this value, the pressure sensor is to send a
signal and the system is to stop. The switching pressure setting in the pressure
sensor is to be changed accordingly.

– Describe how you proceed.

Description: Changing the switching function

1. Press the EDIT button 2x (selection of switch output omitted.)

2. Press the UP/DOWN button until the desired switching function is obtained, in this case threshold
value comparator.

3.Press the EDIT button

4. Press the UP/DOWN button until the desired switching pressure [SP] is set, in this case 4 bar.

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

C-76 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 3 of 4

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

1. Press the EDIT button 2x (selection of switch output omitted.)

2. Press the UP/DOWN button until the desired switching function is obtained, in this case window
comparator.

3.Press the EDIT button

4. Press the UP/DOWN button until the desired minimum switching pressure [SPMIN/SP.L] is set, in
this case 4 bar.

5. Press the EDIT button

6. Press the UP/DOWN button until the desired maximum switching pressure [SPMAX/SP.H] is set, in
this case 5 bar.

7. Press the EDIT button

8. Press the UP/DOWN button until the desired hysteresis [HY] is set.

9. Press the EDIT button

10. Press the UP/DOWN button until the desired switching characteristic is set, in this case [NO].

11. Press the EDIT button in order to change to RUN mode

© Festo Didactic GmbH & Co. KG • 541091 C-77

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Fundamentals: Pressure sensor Sheet 4 of 4

The range of hysteresis can be changed on the pressure sensor used.

– Describe what is understood by the term“hysteresis“.

Description: Hysteresis

The greatest difference between two output values, e.g. switch-on and switch-off points when the
measuring range, as in this case, is first passed through in incrementing and then in decrementing
direction. Consequently, mechanical pressure sensors can for instance exhibit a hysteresis in the
switching point as a result of internal frictional resistance. With increasing pressure, the electrical
output signal follows once the switch-on point is obtained. If pressure drops, the pressure sensor
does not switch at the same point, since the switch-on point is not the same as the switch-off point.
This behaviour is to be observed when setting the pressure sensor.

C-78 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-79

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– 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 K1 S1 K1 K4 K2 K4
CONTINUOUS START
14 11 14 21 BK BK BK 11 21 21
ON
p
12 14 12 14
BU BU BU
K2 K3
11 11

31 31
S4 S2
CONTINUOUS STOP AT
32 32
OFF CYCLE END

12 14
K5
11

2 4
P6
1
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 .2 11 14 .4 11 14 .13 11 14 .11 11 14 .3 11 14 .3
22 22 22 22 22 22
21 24 .4 21 24 .13 21 24 21 24 .14 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 format in Part D)

C-80 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Process description Sheet 1 of 2

Pressure sensing
Irrespective of the mode of operation, a cycle is started only once the operating
pressure preset in the pressure sensor 1B3 is available (relay K5 energised,
changeover contact K5 in current path 3 closed). If pressure drops below the set
value, the current cycle is still completed and the system stops subsequently.

Predetermining counter
Irrespective of the mode of operation, only as many cycles are executed as have
been set in the predetermining counter P6. As soon as cylinder 1A1 reaches the
forward end position (1B2 actuated, relay K4 energised, changeover contact K4 in
current path 11 closed), the predetermining counter is actuated.
The predetermining counter is manually reset.

Automatic mode of operation

Individual cycle
Relay K1 de-energised. Consequently, the self-latching loop of the START button in
current path 4 cannot be activated.
Only one cycle is executed if the START button is pressed.

Continuous cycle
Relay K1 is energised. The self-latching loop is activated via the changeover contact
K1 in current path 2. At the same time, the activation of the self-latching loop of the
START button is prepared via the changeover contact K1 in current path 4.
If the START button is pressed, several cycles are executed consecutively until the
continuous cycle is terminated via the actuation of STOP AT CYCLE END or until all
set cycles in the predetermining counter P6 are executed.

© Festo Didactic GmbH & Co. KG • 541091 C-81

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Process description Sheet 1 of 2

Sequence (individual cycle)

Cylinder 1A1 is in the retracted end position (1B1 normally open contact actuated,
relay K3 energised, changeover contact K3 in current path 13 closed) AND the START
button is actuated (relay K2 picks up, changeover contact K2 in current path 13
closed). The current path of the solenoid coil 1M1 is closed. The double solenoid
valve 1V1 reverses and cylinder 1A1 advances.

If cylinder 1A1 moves out of the retracted end position, proximity sensor 1B1 is no
longer actuated. The changeover contact K3 in current path 13 opens. The circuit of
solenoid coil 1M1 is open.

When cylinder 1A1 reaches the forward end position (1B2 actuated, relay K4
energised, changeover contact K4 in current path 14 is closed), the current path of
solenoid coil 1M2 is closed. The double solenoid valve 1V1 switches back and
cylinder 1A1 retracts again.
At the same time, changeover contact K4 closes in current path 11. The preset value
at the predetermining counter P6 is reduced by 1.

If cylinder 1A1 moves out of the forward end position, the proximity sensor 1B2 is no
longer actuated. The changeover contact K4 in current path 14 opens and the circuit
of solenoid coil 1M1 is open.

C-82 © Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation
Solutions

Exercise 8: Selecting modes of operation

Name: Date:

Completing the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Complete the equipment list by entering the number of required components in

the table below.

Quantity Description

1 Cylinder, double-acting

2 One-way flow control valve

1 5/2-way double solenoid valve (plate J on valve terminal)

2 Proximity sensor, electronic

1 Pressure sensor

1 Predetermining counter, electrical

2 Pushbutton (normally open contact)

2 Pushbutton (normally closed contact)

5 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-83

Exercise 8: Selecting modes of operation
Solutions

C-84 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9:
Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 1 of 3

– Identify the parts of a machine to which an EMERGENCY-STOP (ES) device could

apply.

System Machine section Componenta

section ES device

Control system Signals, displays, warnings

Actuating components X

Control devices, i.e. command devices X

Data storage and data processing X

Sensors

Non-separating protective devices

X
Power/control elements
Plant section

Drive components

Separating devices, brakes X

Power transmission components, working components

Separating protective devices

© Festo Didactic GmbH & Co. KG • 541091 C-85

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 2 of 3

– List the general requirements to be met by EMERGENCY-STOP.

General requirements to be met by EMERGENCY-STOP

• The EMERGENCY-STOP function must be available and fully functional at any time irrespective of mode of operation.

• The control unit and its actuating components must operate according to the principle of forced actuation.

• The EMERGENCY-STOP device must not be used to replace adequate protective measures or for automatic safety devices, but can be
used as a support measure.

• Once the actuating component is actuated, the EMERGENCY-STOP device is to operate such as to automatically avert or minimise any
danger in the best possible way.

• The EMERGENCY-STOP function must act as STOP category 0 or 1.

• The EMERGENCY-STOP device must be devised such that the decision to actuate the EMERGENCY-STOP actuating component does not
require any thought on the part of the person with regard to the resulting effects (section switch off, degree of delay , etc.).

• The EMERGENCY-STOP must have priority over all other commands.

• The machine reaction must not create any additional hazards.

• The EMERGENCY-STOP function must not impair the effectiveness of safety equipment in respect of safety-related functions.

• The EMERGENCY-STOP function must not impair equipment intended for the freeing of persons from hazardous situations, but can assist
in the taking effect of devices intended for this purpose.

• Any action of the actuating component resulting in the generation of the EMERGENCY-STOP command must also lead to a latching of the
control unit in order for the EMERGENCY-STOP command to be continued until the control unit is reset (unlatched). The control unit must
not latch without generating an EMERGENCY-STOP command. In the case of a fault within the control unit (latching unit included), the
function for the generation of the EMERGENCY-STOP command must have priority over the latching function.

• Reset of the control unit must only be possible as a result of a manually induced action at the control unit. Reset of the control unit alone
must not trigger a re-start command. Restarting of the machine or system must not be possible until all actioned actuating components
have been individually, manually and deliberately reset.

• The EMERGENCY-STOP actuating components must be designed so that they can be easily actuated and used by operators, i.e.
mushroom actuators, wires/steel cables, leads, rods, knobs and in special cases pedal switches without protective cover, safety shut-off
mats or serrated foot plates, etc.

• EMERGENCY-STOP actuating components must be red. Insofar as there is a background to the actuating component and it is practicable,
this should be yellow.

• In the event of an EMERGENCY-STOP cable break or trailing wire/steel cables or leads, the EMERGENCY-STOP command must be
automatically generated.

C-86 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals Sheet 3 of 3

– Name the main EMERGENCY-STOP conditions, i.e. functions required in relation

to a cylinder.

EMERGENCY-STOP conditions

• Piston rod always moves into the initial position

• Piston rod always moves into the initial position, however whilst adhering to a specific sequence

• Cylinder is to be exhausted

• Piston rod is to be stopped

• Piston rod always moves in the opposite direction

– Decribe the difference between these categories.

Stop category 0 Stop category 1

The system is stopped by means of immediately This entails controlled shutdown with energy
cutting off the energy supply to the drive element supply to the drive element(s) in order to achieve
or mechanical interruption (uncoupling) between the stop and subsequently, after the stop is
hazardous components and their drive elements, achieved, interruption of the energy supply .
and, if necessary, by braking (uncontrolled
shutdown).

– Describe this principle.

Description: Principle of forced actuation

If a moving, mechanical component unavoidably also causes another component to move (as a result
of direct contact or via rigid components, this is referred to as the positive locking of components.
This equally applies if components prevent any movement of another component merely by being
present.
Note: Where a mechanical component is moving, consequently enabling another component to move
freely (e.g. by means of gravitational force, spring force), no mechanically positive locking effect
occurs from one component to another (EN 292-2, section 3.5).
A switch with forced opening is an example for a suitable control. According to DIN EN 60947-5-1
(Section 3, Paragraph. 2.2), forced opening is “the execution of the contact separation as a direct
result of a defined movement of the operating element of the switch via unsprung components“

© Festo Didactic GmbH & Co. KG • 541091 C-87

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

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

Pneumatic circuit diagram

C-88 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the handling device.

Signal input
+24 V 1 2 3 4 5 6 7 8 9

21 12 14
ES K10
EMERGENCY- 22 Signal processing Signal output
11
STOP 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 .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
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-

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-89

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 1 of 3

Sequence
Cylinders 1A1 and 2A1 are initially in the retracted end position. Limit switches 1B1
and 2B1 and proximity sensors 1B2 and 2B2 are linked to relays K1, K2, K3 and K4 in
the electrical circuit diagram.

Steps 1-2
If cylinder 1A1 is in the retracted end position (1B1 normally open contact actuated,
relay K1 energised) AND the START button S1 is actuated (relay K5 picks up), the
relay K6 in current path 10 picks up and the self-latching loop (changeover contact
K6 in current path 11) is activated.
At the same time, the changeover contact K6 in current path 12 closes and prepares
step 2.
Similarly, changeover contact K6 in current path 18 is simultaneously closed. The
circuit of solenoid coil 1M1 is closed. The solenoid valve 1V1 reverses and cylinder
1A1 advances.

Steps 2-3
When cylinder 1A1 reaches the forward end position (1B2 normally open contact,
relay K2 picks up) AND step 1 is set (relay K6 energised), relay K7 in current path 12
picks up and the self-latching loop (changeover contact K7 in current path 13) is
activated.
The changeover contact K7 in current path 14 closes at the same time and prepares
step 3.
Similarly, changeover contact K7 in current path 19 closes simultaneously. The
circuit of solenoid coil 2M1 is closed. The solenoid coil 2V1 reverses and cylinder
2A1 advances.

C-90 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 2 of 3

Steps 3-4
When cylinder 2A1 reaches the forward end position (2B2 normally open contact
actuated, relay K4 picks up) AND step 2 is set (relay K7 energised), relay K8 in
current path 14 picks up and the self-latching loop (changeover contact K8 in current
path15) is activated.
At the same time changeover contact K8 in current path 16 closes and prepares
step 4.
Similarly, changeover contact K8 in current path 19 opens simultaneously. The
circuit of solenoid coil 2M1 is open. Solenoid valve 2V1 switches back via spring
return and cylinder 2A1 retracts.

Steps 4-5
When cylinder 2A1 reaches the retracted end position (2B1 normally open contact
actuated, relay K3 picks up) AND step 3 is set (relay K8 energised), relay K9 in
current path 16 picks up and the self-latching loop (changeover contact K9 in current
path 17) is activated.
At the same time changeover contact K9 in current path 18 opens. The circuit of
solenoid coil 1M1 is open. Solenoid valve 1V1 switches back via spring return and
cylinder 1A1 retracts.
Similarly, changeover contact K9 in current path 10 opens simultaneously and clears
the self-latching loop of relay K6 (step 1)). This causes the changeover contact K6 in
current path 12 to open and to clear the self-latching loop of relay K7 (step 2).
Changeover contact K7 in current path 14 opens and clears the self-latching loop of
relay K8 (step 3); changeover contact K8 in current path 16 opens and clears the
self-latching loop of relay K9 (step 4).
Consequently, all steps are cleared.

© Festo Didactic GmbH & Co. KG • 541091 C-91

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 1 of 3

EMERGENCY-STOP function
The control elements (START buttons) and sensor signals (1B1, 1B2, 2B1, 2B2) are
switched to Continuous-Plus and are not switched off if the EMERGENCY-STOP
mushroom actuator is pressed. The machine status can therefore be detected even if
the EMERGENCY-STOP is actuated.

The EMERGENCY-STOP mushroom actuator is in the form of a normally closed

contact. Consequently, the circuit functions even in the event of a cable break.

The changeover contact K10 in current path 9 switches the entire signal processing
and signal output section to zero current.

If the EMERGENCY-STOP is actuated (or in the event of a power failure), the solenoid
valves 1V1 and 2V1 immediately switch back into the initial position via the return
spring. Cylinders 1A1 and 2A1 simultaneously move into their retracted end
positions.

C-92 © Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function

Name: Date:

Checking the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Check the equipment list. Are the required components entered in the table
below?

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

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)

10 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-93

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function
Solutions

C-94 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10:
Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Additional exercise Sheet 1 of 2

– Complete the electrical circuit diagram for the EMERGENGY-STOP condition

described.

Signal input
+24 V 1 2 3 4 5 6 7 8 13

21 12 14
ES K1
EMERGENCY- 22 Signal processing Signal output
11
STOP 9 10 11 12

12 14 12 14 12 22 24 12 14 22 24
1B2 BN 13 13
1B1 BN K4 K6 K6 K5 K1
S1 ACKNOW-
BK BK START LEDGE 11 11 21 11 21
14 14
EMERGENCY-
STOP 12 14
BU BU
K2
11

12 14
K3
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 .8 11 14 .9 11 14 .9 11 14 .9 11 14 .12 11 14 .10 1A1–
22 22 22 22 22 22
21 24 .13 21 24 21 24 21 24 21 24 21 24 .11
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

1A1+
1A1–

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-95

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 1 of 1

Cylinder 1A1 is in the retracted end position in the initial position. The magnetic
proximity sensors 1B1 and 1B2 at cylinder 1A1 are linked to relays K2 and K3 in the
electrical circuit diagram.

EMERGENCY-STOP function
The control elements (START buttons) and sensor signals (1B1, 1B2) are switched to
Continuous Plus and are not switched off via the EMERGENCY-STOP mushroom
actuator. The machine status can therefore be detected even if the EMERGENCY-
STOP is actuated. The EMERGENCY-STOP mushroom actuator is in the form of a
normally closed contact. Consequently, the circuit functions even in the event of a
cable break.

If the EMERGENCY-STOP is actuated, relay K1 drops out and the changeover contact
K1 in current path 13 opens. The circuit of solenoid coil 1M1 is closed. The upstream
double solenoid valve 1V1 switches and shuts off the compressed air supply.
At the same time, relay K6 drops out and the changeover contact K6 in current
path 11 opens, the solenoid valve 1V2 moves into the normal position and the
connections of cylinder 1A1 are exhausted.

Note
The position of the piston rod changes if an external force acts on the piston rod.

No movement occurs if the EMERGENCY-STOP mushroom actuator is released. A re-

start is not possible until the relay K5 in current path 7 picks up by actuating the
“acknowledge EMERGENCY-STOP” mushroom actuator. The changeover contact K5
in current path 12 closes and the circuit of the solenoid coil 1M2 is closed. The
upstream double solenoid valve 1V1 switches back and the compressed air supply is
switched on.

C-96 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Pneumatic circuit diagram for 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

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541091 C-97

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

– Complete the electrical circuit diagram for the bending device.

Signal input Signal processing Signal output

+24 V 1 2 3 4 5 6 7 8 9 23 25

21 12 14 22 24 32 34
ES K11 K11 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 22 24
2B2 BN 13
1B2 BN K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
2 4 2 4 S1
BK BK 11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
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 .23 21 24 .18 21 24 21 24 .25 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 .25 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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

C-98 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 1 of 4

Sequence
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position. In the
electrical circuit diagram, the limit switches 1B1 and 2B1 and proximity sensors 1B2
and 2B2 are linked to relays K1, K2, K3 and K4 respectively.

Steps 1-2
If the cylinder 1A1 is in the retracted end position (1B1 normally open contact
actuated, relay K1 energised) AND the START button S1 is actuated (relay K5 picks
up), then relay K6 picks up and the self-latching loop (changeover contact K6 in
current path 11) is activated.
At the same time the changeover contact K6 in current path 12 closes and prepares
step 2.
Similarly, the changeover contact K6 in current path 20 closes simultaneously. The
circuit of solenoid coil 1M1 is closed. The double solenoid valve 1V1 reverses and
the cylinder 1A1 advances.

Steps 2-3
When cylinder 1A1 has reached the forward end position (1B2 normally open contact
actuated, relay K2 energised) AND step 1 is set (relay K6 energised), then relay K7
picks up and the self-latching loop (changeover contact K7 in current path 13) is
activated.
At the same time the changeover contact K7 in current path 14 closes and prepares
step 3.
Similarly, changeover contact K7 in current path 20 opens simultaneously and the
circuit of solenoid coil 1M1 is open.
Also, the changeover contact K7 in current path 21 closes simultaneously. The circuit
of solenoid coil 2M1 is closed. The double solenoid valve 1V2 reverses and cylinder
2A1 advances.

© Festo Didactic GmbH & Co. KG • 541091 C-99

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting bracket and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 2 of 4

Steps 3-4
When cylinder 2A1 has reached the forward end position (2B2 normally open contact
actuated, relay K4 energised) AND step 2 is set (relay K7 energised), then relay K8
picks up and the self—latching loop (changeover contact K8 in current path 15) is
activated.
At the same time the changeover contact K8 in current path 16 closes and prepares
step 4.
Similarly, the changeover contact K8 in current path 21 opens simultaneously and
the circuit of the solenoid coil 2M1 is open.
Also, the changeover contact K8 in current path 22 closes simultaneously and the
circuit of the solenoid coil 2M2 is closed. The double solenoid valve 2V1 reverses
and cylinder 2A1 retracts.

Steps 4-5
When cylinder 2A1 has reached the retracted end position (2B1 normally open
contact actuated, relay K3 energised) AND step 3 is set (relay K8 energised), then
relay K9 picks up and the self-latching loop (changeover contact K9 in current path
17) is activated.
At the same time the changeover contact K9 in current path 18 closes and prepares
step 5.
Similarly, the changeover contact K9 in current path 22 opens simultaneously and
the circuit of solenoid coil 2M2 is open.
Also, the changeover contact K9 in current path 24 closes. The circuit of solenoid coil
1M2 is closed. The double solenoid coil 1V1 reverses and cylinder 1A1 retracts.

C-100 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 3 of 4

Steps 5-6 (control step)

When cylinder 1A1 has reached the retracted end position (1B1 normally open
contact, relay K1 energised) AND step 4 is set (relay K9 energised), then relay K10
picks up and the self-latching loop (changeover contact K10 in current path 19) is
activated.
At the same time the changeover contact K10 in current path 24 opens and the
circuit of solenoid valve 1M2 is open.
Similarly, the changeover contact K10 in current path 10 opens simultaneously and
clears the self-latching loop of relay K6 (step 1). This causes the changeover contact
K6 in current path 12 to open and clear the self-latching loop of relay K7 (step 2).
The changeover contact K7 in current path 14 opens and clears the self-latching loop
of relay K8 (step 3). The changeover contact K8 in current path 16 opens and clears
the self-latching loop of relay K9 (step 4). The changeover contact K9 in current path
18 opens and clears the self-latching loop of relay K10 (step 5).
Consequently all steps are cleared again.

© Festo Didactic GmbH & Co. KG • 541091 C-101

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 4 of 4

EMERGENCY-STOP function
The control elements (START buttons) and sensor signals (1B1, 1B2, 2B1, 2B2) are
switched to Continuous-Plus and are not switched off via the EMERGENCY-STOP
mushroom actuator. Consequently, the machine status can be detected even if the
EMERGENCY-STOP is actuated.

The EMERGENCY-STOP mushroom actuator is in the form of a normally closed

contact and the circuit therefore functions even in the event of a cable break.

Sequence during EMERGENCY-STOP

Relay K11 drops out if the EMERGENCY-STOP is actuated. The changeover contact
K11 in current path 9 opens and the entire signal processing and signal output
section is without current.

At the same time, the changeover contact K11 in current path 23 closes and the
circuit of the solenoid coil 2M2 is closed. The double solenoid valve 2V1 reverses
and cylinder 2A1 retracts.

Similarly, the changeover contact K11 in current path 25 closes. Changeover contact
K3 in current path 25 closes when cylinder 2A1 has reached the retracted end
position. The circuit of solenoid coil 1M2 is closed. The double solenoid valve 1V1
switches back and cylinder 1A1 retracts.

C-102 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function

Name: Date:

Checking the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Check the equipment list. Are the required components in the table below?

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way double solenoid valve (plate J on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

1 Mushroom actuator (normally closed contact)

11 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-103

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

List of connectors – construction of bending device with EMERGENCY-STOP

function

Universal cable, blue 50 mm, 10 off Qty

Line 0V Signal input unit to 0V relay units 1/2/3/4 4

Line 0V Relay K1 (A2) to Relay K2 (A2) 1

Line 0V Relay K2 (A2) to relay K3 (A2) 1

Line 0V Relay K4 (A2) to relay K5 (A2) 1

Line 0V Relay K7 (A2) to relay K8 (A2) 1

Line 0V Relay K8 (A2) to relay K9 (A2) 1

Line 0V Relay K10 (A2) to relay K11 (A2) 1

Universal cable, blue 300 mm, 5 off Qty

Line 0V Relay K5 (A2) to relay K6 (A2) 1

Line 0V Relay K3 (A2) to 0V relay unit 1 1

Line 0V Relay K6 (A2) to 0V relay unit 2 1

Line 0V Relay K9 (A2) to 0V relay unit 3 1

Line 0V Relay K11 (A2) to 0V relay unit 4 1

Universal cable, blue 1500 mm, 1 off Qty

Line 0V power supply unit to 0V signal input unit 1

Universal cable, red 50 mm, 10 off Qty

Line 24V Signal input unit to 24V relay units 1/2/3/4 4

Line Relay K1 (24) to relay K2 (14) 1

Line Relay K2 (14) to relay K3 (14) 1

Line Relay K7 (14) to relay K7 (34) 1

Line Relay K11 (22) to relay K11 (32) 1

Line Relay K11 (32) to 24V relay unit 4 1

Line 24V Signal input unit to pushbutton S1 (13) 1

C-104 © Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Universal cable, red 300 mm, 26 off Qty

Line of pushbutton S1 (14) to relay K5 (A1) 1

Line 24V Relay K11 (14) to 24V relay unit 4 1

Line Relay K1 (14) to relay K5 (11) 1

Line Relay K1 (11) to relay K6 (11) 1

Line Relay K1 (24) to relay K4 (14) 1

Line Relay K1 (24) to relay K5 (14) 1

Line Relay K2 (11) to relay K6 (24) 1

Line Relay K3 (11) to relay K9 (11) 1

Line Relay K3 (14) to relay K6 (14) 1

Line Relay K4 (14) to relay K7 (14) 1

Line Relay K4 (11) to relay K7 (24) 1

Line Relay K5 (14) to relay K8 (14) 1

Line Relay K6 (14) to relay K6 (34) 1

Line Relay K6 (24) to relay K7 (11) 1

Line Relay K6 (21) to relay K7 (A1) 1

Line Relay K6 (31) to relay K7 (42) 1

Line Relay K7 (14) to relay K10 (14) 1

Line Relay K7 (21) to relay K8 (A1) 1

Line Relay K7 (24) to relay K8 (11) 1

Line Relay K7 (34) to relay K8 (34) 1

Line Relay K8 (21) to relay K9 (A1) 1

Line Relay K8 (24) to relay K9 (11) 1

Line Relay K8 (34) to relay K9 (34) 1

Line Relay K9 (21) to relay K10 (A1) 1

Line Relay K9 (24) to relay K10 (11) 1

Line Relay K10 (14)) to relay K11 (11) 1

© Festo Didactic GmbH & Co. KG • 541091 C-105

Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function
Solutions

Universal cable, red 500 mm, 11 off Qty

Line ES-pushbutton ES (14) to 24V signal input unit 1

Line Relay K1 (21) to relay K9 (24) 1

Line Relay K3 (21) to relay K10 (31) 1

Line Relay K3 (24) to relay K11 (31) 1

Line Relay K6 (11) to relay K10 (21) 1

Line Relay K6 (A1) to relay K10 (22) 1

Line Relay K7 (31) to relay K8 (42) 1

Line Relay K8 (14) to relay K9 (14) 1

Line Relay K8 (31) to relay K9 (42) 1

Line Relay K9 (31) to relay K10 (32) 1

Line Relay K9 (41) to relay K11 (21) 1

Universal cable, red 1000 mm, 1 off Qty

Line ES-pushbutton ES (11) to relay K11 (A1) 1

Universal cable, red 1500 mm, 1 off Qty

Line 24V Power supply unit to 24V signal input unit 1

C-106 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11:
Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Fundamentals: Flow control valves and non-return valves Sheet 1 of 3

– Describe the design and function of the pneumatic valves shown.

Symbol 1 Symbol 2 Symbol 3

1 2 2

1 1/3
1 21

Description: Design/Function

Design: Adjustable one-way flow control valve (combination of flow control and non-return valve)
Function: The one-way flow control valve consists of a combination of a flow control valve and a non-
return valve. The non-return valve shuts off the air flow in one direction, causing the air to flow via the
flow control valve, whereby the air flow is infinitely adjustable. The flow control is effected in one
direction only; in the opposite direction air flows freely via the non-return valve.

Design: Non-return valve, pilot actuated

Function: If the input pressure at 1 is higher than the output pressure at 2, the non-return valve
releases flow, otherwise it shuts off flow. In addition, the non-return valve can be vented via the pilot
line 12, thereby enabling air to flow in both directions.

Design: Shuttle valve (non-return valve )

Function: The shuttle valve consists of the two inputs 1 and one output 2. If one of the inputs is
pressurised, the sealing element closes the opposite input and air flows only to 2 (OR function). If
both inputs 1 are pressurised simultaneously, the higher pressure reaches the output.

© Festo Didactic GmbH & Co. KG • 541091 C-107

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying of bars of chocolate and the use of the EMERGENCY-STOP function

Name: Date:

Fundamentals: 5/3-way solenoid valve Sheet 2 of 3

– Describe the mode of operation of the directional control valve shown.

4 2
14 12
(1M1) (1M2)
5 3
1

Description: Mode of operation of the directional control valve

Pilot actuated, spring-return 5/3-way solenoid valve, normally closed, with manual override
Mode of operation:
The 5/3-way solenoid valve has five power ports and three switching positions.
In the normal position, the solenoid coils are de-energised and the piston is centred in the mid-
position through the two springs (normal position). All ports are closed.
If the lefthand solenoid coil is pressurised, the piston moves up to the right stop and ports 1 (supply
port) and 4 (power port) i.e. 2 (power port) and 3 (exhaust port) are interconnected. Port 5 (exhaust
port) is closed.
If current flows through the righthand solenoid coil, the piston moves up to the left stop. In this
position, ports 1 and 2 as well as 4 and 5 are connected. Port 3 (exhaust port) is closed.
Each of the two actuated switching positions are held for as long as the corresponding solenoid coil is
current carrying. If the current flow is interrupted, the piston switches into the mid-position (normal
position). The same applies if both solenoids are energised simultaneously, since these then
counteract one another with identical force.
In the de-energised state, the valve can be switched by means of a manual override.
With this valve, double-acting cylinders can be stopped within the stroke range; the cylinder piston is
briefly clamped in the mid-position (normal position) of the valve.

C-108 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of the EMERGENCY-STOP function

Name: Date:

Fundamentals: 5/3-way solenoid valves Sheet 3 of 3

– Describe the effects of different mid-positions on the behaviour of a double-

acting cylinder if a 5/3-way solenoid valve is switched into the mid-position.

Description: Effect of mid-position on cylinder behaviour

5/3-way solenoid valve, mid-position closed:

In the mid-position (normal position), all ports are closed. With a 5/3-way valve that closes all ports in
mid-posiiton, the piston rod remains stationary, i.e. it is clamped. The same applies if the piston rod is
not located at the stop.

5/3-way solenoid valve, mid position pressurised:

In the mid-position (normal position), ports 2 and 4 are pressurised and exhaust ports 3 and 5 are
closed. With a 5/3-way valve pressurised in mid-position, the piston rod advances with reduced force
(since the effective pressure surface on the piston at the piston rod side is reduced).

5/3-way solenoid valve, mid-position exhausted:

In the mid-position (normal position), ports 2 and 4 are exhausted via 3 and 5, supply port 1 is closed.
In the case of a 5/3-way valve which exhausts the supply ports in mid position, the drive piston does
not exert any force on the piston rod. The piston rod is freely movable.

© Festo Didactic GmbH & Co. KG • 541091 C-109

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

Pneumatic circuit diagram of the handling unit with EMERGENCY-STOP function.

1A1
1B1 1B2

1V2 1 1 1V3

2 2

1V1 4 2

1M1 1M2
5 3

Pneumatic circuit diagram

C-110 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

The equipment set does not comprise a 5/3-way solenoid valve.

– How can you replace this solenoid valve by means of a suitable circuit? Complete
the pneuamatic circuit diagram.

1A1
1B1 1B2

1V5 2 1V6 2

1 21 1 21

1V3 1 1 1V4

2 2

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 -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 diagram (Circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-111

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– Complete the electrical circuit diagram for the handling unit.

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 21

13 12 14 13 12 14 13 12 14 13 22 24 22 24 12 14 22 24 12 14 32 34 22 24 22 24
1B1 1B2
AUTO K4 RESET K5 CONTINUOUS K6 S1 K6 K7 K8 K3 K9 K8 K9 K5
ON START
14 11 14 11 14 11 14 21 21 11 21 11 31 21 21

12 14 22 24 32 34
K7 K2 K2
11 21 31

31 31 31
MAN CONTINUOUS STOP AT
OFF CYCLE END
32 32 32

22 24 32 34 12 14 22 24
K4 K4 K3 K8
21 31 11 21

12 14
K2
11
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 .9 11 14 .15 11 14 .8 11 14 .10 11 14 .12 11 14 .14 11 14 .16 11 14 .18
22 22 22 22 22 22 22 22 22
21 24 21 24 .15 21 24 .17 21 24 .9 21 24 .21 21 24 .14 21 24 .15 21 24 .17 21 24 .20
32 32 32 32 32 32 32 32 32
31 34 31 34 .18 31 34 31 34 .11 31 34 31 34 31 34 31 34 .19 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

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

Note
The equipment sets TP201 and TP202 contain a total of 4 pushbuttons and 2 control
switches. You will need either a third electrical signal input or you can proceed as
follows:

1. Dispense with the STOP AT CYCLE END pushbutton.

2. Use a control switch instead of the MANUAL pushbutton.
3. Use a control switch instead of the RESET pusbutton.

C-112 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 1 of 2

Modes of operation
AUTO/MAN
This enables you to select between automatic mode or manual mode.

RESET
After an EMERGENCY-STOP the system may be in an undefined position. The RESET
function restores the initial position. However, the RESET function only works in
MANUAL mode.

SINGLE CYCLE
Only one cycle is executed if the START button is pressed.

CONTINUOUS CYCLE
Several cycles are executed consecutively if the START button is pressed and this
until the continuous cycle is stopped via the actuation of STOP or MAN.

START/STOP
This either starts or stops the system in the selected mode of operation.

© Festo Didactic GmbH & Co. KG • 541091 C-113

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Process description Sheet 2 of 2

EMERGENCY-STOP function
Sensor signals 1B1 and 1B2 switched to Continuous Plus and are not switched off
via the EMERGENCY-STOP mushroom actuator. Consequently the machine status
can be identified even during EMERGENCY-STOP. All modes of operation are
subordinate to the EMERGENCY-STOP function. The EMERGENCY-STOP switch is
designed in the form of an normally closed contact. Consequently the circuit
functions even in the event of a cable break.

Sequence with EMERGENCY-STOP

Relay K1 drops out if EMERGENCY-STOP is actuated. The changeover contact K1 In
current path 6 opens. The entire signal processing and signal output section is de-
energised.

The two 3/2-way solenoid valves 1V1 and 1V2 (normally closed) are immediately
switched into the normal position via the return-springs and close the air supply to
cylinder 1A1. The two piloted non-return valves close the exhaust air flow from the
cylinder. The cylinder remains pressurised in the current position.

Sequence with RESET

The RESET mode (current path 9) is to be used to return cylinder 1A1 to a defined
position again after the EMERGENCY-STOP has been actuated.

If RESET is actuated in manual mode (changeover contact 4 in current path 9 opens),

relay K5 picks up (current path 9) and the self-latching loop (changeover contact K5
in current path 10) is actuated.
At the same time changeover contact K5 in current path 21 closes. The circuit of
solenoid coil 1M2 is closed. The 3/2-way solenoid valve 1V2 switches and cylinder
1A1 returns into the retracted end position.
Proximity sensor 1B1 in the retracted end position is actuated and relay K2 picks up.
The changeover contact K2 in current path 9 closes and relay K5 drops out.

C-114 © Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function

Name: Date:

Checking the equipment list Sheet 1 of 1

Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.

– Check the equipment list. Are the required components entered in the table
below?

Quantity Description

1 Cylinder, double-acting

2 Non-return valve, pilot actuated

2 One-way flow control valve

2 5/2-way solenoid valve (plate M on valve terminal)

2 Proximity sensor, electronic

4 Pushbutton (normally open contact)

3 Pushbutton (normally closed contact)

1 Mushroom actuator (normally closed contact)

9 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG • 541091 C-115

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function
Solutions

C-116 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 1 of 4

The following fault occurs in the circuit shown below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and
remain in the forward end position.

– Describe the possible causes of the 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 diagram (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 C-117

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 2 of 4

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

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-

Electrical circuit diagram (circuit diagram in DIN A3 format in Part D)

List of possible error causes

Proximity sensor 2B2 at cylinder 2A1 maladjusted or faulty (e.g. cable break in current path 5)

Cable break in signal line of proximity sensor 2B2 (current path 6)

Cable break in earthing cable of relay K4, relay K4 faulty (current path 6)

Cable break in connecting line of changeover contact K4 connection 14 (current path 12)

Cable break in connecting line of changeover contact K4 connection 11 to changeover contact K7

connection 24 (current path 12)

Cable break in connecting line of changeover contact K7 connection 21 to relay K8 connection A1

(current path 12)

Changeover contact K7 in current path 12 faulty (does not close)

Cable break in earth line of relay K8, relay K8 faulty (current path 12)

Changeover contact K8 in current path 17 faulty (does not open)

C-118 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Fault finding in complex electropneumatic systems Sheet 3 of 4

A cable break occurs at the points marked in the circuit shown below.

– Describe what the effects of a line break at the respective points are on the
functioning of the circuit.

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

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)

© Festo Didactic GmbH & Co. KG • 541091 C-119

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on machining station

Name: Date:

Fault finding in complex electropneumatic circuits Sheet 4 of 4

Fault Effect of fault

Cable break in signal line of Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston rod of cylinder 2A1 moves
limit switch 2B1 (current into the forward end position, proximity sensor 2B2 is actuated
piston rod of cylinder 2A1 moves into the
path 4) retracted end position
relay K3 does not pick up
changeover switch K3 in current path14 (connected
in the form of a normally open contact) does not switch
relay K9 does not pick up
changeover contact
of K9 in current path 16 (connected in the form of a normally closed contact) does not switch
circuit of
solenoid coil 1M1 remains closed, piston rod of cylinder 1A1 remains advanced.

Cable break in supply line to Piston rod of cylinder 1A1 advances
once it moves out of the retracted end position, limit switch 1B1 is
changeover contact K6 no longer actuated
the changeover contact K1 in current path 8 (connected in the form of a normally
connection 11 open contact) opens
due to the cable break the self-latching loop of relay K6 is not activated
relay K6
(current path 9) drops out and the circuit of solenoid coil 1M1 is opened
the piston rod of 1A1 briefly advances and
retracts without actuating proximity sensor 1B2, i.e. triggering the subsequent movement 2A1+
piston
rod of cylinder 2A1 does not move into the forward end position (remains retracted).

Cable break in earthing The piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
current path 10 is not closed,
cable of relay K7 (current relay K7 does not pick
the subsequent movement 2A1+ is not triggered
piston rod of cylinder 2A1
path 10) does not move into the forward end position (remains retracted), piston rod of cylinder 1A1 remains
advanced.

Cable break in supply line of Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston rod of cylinder 2A1 moves
changeover contact K8 into the forward end position, proximity sensor 2B2 is actuated
relay K8 picks up, changeover contact K8
connection 11 in current path 17 (connected in the form of a normally closed contact) opens, the circuit of solenoid coil
(current path 13) 2M1 is open
the piston rod of cylinder 2A1 retracts
as soon as it leaves the forward end position, the
proximity sensor 2B2 is no longer actuated
due to the cable break the self-latching loop of relay K8 is not
activated
relay K8 picks only for as long as proximity 2B2 is actuated
if signal 2B2 is no longer
applied, changeover contact K8 in current path 17 (connected in the form of a normally closed contact)
closes the current path again
the circuit of solenoid coil 2M1 is closed again
the piston rod of cylinder
2A1 oscillates between retracting and advancing without actuating limit switch 2B1, i.e. triggering the
subsequent movement 1A1–
piston rod of 1A1 does not move into the retracted end position (remains
advanced).

Cable break in supply line of Piston rod of cylinder 1A1 advances
piston rod of cylinder 2A1 advances
piston rod of cylinder 2A1
changeover contact K8 retracts
limit switch 2B1 is actuated
relay K3 picks up
the changeover contact K3 in current path 14
connection 21 to relay K9 (connected in the form of a normally open contact) closes, as does the changeover contact K8 (connected in
connection A1 the form of a normally open contact)
however, due to the cable break current path 14 does not close and
(current path 14) relay K9 does not pick up
the changeover contact K9 in current path 16 (connected in the form of a
normally closed contact) remains closed
the circuit of solenoid coil 2M1 remains closed
the
subsequent movement 1A1– is not triggered and the piston rod of cylinder 1A1 remains advanced.

C-120 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Error list Sheet 1 of 2

Simulation of fault Cause of fault Effect of fault

Remove signal line in Proximity sensor 1B2 at If the START button S1 is actuted, the piston rod of cylinder 1A1 advances, and
current path 3 cylinder 1A1 faulty, no proximity sensor 1B2 is actuated
relay K2s does not pick up
current path
(proximity sensor 1B2) signal at relay K2 10 is not closed
relay K7 does not pick up
circuit of solenoid coil 2M1
closes
piston rod of cylinder 2A1 does not advance
system stops, piston
rod of cylinder 1A1 remains advanced.

Remove signal line in Limit switch 2B1 at Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston
current path 4 cylinder 2A1 faulty, no rod of cylinder 2A1 moves into the forward end position, proximity sensor 2B2 is
(limit switch 2B1) signal at relay K3 actuated
piston rod of cylinder 2A1 moves into the retracted end position

relay K3 does not pick up
the changeover contact K3 in current path 14
(connected in the form of a normally open contact) does not switch
relay K9
does not pick up
changeover contact K9 in current path 16 (in the form of a
normally closed contact) does not switch
circuit of solenoid coil 1M1 remains
closed, piston rod of cylinder 1A1 remains advanced.

Remove signal line in Proximity sensor 2B2 at Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston
current path 6 cylinder 2A1 faulty, no rod of cylinder 2A1 moves into the forward end position, proximity sensor 2B2 is
(proximity sensor 2B2) signal at relay K4 actuated
relay K4 does not pick up
the changeover contact K4 in current
path 12 (connected in the form of a normally open contact) does not switch

relay K8 does not pick up
changeover contact K8 in current path 17
(connected in the form of a normally closed contact) does not switch
circuit of
solenoid coil 2M1 remains closed, piston rod of cylinder 2A1 remains advanced,
piston rod of cylinder 1A1 remains advanced.

Remove the supply line of Cable break in Actuation of the START button S1 does not trigger any reaction
relay K5 is
changeover K1 current path 8 energised
changeover contact K5 in current path 8 (connected in the form of a
connection 11 at K1 to normally open contact) is actuated, due to the cable break current path 8 is not
changeover contact K9 closed and relay K6 consequently does not pick up
no cylinder movements
connection 22 take place.
(current path 8)

Remove supply line of Cable break in current Piston rod of cylinder 1A1 advances
once it has moved out of the retracted
changeover contact K6 path 9, self-latching loop end position, limit switch 1B1 is no longer actuated
the changeover contact
connection 11 of relay K6 not K1 in current path 8 (connected in the form of a normally open contact) opens

(current path 9) functioning due to the cable break, the self-latching loop of relay K6 is not activated
Relay
K6 picks up only for as long as limit switch 1B1 is actuated
the piston rod of
1A1 briefly advances and retracts without actuating proximity sensor 1B2, i.e.
triggering the subsequent movement of 2A1+
piston rod of cylinder 2A1 does
not move into the forward end position (remains retracted).

© Festo Didactic GmbH & Co. KG • 541091 C-121

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

List of faults Sheet 2 of 2

Simulation of fault Cause of fault Effect of fault

Remove earthing cable of Cable break in Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston
relay K8 (current path 12) current path 12 i.e. rod of cylinder 2A1 moves into the forward end position, proximity sensor 2B2 is
earthing cable of K8 actuated
relay K8 does not pick up
the changeover contact K8 in current
path 17 (connected in the form of a normally closed contact) remains unactuated

the circuit of solenoid coil 2M1 remains closed, the piston rod of cylinder 2A1
remains advanced, the subsequent movements of 2A1– and 1A1– are not
triggered.

Remove connecting cable Cable break in Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
piston
between changeover current path 13 rod of cylinder 2A1 moves into the forward end position, proximity sensor 2B2 is
contact K8 connection 11 actuated
relay K8 picks up, changeover contact K8 in current path 17
in current path 13 and (connected in the form of a normally closed contact) opens
the circuit of
changeover contact K4 solenoid coil 2M1 opens
the piston rod of cylinder 2A1 retracts
as soon as
i.e. K7 in current path 12 it moves out of the forward end position, the proximity sensor 2B2 is no longer
actuated
due to the cable break the self-latching loop of relay K8 is not
activated
relay K8 is only energised for as long as proximity sensor 2B2 is
actuated
if the signal of 2B2 is not longer applied, the changeover contact K8
in current path 17 (connected in the form of a normally closed contact) closes the
current path again
the circuit of solenoid coil 2M1 is closed again
the
piston rod of cylinder 2A1 oscillates between retracting and advancing without
actuated the limit switch 2B1, i.e. triggering the subsequent movement 1A1–

piston rod of cylinder 1A1 does not move into the retracted end position
(remains advanced).

Remove connecting cable Cable break in Piston rod of cylinder 1A1 advances
piston rod of cylinder 2A1 advances

between changeover current path 14 piston rod of cylinder 2A1 retracts
limit switch 2B1 is actuated
relay K3
contact K3 connection 11 picks up
the changeover contact K3 in current path 14 (connected in the form
and changeover contact of a normally open contact) closes as does the changeover contact K8
K8 of connection 24 (connected in the form of a normally open contact)
due to the cable break
current path 14 is not closed and relay K9 does not pick up
the changeover
contact K9 in current path 16 (connected in the form of a normally closed
contact) remains closed
the current path of solenoid coil 2M1 remains closed

the subsequent movement 1A1– is not triggered, piston rod of cylinder 1A1
remains advanced.

Remove connecting cable Cable break in Piston rod of cylinder 1A1 advances, proximity sensor 1B2 is actuated
relay
between changeover current path 17 K7 picks up
due to the cable break between the changeover contacts K7 and
contact K7 connection 31 K8, current path 17 is not closed
the circuit of solenoid coil 2M1 is not closed,
and changeover contact the piston rod of cylinder 2A1 remains retracted, the piston rod of 1A1 remains
K8 of connection 32 advanced.

C-122 © Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Notes for the trainer Sheet 1 of 1

Notes for the trainer It is advisable to deal with this exercise after solving exercise 4 of TP202, since the
correct configuration of the circuit will then be available in tested form.

The fault can be directly built into the circuit by the trainer (see list of simulation of
faults).

It is important to make sure that trainees proceed systematically during fault finding.

Alternative
If the circuit of exercise 4 is not available fully assembled, it is also possible to carry
out the fault finding theoretically:
• The trainer explains the fault („cylinder 1A1 advances, the circuit then comes to a
stop.“)
• The trainees then localise the fault with the help of GRAFCET.
• The trainees draw up a list of potential causes of faults and describe how they
proceed during the fault finding (where do you need to measure, what needs to
be checked).

© Festo Didactic GmbH & Co. KG • 541091 C-123

Exercise 12: Eliminating a fault on a machining station
Solutions

Exercise 12: Eliminating a fault on a machining station

Name: Date:

Equipment list Sheet 1 of 1

Quantity Description

2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way solenoid valve (plate M on valve terminal)

2 Limit switch, electrical

2 Proximity sensor, electronic

1 Pushbutton (normally open contact)

9 Relay

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list of machining station

C-124 © Festo Didactic GmbH & Co. KG • 541091

Part D – Appendix

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4

Data sheets Relay, 3 off______________________________________________________ 162241

Signal input plate, electrical ________________________________________ 162242
Time relay, 2 off__________________________________________________ 162243
Preselect counter, electrical, incrementing ____________________________ 162355
Proximity sensor, inductive ________________________________________ 178574
Proximity sensor, capacitive ________________________________________ 178575
EMERGENCY-STOP button _________________________________________ 183347
Valve terminal with 4 valve slices____________________________________ 540696
Non-return valve, piloted __________________________________________ 540715

Circuit diagrams Exercise 1: Realising a diverting device – pneumatic circuit diagram

Exercise 2: Insertion of drinks bottles – pneumatic circuit diagram
Exercise 3: Realising a selection station – pneumatic circuit diagram
Exercise 3: Realising a selection station – electrical circuit diagram
Exercise 4: Machining of key blanks – pneumatic circuit diagram
Exercise 4: Machining of key blanks – electrical circuit diagram
Exercise 5: Bending of mounting brackets – pneumatic circuit diagram
Exercise 5: Bending of mounting brackets – electrical circuit diagram
Exercise 6: Realising a filling system – electrical circuit diagram
Exercise 7: Bonding of components – pneumatic circuit diagram
Exercise 8: Selecting modes of operation – pneumatic circuit diagram
Exercise 8: Selecting modes of operation – electrical circuit diagram
Exercise 9: Machining of key blanks – electrical circuit diagram
Exercise 10: Bending of mounting brackets – electrical circuit diagram,
additional exercise
Exercise 10: Bending of mounting brackets – electrical circuit diagram
Exercise 11: Conveying bars of chocolate – pneumatic circuit diagram
Exercise 11: Conveying bars of chocolate – electrical circuit diagram
Exercise 12: Eliminating a fault on a machining station – pneumatic circuit diagram
Exercise 12: Eliminating a fault on a machining station – electrical circuit diagram
Exercise 12: Eliminating a fault on a machining station – electrical circuit diagram
with markings

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

Organiser

Equipment set TP101 in the organiser

All components of the equipment set for the technology package TP201 are stored in
the organiser.
The organiser also serves as a drawer insert for use in conjunction with our range of
laboratory furniture.

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

Mounting technology The components of the equipment set are intended for assembly on the Festo
Didactic profile plate, which consists of 14 parallel T-slots, 50 mm apart.

Three variants are available for the assembly of equipment on the profile plate:

Variant A
A latching system, without auxiliary means, clamping mechanism using a lever and
spring, adjustable in the direction of the slot, for lightweight non-loadable
components

Variant B
A rotary system, without auxiliary means, knurled nut with locking disc and T-head
bolts, vertical or horizontal alignment, for medium weight loadable components.

Variant C
A screw system, with auxiliary means, socket head screw with T-head bolt, vertical
and horizontal alignment, for heavy loadable components and equipment that is
rarely released from the profile plate

The proven ER units on a plug-in board can be attached to the profile plate using
adapters.

In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide
is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back
whereby the component can be removed from or attached to the profile plate.
Components are aligned along the slot and can be moved in the direction of the slot.

With variant B, components are attached to the profile plate by means of a T-head
bolt and blue knurled nut. A locking disc serves to fix the device in position, which
can be secured in any 90° direction. Devices can thus be mounted on the profile
plate either lengthwise or perpendicular to the slot.
Once the desired locking disc position is set, the device is mounted on the profile
plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in
the slot by 90° owing to thread friction. The component is pressed against the profile
plate by further turning the knurled nut.

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

 Variant C is used for heavy or similar devices, screwed on to the profile plate only
once or removed very seldom. Components are attached by means of socket head
screws with internal hex and T-head bolts.
The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be
mounted on the profile plate using adapters. A black plastic adapter is required for
each locating pin. The adapters are plugged into the T-slot, positioned at intervals of
50 mm and secured by means of a 90° turn. The locating pins of the ER unit are
plugged into the adapter holes.

Plastic tubing The polyurethane tubing is particularly flexible and kink resistant.

Technical data

Pneumatics

Colour Silver metallic

Outer diameter 4 mm

Inner diameter 2.5 mm

Minimum bending radius within temperature range of -35 to +60°C 17 mm

Maximum operating pressure within

Temperature range of -35 to +30°C 10 bar (1000 kPA)

Temperature range of +30 to +40°C 9 bar ( 900 kPA)
Temperature range of -40 to +60°C 7 bar ( 700 kPA)

Subject to change.

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

 162241
Relay, 3-off

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

Design This component consists of three relays with connections and two bus-bars for the
power supply. All electrical connections are in the form of 4 mm sockets. The unit
can be mounted in a mounting frame or on the profile plate using four plug-in
adapters.

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/4
162241
Relay, 3-off

2 3

A1 A2 4 2 1
7 6

Function The relay consists of a coil with a core (1) and winding (3) with connection lugs (7),
an armature (4), a return spring (2) and a contact assembly with four changeover
contacts (5) and connection lugs (6). When power is applied to the coil connections,
current flows through the winding, creating a magnetic field. The armature is pulled
onto the coil core and the contact assembly is actuated. Electrical circuits are
opened or closed via this assembly.
When the electrical current is removed, the magnetic field collapses and the
armature and contact assembly are returned to their original position by a return
spring.

Note The switching status of the relays is indicated by LEDs, which are protected against
incorrect polarity.
The four changeover contacts of the contact assembly can be used as normally-open
contacts (1), normally-closed contacts (2) or changeover contacts (3).

2/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 162241
Relay, 3-off

+24 V 1 2

13 12 14
S1 K1
14 11

A1
K1 1M1
A2

0V 12
11 14 .2
22
21 24
32
31 34
42
41 44

Example of application: Circuit diagram, electrical

+24 V 1 2 +24 V 1 2

A1 12 14 A1 12 14
K1 K1
A2 11 A2 11

Changeover switch connected as Changeover switch connected as

normally-open contact normally-closed contact

Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 3/4
162241
Relay, 3-off

Technical data Electrical

Voltage 24 V DC

Contact assembly 4 changeover contacts

Contact rating Max. 5 A

Contact interrupt rating Max. 90 W

Pichup time 10 ms

Drop-off time 8 ms

Connections For 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

4/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 162242
Signal input plate, electrical

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

Design This component consists of two illuminated pushbuttons in the form of momentary-
contact switches and one illuminated pushbutton in the form of a detented switch.
All electrical connections are in the form of 4 mm safety connectors. The unit can be
mounted in a mounting frame or on the profile plate using four plug-in adapters.

Function The illuminated pushbutton in the form of a detented switch consists of a contact
assembly with two normally-open contacts and two normally-closed contacts,
together with a colourless transparent pushbutton cap with a miniature lamp. The
contact assembly is actuated by pressing this cap. Electrical circuits are opened or
closed via the contact assembly. When the cap is released, the switching status is
maintained. The contact assembly is returned to its initial position by pressing the
pushbutton a second time.
The illuminated pushbuttons in the form of momentary-contact switches consist of
a contact assembly with two normally-open contacts and two normally-closed
contacts, together with a colourless transparent pushbutton cap with a miniature
lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are
opened or closed via the contact assembly. When the cap is released, the contact
assembly returns to its initial position.

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
162242
Signal input plate, electrical

Note When power is applied to the connections of the visual indicator, the switching
status is displayed by the built-in miniature lamp in the pushbuttons.

+24 V 1 2

13 12 14
S1 K1
14 11

A1
K1 1M1
A2

0V 12
11 14 .2
22
21 24
32
31 34
42
41 44

Example: Circuit diagram, electrical

Technical data Electrical

Voltage 24 V DC

Contact assembly 2 normally-open contacts, 2 normally-closed contacts

Contact rating Max. 1 A

Power consumption (miniature lamp) 0.48 W

Connections For 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 162243
Time relay, 2-off

17 27 35 45
A1

A2
18 28 36 46

17 27 35 45
A1

A2
18 28 36 46

Design The unit consists of two printed circuit boards with one switch-on and one switch-off
relay with time delay, mounted on a plug-in plate. All electrical connections are in
the form of 4 mm safety connectors. The unit can be mounted in a mounting frame or
on the profile plate using four plug-in adapters.

Function The time period of the relay with switch-on delay can be infinitely adjusted via the
rotary knob of the potentiometer. The contact set consists of two normally open
contacts and two normally closed contacts. When the voltage is applied to the coil
connections, the set time delay takes effect. When the time delay has expired, the
contact set is actuated. Circuits are opened or closed via the contact connections.
When the time delay has expired, the contact set returns to its initial position
without delay. A protective circuit protects the switch-on delay time relay against
polarity reversal.
The time period of the switch-off time relay is infinitely adjustable via the rotary
knob of the potentiometer. The contact set consists of two normally open contacts
and two normally closed contacts. The contact set is actuated without delay when
the voltage is applied. Circuits are opened or closed via the contact connections.
When the voltage is removed, the set time delay takes effect. When the time delay
has expired, the contact set is returned to its initial position. The switch-off time
relay is protected against polarity reversal.

© Festo Didactic GmbH & Co. KG, 06/2005 Subject to change 1/2
162243
Time relay, 2-off

Note The correct polarity must be observed for proper function in industrial use.

Technical data Electrical

Voltage 24 V DC

Contact set 2 normally open, 2 normally closed contacts

Contact load maximum 5 A

Cut-off capacity maximum 100 W

Time delay 0.5 to 10 s (adjustable)

Connection For 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 06/2005
 162355
Preselect counter, electrical, incrementing

A1 1 R1

A2 R2
4 2

Design The unit consists of an electrical preselect counter with connections and two
busbars for the voltage supply. All electrical connections are in the form of 4 mm
safety connectors. The unit is mounted on the cabinet frame or on a profile plate by
means of four plug-in adapters.

Function The electrical preselect counter is adjusted by pressing the white release button and
entering the preselected value simultaneously. The preselected digit is displayed in
the window. The electrical counting pulses are input via connections A1 and A2 and
areadded up by the counter. When the preselected value has been reached, the
contact set is actuated. Circuits are opened and closed via the contact sets. The
counter is reset manually via the black reset button or electrically by a reset pulse
via connections R1 and R2. The set preselected value is maintained when the
counter is reset.

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
162355
Preselect counter, electrical, incrementing

Note The preselected value may also be adjusted during operation. The reset signal of the
component is limited to one second. Counting pulses incoming during the reset time
are not processed. The electrical preselect counter functions irrespective of the
polarity of the voltage applied.

Technical data Electrical

Voltage 24 V DC

Contact set 1 changeover switch

Contact load max. 1 A

Power consumption 2.4 W

Duration of counting pulse minimum 20 ms

Reset manual or electrical

Duration of reset pulse minimum 200 ms

Display 3 digit

Connection for 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 178574
Proximity sensor, inductive

Design The inductive proximity sensor with LED and electrical connections is assembled on
a polymer assembly base. The electrical connection is effected by means of safety
connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a
quick release detent system with blue triple grip nut (Mounting alternative “B”).

Function The inductive proximity sensor consists of an oscillator circuit, which is made up of a
parallel resonant circuit with coil and capacitor as well as an amplifier. The
electromagnetic field is directed outwardly by means of a ferrite shell core. When a
electrically conductive material is brought into the electromagnetic stray field, this
creates eddy currents in the material in accordance with the law of induction, which
attenuate the oscillator. Depending on the conductivity, the size and proximity of the
conducting object, the oscillator may be attenuated so strongly that oscillation
ceases. The attenuation of the oscillator is evaluated in the triggering stage which
supplies an output signal.
The proximity sensor has a PNP output, i.e. the signal line is switched to a positive
potential in the switched status. The switch is designed in the form of a normally
open contact. The connection of the load takes place between the signal output of
the proximity sensor and the load. The active surface can be identified by a blue
polymer disc. The operating status is indicated via an LED display. The sensor is
protected against polarity reversal, overload and short circuit.

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
178574
Proximity sensor, inductive

+24V-

BN +
B

BK

BU

Note The correct polarity of the applied voltage is necessary for proper functioning. The
connections for the operating voltage are colour coded as follows: red for positive,
blue for negative and black for the signal output. The load is connected to the
switching output and connected to the negative terminal of the current supply.

Technical data Electrical

Switching voltage 10 – 30 V DC

Residual ripple maximum 10%

Nominal switching distance 4 mm

Switching frequence maximum 800 Hz

Output function normally open contact, positive switching

Output current maximum 400 mA

Protection class IP65

Connections for 4 mm safety connector plug or 3-pin socket

Electromagnetic compatibility

Emitted interference tested to EN EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 178575
Proximity sensor, capacitive

Design The capacitive proximity sensor with LED and electrical connections is assembled on
a polymer assembly base. The electrical connection is effected by means of safety
connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a
quick release detent system with blue triple grip nut (mounting alternative “B”).

Function The operational principle of a capacitive sensor is based on the evaluation of the
capacity change of a capacitor in a RC resonant circuit. When a material approaches
the proximity sensor, the capacity of the capacitor is stimulated (increased),
whereby the change in the oscillatory characteristics of the RC circuit can be
evaluated. The capacity change largely depends on the distance, size and dielectric
constant of the material used.
The proximity sensor has a PNP output, i.e. the signal line is switched to a positive
potential in the switched status. The switch is designed as a normally open contact.
The connection of the load takes place between the signal output of the proximity
sensor and the load. A yellow LED indicates the switching status. The sensor is
protected against polarity reversal, overload and short circuit.

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
178575
Proximity sensor, capacitive

+24V-

BN +
B

BK

BU

Note The correct polarity of the applied voltage is to be observed for proper functioning.
The connections for the operating voltage are colour coded as follows, red for
positive, blue for negative and black for the signal output. The load is connected to
the switching output and linked to the negative terminal of the current supply.

Technical Data Electrical

Switching voltage 10 – 30 V DC

Residual ripple maximum 10%

No-load current approx. 15 mA

Nominal switching distance 4 mm

Reproducible switching point at ≤ 0.01 mm

constant temperature

Switching frequency maximum 100 Hz

No-load current approx. 15 mA

Output current maximum 200 mA

Switching capacity maximum 4.8 W

Protection class IP65

Connection for 4 mm safety connector plug or 3-pin socket

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 183347
EMERGENCY-STOP button

13 21

14 22

Design The EMERGENCY-STOP button consisting of an illuminated mushroom actuator and a

contact set with normally open and normally closed contacts, is built into a yellow
polymer housing. The electrical connection is effected by means of safety
connectors. The unit is mounted on the profile plate via a quick release detent
system with blue lever (mounting alternative “A”).

Function The contact set consists of a normally open and a normally closed contact; the valve
actuator is a red mushroom button with detent. The contact set is actuated by
depressing the red button. Electrical circuits can be opened or closed via the contact
connections. The operating status is maintained when the mushroom button is
released. Turning of the detent button disengages the actuator and returns the
contact set to its original position.

© Festo Didactic GmbH & Co. KG, 07/2005 Subjects to change 1/2
183347
EMERGENCY-STOP button

Note The EMERGENCY-STOP function is a safety device to prevent injuries and material
damage. The control sequence is determined by preset conditions and is different
from the automatic program sequence. The operating status is displayed via the
built in lamp in the mushroom button when the voltage is applied to the visual
display connections.

Technical Data Electrical

Voltage 24 V DC

Actuator mushroom button with detent

Contact set 1 normally open contact, 1 normally closed contact

Contact load maximum 8 A

Connection for 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 540696
Valve terminal with 4 valve slices (MMJJ)

1V1 4 2 2V1 4 2 3V1 4 2 4V1 4 2

S M M J J

14 14 14 12 14 12
1M1 1M1 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
1 1 1 1 1 1

1 1

Design This valve terminal with quick push-in connectors is screwed onto the adapter
plates, equipped with P-connection and silencer. The four electrical connections are
equipped with safety sockets. The unit is mounted on the profile plate grid using the
the blue lever system (assembly variant “A”).

Function A double solenoid valve is reversed by applying voltage at the solenoid coil and,
when the signal is cancelled, it remains in this switching position until a counter
signal is given. The switching signals are displayed via the light emitting diodes in
the terminal housing. The valve is equipped with two manual overrides.

Note The distinguishing characteristics of the solenoid coil are low power consumption
and minimal temperature rise. The electrical connections include reverse polarity
protection for the LEDs and protective circuits.
The solenoid coil connections are identified by 0–14 (1V1), 1–14 (2V1), 2–12 and 2–
14 (3V1), 3–12 and 3–14 (4V1).

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
540696
Valve terminal with 4 valve slices (MMJJ)

Technical data Pneumatics

Medium Compressed air, filtered, lubricated or unlubricated

Design Spool valves, pilot actuated

Max. number of valve positions 24

Operating pressure -0.9 – 10 bar (-90 – 1000 kPa)

Pilot pressure 3 – 8 bar (300 – 800 kPa)

Standard nominal flow 360 l/min

Connection QS-1/8-4-I for plastic tubing PUN 4 x 0.75

Electrics

Voltage 24 V DC

Protection Class IP65

Connection Cable with 4 mm jack plugs

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
 540715

Non-return valve, piloted

1 21

Design Non-return valve directly connected to the cylinder connection via a push-in sleeve.

Function The non-return valve shuts off flow from port 2 to port 1. The non-return valve can be
released through the application of compressed air at port 21.

Technical data Pneumatics

Medium Compressed air, filtered, lubricated or unlubricated

Design Non-return valve, piloted

Operating pressure 0.5 to 10 bar (50 to 1000 kPa)

Standard nominal flow rate 108 l/min

Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
Exercise 1: Realising a diverting device – pneumatic circuit diagram with valve terminal

0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J

14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2

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

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 1: Realising a diverting device – pneumatic circuit diagram with valve terminal
Solution

1A1

1V2 1 1 1V3

2 2

0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J

14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2

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

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles – pneumatic circuit diagram with valve terminal

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 2: Insertion of drinks bottles – pneumatic circuit diagram with valve terminal
Solution

1A1 2A1
1B1 2B2
1B1 1B2

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station – pneumatic circuit diagram with valve terminal
Solution

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station – electrical circuit diagram

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 3: Realising a selection station – electrical circuit diagram
Solution

Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13

12 14 12 14 22 24 32 34
1B2 BN 2B2 BN 13
K1 K6 K6 K6
2 4 2 4 S1
BK BK START 11 11 21 31
1B1 2B1 14
1 1 12 14
BU BU
K3
11

12 14 12 14 22 24
K5 K2 K3
11 11 21

12 14
K4
11
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 .8 11 14 .11 11 14 .8 11 14 .8 11 14 .8 11 14 .9 Group 1 Group 2
22 22 22 22 22 22
21 24 21 24 21 24 .13 21 24 21 24 21 24 .10
32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .12
42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44

© Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks – pneumatic circuit diagram
Solution

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks – electrical circuit diagram

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-

© Festo Didactic GmbH & Co. KG • 541091

Exercise 4: Machining of key blanks – electrical circuit diagram
Solution

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

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-

© Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets – pneumatic circuit diagram
Solution

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets – electrical circuit diagram

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 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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 5: Bending of mounting brackets – electrical circuit diagram
Solution

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 18 19 20 21

12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 22 24 32 34 42 44 42 44 42 44
1B2 BN 2B2 BN 13
K1 K6 K2 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9
2 4 2 4 S1
BK BK Start 11 11 11 11 11 11 11 11 21 21 31 41 41 41
1B1 2B1 14
1 1 12 14
BU BU
K5
11

12 14 22 24 22 24 22 24 22 24 32 34 32 34 32 34 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
11 21 21 21 21 31 31 31 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 .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 11 14 .8
22 22 22 22 22 22 22 22 22 22
21 24 .16 21 24 21 24 21 24 21 24 21 24 .10 21 24 .12 21 24 .14 21 24 .16 21 24 .17
32 32 32 32 32 32 32 32 32 32
31 34 31 34 31 34 31 34 31 34 31 34 .18 31 34 .18 31 34 .19 31 34 .20 31 34 .21
42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 .19 41 44 .20 41 44 .21 41 44

1A1+ 2A1+ 2A1- 1A1- Control

step

© Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system – electrical circuit diagram

Signal input Signal processing and signal output

+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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 6: Realising a filling system – electrical circuit diagram
Solution

Signal input Signal processing and signal output

+24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

13 12 14 12 14 12 14 12 14 22 24 12 14
1B2 BN 2B2 BN B1 BN B2 BN B3 BN S1 K8 K1 K9 K2 K9 K4
2 4 2 4 START
BK BK BK BK BK 14 11 11 11 11 21 11
1B1 2B1
1 1 12 14 12 14 22 24
BU BU BU BU BU
K3 K5 K5
11 11 21

31 22 24 12 14 22 24
S2 K8 K6 K6
STOP
32 21 11 21

12 14 22 24
K7 K7
11 21
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 .15 11 14 .17 11 14 .15 11 14 .19 11 14 .16 11 14 .16 11 14 .16 11 14 .14 11 14 .16
22 22 22 22 22 22 22 22 22
21 24 21 24 21 24 21 24 21 24 .18 21 24 .18 21 24 .18 21 24 .15 21 24 .18
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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 7: Bonding of components – pneumatic circuit diagram
Solution

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation – pneumatic circuit diagram
Solution

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation – electrical circuit diagram

+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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 8: Selecting modes of operation – electrical circuit diagram
Solution

+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 K1 S1 K1 K4 K2 K4
CONTINUOUS START
14 11 14 21 BK BK BK 11 21 21
ON
p
12 14 12 14
BU BU BU
K2 K3
11 11

31 31
S4 S2
CONTINUOUS STOP AT
32 32
OFF CYCLE END
12 14
K5
11

2 4
P6
1
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 .2 11 14 .4 11 14 .13 11 14 .11 11 14 .3 11 14 .3
22 22 22 22 22 22
21 24 .4 21 24 .13 21 24 21 24 .14 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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function – electrical circuit diagram

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-

© Festo Didactic GmbH & Co. KG • 541091

Aufgabe 9: Machining of key blanks and the use of an EMERGENCY-STOP function – electrical circuit diagram
Solution

Signal input
+24 V 1 2 3 4 5 6 7 8 9

21 12 14
ES K10
EMERGENCY- 22 Signal processing Signal output
11
STOP 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 .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
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-

© Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets – electrical circuit diagram, additional exercise

+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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets – electrical circuit diagram, additional exercise
Solution

Signal input
+24 V 1 2 3 4 5 6 7 8 13

21 12 14
ES K1
EMERGENCY- 22 Signal processing Signal output
11
STOP 9 10 11 12

12 14 12 14 12 22 24 12 14 22 24
1B2 BN 13 13
1B1 BN K4 K6 K6 K5 K1
S1 ACKNOW-
BK BK START LEDGE 11 11 21 11 21
14 14
EMERGENCY-
STOP 12 14
BU BU
K2
11

12 14
K3
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 .8 11 14 .9 11 14 .9 11 14 .9 11 14 .12 11 14 .10 1A1–
22 22 22 22 22 22
21 24 .13 21 24 21 24 21 24 21 24 21 24 .11
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

1A1+
1A1–

© Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets – electrical circuit diagram

Signal input Signal processing Signal output

+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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 10: Bending of mounting brackets – electrical circuit diagram
Solution

Signal input Signal processing Signal output

+24 V 1 2 3 4 5 6 7 8 9 23 25

21 12 14 22 24 32 34
ES K11 K11 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 22 24
2B2 BN 13
1B2 BN K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
2 4 2 4 S1
BK BK 11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
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 .23 21 24 .18 21 24 21 24 .25 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 .25 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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function – 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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function – pneumatic circuit diagram
Solution

1A1
1B1 1B2

1V5 2 1V6 2

1 21 1 21

1V3 1 1 1V4

2 2

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 -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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function – electrical circuit diagram

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function – electrical circuit diagram
Solution

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 21

13 12 14 13 12 14 13 12 14 13 22 24 22 24 12 14 22 24 12 14 32 34 22 24 22 24
1B1 1B2
AUTO K4 RESET K5 CONTINUOUS K6 S1 K6 K7 K8 K3 K9 K8 K9 K5
ON START
14 11 14 11 14 11 14 21 21 11 21 11 31 21 21

12 14 22 24 32 34
K7 K2 K2
11 21 31

31 31 31
MAN CONTINUOUS STOP AT
OFF CYCLE END
32 32 32

22 24 32 34 12 14 22 24
K4 K4 K3 K8
21 31 11 21

12 14
K2
11
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 .9 11 14 .15 11 14 .8 11 14 .10 11 14 .12 11 14 .14 11 14 .16 11 14 .18
22 22 22 22 22 22 22 22 22
21 24 21 24 .15 21 24 .17 21 24 .9 21 24 .21 21 24 .14 21 24 .15 21 24 .17 21 24 .20
32 32 32 32 32 32 32 32 32
31 34 31 34 .18 31 34 31 34 .11 31 34 31 34 31 34 31 34 .19 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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station – pneumatic circuit diagram

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

© Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station – electrical circuit diagram

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

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-

© Festo Didactic GmbH & Co. KG • 541091

Exercise 12: Eliminating a fault on a machining station – electrical circuit diagram with markings

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

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
x x
x 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 x 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
x 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-

© Festo Didactic GmbH & Co. KG • 541091