festo

Workbook TP 202

CD-ROM included

Festo Didactic

541091 en

ElectropneumaticsAdvanced Level

2 Festo Didactic GmbH & Co. KG 541091

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.: Status: Authors: Editor: Graphics: Layout:

541091 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 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.

Intended use

Festo Didactic GmbH & Co. KG 541091 3

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

Contents

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


the use of an EMERGENCY-STOP function ______________________C-85


the use of an EMERGENCY-STOP function______________________C-95


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


Festo Didactics 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.

Preface

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.


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.).

Introduction

Introduction



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.

Notes on safety and operation

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.


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.

Fixed workstation with Festo Didactic profile plate

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

Technology package for electropneumatics (TP200)

Important elements of

TP200

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.


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.

Training aims of Advanced Level (TP202)

Training aims of Advanced Level (TP202)



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 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.


and function of a pneumatic-electrical

converter.


function and possible applications of a

time relay with switch-on delay.

Allocation of training aims and exercises

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.


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.


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.


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.

Description Order No. Quantity

EMERGENCY-STOP button 183347 1

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

Equipment set Advanced Level (TP202)

Equipment set Advanced

Level (TP202

Order No.: 540713)



Description Symbol

Relay, 3-off

1412 2422 3432

32

4442

11 21 31 41

A1

A2

1412 2422 34 4442

11 21 41

A1

A231

1412 2422 3432 4442

11 21 31 41

A1

A2

Signal input plate, electrical 13

13

13

23

23

23

14

14

14

24

24

24

31

31

31

41

41

41

32

32

32

42

42

42

Equipment set symbols



Description Symbol

Time relay, 2-off

with switch-on delay

with switch-off delay

17

17

27

27

18

18

28

28

35

35

45

45

36

36

46

46

A1

A1

A2

A2

Preselect counter, electrical

4 2

1A1 R1

A2 R2

Proximity sensor, inductive

Proximity sensor, capacitive

EMERGENCY-STOP button 13

14

21

22

Non-return valve, piloted 2

1 21


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

closed

1

Non-return valve, piloted 2

Valve terminal with 4 valve slices

(MMJJ)

1 1 1 1 1 1 1 1 1 1 1 1

Preselect counter, electrical 1

Time relay, 2-off 1

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

closed contact

2 3

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

valve

1 1 1 1 1 1 1 1 1 1 1 1

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

Allocation of equipment and exercises

Equipment set TP202

Equipment set TP201

Allocation of equipment and exercises



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 trainees 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.

Methodological help for the trainer

Methodological help for the trainer



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

Methodological structure of the exercises


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, ...

Designation of equipment


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 are available for the various pieces of equipment of the

technology package to assist you in the use and commissioning of the equipment.

The data sheets for the equipment of the technology package are available in the

form of pdf files.

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.

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 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.

Contents of the CD-ROM

Operating instructions

Data sheets

Demo

Festo catalogue

FluidSIM circuit diagrams

Contents of the CD-ROM


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.

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.

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.

A number of videos of industrial applications complete the media for the training

package. Short sequences are shown of practice-related applications.

Industrial applications

Presentations

Product information

Videos


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.

Description Order No. Quantity

2 x 3/2-way way solenoid valve, normally open 539776 1

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

Equipment set Basic Level (TP201)

Equipment set Basic:

Level (TP201

Order No.: 540712)


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.

Training aims of Basic Level (TP201)

Festo Didactic GmbH & Co. KG 541091 A-1

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


the use of an EMERGENCY-STOP function ______________________A-85


the use of an EMERGENCY-STOP FUNCTION ____________________A-95


the use of an EMERGENCY-STOP function____________________ A-103

Exercise 12: Eliminating a fault on a machining station ___________________ A-113

Contents

Contents

A-2 Festo Didactic GmbH & Co. KG 541091


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


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.

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.

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.

Exercise 1: Realising a diverting device

Training aims

Problem definition

Parameters

Project task



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.

Positional sketch




Name: Date:

Fundamentals: Installation costs Sheet 1 of 5

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

control system should be selected such as to keep the sum total of equipment,

installation and maintenance costs as low as possible. The following choices are

available as regards wiring:

Conventional wiring technology, e.g. terminal strips

Advanced installation concepts, e.g. wiring using multi-pin connectors

The following choices are available in respect of configuration, i.e. number of drives

and tubing requirements:

Individual mounting of solenoid operated directional control valves

Block mounting (manifold or valve terminal)




Name: Date:


Compare the above listed concepts using the example of this control system in

terms of reducing the tubing costs.

Note

Use the individual valves from TP201 or the MPA valve terminal from TP202 and the

respective technical descriptions.

Components Individual mounting

of directional control

valves

Block mounting of

directional control

valves

Saving when using

block mounting

Tubing

Number of compressed

air distribution units

Amount of tubing for

supply to compressed air

distribution unit

Amount of tubing for

compressed air supply to

control chains

Amount of tubing

between directional

control valves and

cylinders

Silencers

Number of silencers for

control chains




Name: Date:


Which concept enables you to achieve a reduction in tubing costs? Explain the

reason for your choice.

Note



Reason Individual mounting

of directional control

valves

Block mounting of

directional control

valves




Name: Date:


Compare the above listed concepts using the example of this control system with

regard to reducing wiring costs

Note

Use the individual valves of TP201 or the MPA valve terminal from TP202 and the


Wiring table

Components Cables Number of

terminals/components

Conventional wiring

technology

Number of

terminals/components

Multi-pin wiring concept

Control cabinet 1 1

Earthing cable

Supply voltage (24 V)

PLC outputs (actuation of solenoid

coils)

Terminal strip 1 in control cabinet

PLC inputs (evaluation of proximity

sensors)

Terminal strip 1 in control cabinet, overall

Cable from control cabinet to

terminal box

Cable between terminal strips 1 and

2

Proximity sensors (3 wires per

proximity sensor)

Cable from terminal strip 2

(in terminal box)

Solenoids

(2 wires per solenoid)

Terminal strip 2, overall

Connection of solenoid coils Cable to directional control valves

and sensors Connection of sensors




Name: Date:

Fundamentals: Reducing the wiring costs Sheet 5 of 5

Which concept enables you to achieve a reduction in wiring costs? Explain the

reason for your choice.

Note



Reason Conventional wiring

technology

Multi-pin wiring

concept




Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

Complete the pneumatic circuit diagram for the diverting device.

24

35

1

Pneumatic circuit diagram with individual valve




Name: Date:


Complete the pneumatic circuit diagram for the diverting device.

14 14 14 1412 12

-M1 -M1 1M1 -M11M2 -M2

0V1

-V- -V- 1V1 -V-4 4 4 42 2 2 2

S M M J J

12/14 12/14 12/14 12/14 12/14

82/84 82/84 82/84 82/84 82/84 82/84

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

1 1 1 1 1 1

1

12/14

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




Name: Date:


Complete the electrical circuit diagram for the diverting device.

1 2+24 V

0 V

3 4

A1 A1

A2 A2

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141

Electrical circuit diagram




Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires

an equipment list.

Compile the equipment list by entering the required equipment in the table

below.

Quantity Description

Equipment list

festo

Documents

exercises exercise

allocation of training

training purposes

training situation

use festo didactic gmbh

festo didactic learning

allocation of equipment

advanced level tp202