Electrohydraulics Festo

Electrohydraulics
Advanced Level
Workbook
TP 602
With CD-ROM
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Festo Didactic
551153 en
Order no. 551153
Revision level: 03/2012
Authors: Renate Aheimer, Eberhard Bauer, Frank Ebel,
Christine Löffler, Annabella Zimmermann
Graphics: Thomas Ocker, Doris Schwarzenberger
Layout: 03/2012, Susanne Durz, Beatrice Huber, Christine Löffler
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

All rights reserved.
+49 711 3467-0 www.festo-didactic.com
+49 711 34754-88500 [email protected]
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
• The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her
own training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical
colleges and training centres, the right of use shall also include use by school and college students and
trainees at the purchaser's site/location for teaching purposes.
• The right of use shall in all cases exclude the right to publish the copyright material or to make this
available for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow
access by a wide variety of users, including those outside of the purchaser's site/location.
• Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part,
shall require the prior consent of Festo Didactic.
Table of Contents
Use for intended purpose ____________________________________________________________________ V

Preface ___________________________________________________________________________________ VI
Introduction _____________________________________________________________________________ VIII
Work and safety instructions ________________________________________________________________ IX
Training package TP 602 – Electro-hydraulics, advanced level ____________________________________ XI
Learning objectives, electro-hydraulics ________________________________________________________ XII
Allocation of learning objectives to exercises __________________________________________________ XIII
Equipment set ____________________________________________________________________________ XIV
Allocation of components to exercises ________________________________________________________ XVII
Notes for the teacher/trainer _______________________________________________________________ XVIII
Structure of the exercises __________________________________________________________________ XIX
Component designations ____________________________________________________________________ XX
CD ROM contents __________________________________________________________________________ XX
Exercises and solutions
Exercise 1: Clamping valve manifolds _______________________________________________________ 3

Exercise 2: Mounting plastic bearings ______________________________________________________ 15
Exercise 3: Milling workpieces ____________________________________________________________ 33
Exercise 4: Deep drawing sheet metal blanks________________________________________________ 51
Exercise 5: Polishing covers ______________________________________________________________ 67
Exercise 6: Stamping figures in a metal strip ________________________________________________ 79
Exercise 7: Forming sheet metal parts ______________________________________________________ 91
Exercise 8: Opening and closing a drying oven door in inching mode ___________________________ 103
Exercise 9: Producing internal profiles with emergency stop function ___________________________ 115
Exercise 10: Veneering panels with emergency stop function __________________________________ 129
Exercise 11: Cutting profiles to length ______________________________________________________ 141
Exercise 12: Eliminating a malfunction in a milling machine ____________________________________ 153
© Festo Didactic 551153 III

Exercises and worksheets

IV © Festo Didactic 551153

Use for intended purpose
The training package for advanced level electro-hydraulics may only be used:
• For its intended purpose in teaching and training applications
• When its safety functions are in flawless condition
The components included in the training package are designed in accordance with the latest technology as
well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and
the components may be impaired, if they are used incorrectly.
The learning system from Festo Didactic has been developed and produced exclusively for training and
continuing vocational education in the field of automation technology. The training companies and/or
trainers must ensure that all trainees observe the safety instructions described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment sets in situations which serve any
purpose other than training and/or vocational education, unless such damages have been caused by Festo
Didactic due to malicious intent or gross negligence.
© Festo Didactic 551153 V

Preface
Festo Didactic’s training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The learning system is therefore broken down as follows:
• Technology-oriented training packages
• Mechatronics and factory automation
• Process automation and control technology
• Mobile robotics
• Hybrid learning factories
The training system for automation and technology is continuously updated and expanded in accordance
with developments in the field of education, as well as actual professional practice.
The technology packages deal with various technologies including pneumatics, electro-pneumatics, closed-
loop pneumatics, hydraulics, electro-hydraulics, proportional hydraulics, closed-loop hydraulics, mobile
hydraulics, programmable logic controllers, sensor technology, electrical engineering, electronics and
electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and
electric drives is possible.
VI © Festo Didactic 551153

All training packages feature the following elements:
• Hardware
• Media
• Seminars
Hardware
The hardware in the training packages is comprised of industrial components and systems that are specially
designed for training purposes. The components contained in the training packages are specifically
designed and selected for the projects in the accompanying media.
Media
The media provided for the individual topics consist of a mixture of teachware and software. The teachware
includes:
• Technical literature and textbooks (standard works for teaching basic knowledge)
• Workbooks (practical exercises with supplementary instructions and sample solutions)
• Lexicons, manuals and technical books (which provide technical information on groups of topics for
further exploration)
• Transparencies and videos (for easy-to-follow, dynamic instruction)
• Posters (for presenting information in a clear-cut way)
Within the software, the following programmes are available:

• Digital training programmes (learning content specifically designed for virtual training)
• Simulation software
• Visualisation software
• Software for acquiring measurement data
• Project engineering and design engineering software
• Programming software for programmable logic controllers
The teaching and learning media are available in several languages. They are intended for use in classroom
instruction, but are also suitable for self-study.
Seminars
A wide range of seminars covering the contents of the training packages round off the system for training
and vocational education.
Do you have tips, feedback or suggestions for improving this workbook?
If so, please send us an e-mail at [email protected].

The authors and Festo Didactic look forward to your feedback.
© Festo Didactic 551153 VII

Introduction
This workbook is part of the learning system for automation and technology by Festo Didactic. The system
provides a solid basis for practice-oriented training and continuing vocational education. Training packages
TP 601 and TP 602 include electro-hydraulic controllers only.
The TP 601 basic level is suitable for fundamental training in the field of electro-hydraulic control
technology. On the basis of practically oriented problems, the workbook imparts knowledge regarding the
basic physical principles of electro-hydraulics, function and use of electro-hydraulic components and typical,
basic electrical circuits. Simple electro-hydraulic controllers can be set up with the equipment set. Basic
knowledge of hydraulic device technology is a prerequisite.
The TP 602 advanced level is targeted at vocational training in the field of electro-hydraulic control
technology. More advanced electro-hydraulic circuits can be set up with this equipment set. The advanced
circuits include step sequences, time and counting functions, operating modes and emergency stop
functions.
Technical prerequisites for setting up the controllers include:

• A Learnline or Learntop-S workstation equipped with a Festo Didactic slotted profile plate. The slotted
profile plate has 14 parallel T-slots at 50 mm intervals.
• A hydraulic power unit (operating voltage: 230 V, 50 Hz, operating pressure: 6 MPa (60 bar),
volumetric flow rate: 2 l/min.
• A power pack with short-circuit protection (input: 230 V, 50 Hz, output: 24 V, max. 5 A).
• Laboratory safety cables
You will need components included in equipment sets TP 601 and TP 602 in order to complete the
12 exercises. The theoretical fundamentals for understanding these exercises are included in the textbooks:
• Hydraulics, basic level
• Electro-hydraulics, basic level
Data sheets for the individual components are also available (cylinders, valves, sensors etc.).
VIII © Festo Didactic 551153

Work and safety instructions
General information
• Trainees should only work with the circuits under the supervision of a trainer.
• Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
• Malfunctions which may impair safety must not be generated in the training environment, and must be
eliminated immediately.
Mechanical components
• Only reach into the setup when it is at a complete standstill.
• Mount all of the components securely onto the slotted profile plate.
• Limit switches may not be actuated frontally.
• Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
• Set all components up so that activation of switches and disconnectors is not made difficult.
• Adhere to the instructions regarding positioning of the components.
• Always set up cylinders together with the appropriate cover.
Electrical components
• Use extra-low voltage only (max. 24 V DC).
• Electrical connections may only be established in the absence of voltage.
• Electrical connections may only be interrupted in the absence of voltage.
• Use only connecting cables with safety plugs for electrical connections.
• Always pull the safety plug when disconnecting connecting cables – never pull the cable.
Hydraulics
• Limit system pressure to 6 MPa (60 bar).
• Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).
• In the case of double-acting cylinders, pressure could be increased relative to the surface area ratio due
to pressure boosting. With a surface area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), it may
amount to more than 10 MPa (100 bar).
• All valves, devices and hose lines are equipped with self-sealing quick-release couplings.
© Festo Didactic 551153 IX

• Danger of injury when switching on the hydraulic power unit!
Cylinders may advance and retract automatically.
• Connecting hosing lines
– Never connect or disconnect hose lines when the hydraulic power unit is running, or while under
pressure!
Couplings must be connected in the unpressurised state.
– Set the coupling socket vertically onto the coupling nipple!
The coupling socket and the coupling nipple must not be fitted askew.
• Setting up hydraulic circuits
– The hydraulic power unit and the electrical power pack must be switched off when assembling
the circuit.
– Before commissioning, make sure that all tank lines have been connected and that all couplings
have been securely fitted.
– Make sure that hose lines connected to the cylinder are rinsed with hydraulic fluid,
if the volume of oil accommodated by the cylinder is less than the volume which can
be contained by the hose lines.
• Commissioning
– Cylinders may only be commissioned with their covers in place.
– Switch on the electrical power pack first, and then the hydraulic power unit.
• Dismantling hydraulic circuits
– Assure that pressure has been relived before dismantling the circuit.
– In the event that a hydraulic reservoir is used:
Render the reservoir pressure-free and disconnect it from the controller with the help
of the integrated on-off valve before dismantling the hydraulic components.
– Switch off the hydraulic power unit first, and then the electrical power pack.
• If connections are decoupled while under pressure, pressure is trapped in the device by the non-return
valve in the coupling. This pressure can be vented with the pressure relief unit.
Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
• Variant A, snap-in system
Lightweight devices which cannot be subjected to loads (e.g. directional control valves and sensors).
Simply clip the components into the slots on the slotted profile plate. Release the components from the
slots by actuating the blue lever.
• Variant B, bolt system
Components with medium load capacity (e.g. hydraulic cylinders). These components are clamped to
the slotted profile plate with T-head bolts. The blue knurled nut is used for clamping and loosening.
• Variant C, screw system
For devices with high load capacity and devices which are seldom removed from the slotted profile plate
(e.g. the hydraulic power unit). These devices are fastened with socket head screws and T-head nuts.
X © Festo Didactic 551153

Training package TP 602 – Electro-hydraulics, advanced level
The training packages TP 601, TP 602 and TP 610 consist of a multitude of training materials. The subject
matter of this package is advanced electro-hydraulic controllers. Individual components included in training
package TP 602 may also be included in other packages.
Important TP 602 components

• Permanent workstation with Festo Didactic slotted profile plate
• Equipment sets or individual components (e.g. cylinders, valves and pressure gauges)
• Complete set of laboratory equipment
Media
The teachware for the TP 602 training package consists of a textbook and a workbook. The textbook imparts
fundamental electrical and hydraulics knowledge regarding electro-hydraulic controllers in a vivid, clear-cut
fashion. The workbook includes exercise sheets and worksheets for each of the 12 exercises, the solutions
to each individual worksheet and a CD-ROM. A set of ready-to-use exercise sheets and worksheets is
included in each workbook for all of the exercises.
Data sheets for the hardware components are made available along with the equipment set.
Media
Textbooks Hydraulics, basic level

Electro-hydraulics, basic level
Workbooks Electro-hydraulics, basic level (TP 601)

Electro-hydraulics, advanced level (TP 602))
DVD Electro-pneumatics and electro-hydraulics, basic level
Set of posters Hydraulics
Simulation programme FluidSIM® Hydraulic
Digital training programmes Web-based training, hydraulics – basic hydraulics principles

Web-based training, electro-hydraulics – basic electro-hydraulics principles
Web-based training, electrical engineering 1 – basic electrical engineering principles
Web-based training, GRAFCET – introduction to GRAFCET
Overview of media for training packages TP 601 and TP 602
Training programmes including hydraulics, electro-hydraulics and electrical engineering 1 are available as
software for training package TP 602. These training programmes concern themselves in detail with the
basic principles of hydraulics, electro-hydraulics and electrical engineering. The GRAFCET training
programme provides a comprehensive introduction to the new GRAFCET standard. Training content is
elucidated on the basis of practical case studies in a systematic, applications-oriented fashion.
The media are offered in several languages. You can find further training materials in our catalogue and on
the Internet.
© Festo Didactic 551153 XI

Learning objectives
• You will become familiar with the modes of operation of various proximity switches.
• You will learn how to select proximity switches according to technical control requirements
• You will learn how to expand electro-hydraulic control systems and accordingly update the
documentation.
• You will learn how to plan and set up circuits for hydraulic motors.
• You will learn how to utilise 4/3-way solenoid valves with various mid-positions.
• You will learn how to represent control sequences as a GRAFCET.
• You will learn how to plan and set up control sequences as standing sequencers.
• You will learn to recognise overlapping signals in control sequences.
• You will learn how to plan and set up pressure dependent control sequences.
• You will become familiar with the function and possible uses of an on-delay timing relay.
• You will become familiar with options for querying time in electro-hydraulic controllers.
• You will learn how to represent a time-dependent controller in a GRAFCET.
• You will become familiar with the function of an electrical preset counter and learn to use it in electro-
hydraulic controllers.
• You will learn how to use the hydraulic reservoir for emergency operation.
• You will become familiar with simple operating modes and learn how to implement controllers with
single cycle and continuous cycle operating modes.
• You will become familiar with the inching mode as a manual operating mode and learn to integrate it
into a controller.
• You will become familiar with the essential characteristics of emergency stop devices and the
emergency stop function.
• You will become familiar with various emergency stop conditions, which may be required for a given
drive.
• You will learn how to plan and set up an emergency stop function with specified motion sequence for a
controller.
• You will learn how to integrate the reset operating mode into an electro-hydraulic controller.
• You will learn how to detect and eliminate errors in complex electro-hydraulic controllers.
• You will learn how to approach error detection and troubleshooting in a systematic fashion.
XII © Festo Didactic 551153

Allocation of learning objectives to exercises
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning objective
You will become familiar with the modes of operation of

•
various proximity switches.
You will learn how to select proximity switches according to

•
technical control requirements
You will learn how to expand electro-hydraulic control systems

• •
and accordingly update the documentation.
You will learn how to plan and set up circuits for hydraulic
•
motors.
You will learn how to utilise 4/3-way solenoid valves with

•
various mid-positions.
You will learn how to represent control sequences as a

• •
GRAFCET.
You will learn how to plan and set up control sequences as

• •
standing sequencers.
You will learn to recognise overlapping signals in control

•
sequences.
You will learn how to plan and set up pressure dependent

•
control sequences.
You will become familiar with the function and possible uses of
• •
an on-delay timing relay.
You will become familiar with options for querying time in

•
electro-hydraulic controllers.
You will learn how to represent a time-dependent controller in

•
a GRAFCET.
You will become familiar with the function of an electrical

preset counter and learn to use it in electro-hydraulic •
controllers.
You will learn how to use the hydraulic reservoir for emergency
•
operation.
You will become familiar with simple operating modes and

learn how to implement controllers with single cycle and • •
continuous cycle operating modes.
You will become familiar with the inching mode as a manual

•
operating mode and learn to integrate it into a controller.
© Festo Didactic 551153 XIII

Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning objective
You will become familiar with the essential characteristics of

•
emergency stop devices and the emergency stop function.
You will become familiar with various emergency stop

•
conditions, which may be required for a given drive.
You will learn how to plan and set up an emergency stop

• • •
function with specified motion sequence for a controller.
You will learn how to integrate the reset operating mode into
•
an electro-hydraulic controller.
You will learn how to detect and eliminate errors in complex

•
electro-hydraulic controllers.
You will learn how to approach error detection and

•
troubleshooting in a systematic fashion.
Equipment set
The equipment set for the advanced level (TP 602) has been put together for vocational training in the field
of electro-hydraulic control technology. The two equipment sets (TP 601 and TP 602) include all of the
components which are necessary for mastering the predefined learning objectives, and can be
supplemented with other equipment sets as desired.
Electro-hydraulics equipment set, advanced level (TP 602), order no. 573038
Designation Order number Quantity
4/3-way solenoid valve, working lines relieved in mid-position 544348 1
Pressure relief valve, compensated 567237 1
Hydraulic motor 152858 1
Diaphragm accumulator with shut-off block 152859 1
Proximity switch, inductive, M12 548643 1
Emergency stop pushbutton, electrical 183347 1
Relay, 3-way 162241 2
Piloted non-return valve 544339 1
T-distributor 152847 1
Electrical preset counter, cumulative 1677856 1
Time relay, 2-way 162243 1
XIV © Festo Didactic 551153

Graphic symbols, equipment set
Component Graphic symbol
4/3-way solenoid valve, working lines

relieved in mid-position A B
M1 M2
P T
M1
M2
Pressure relief valve, compensated

P
Hydraulic motor
Diaphragm accumulator with shut-off block
1 0 2
P T
Proximity switch, inductive, M12

1
4
Emergency stop pushbutton, electrical
© Festo Didactic 551153 XV

Component Graphic symbol
Relay, 3-way
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
Piloted non-return valve

B
A X
T-distributor
Electrical preset counter, cumulative
0
A1 R1 1
A2 R2 4 2
Time relay, 2-way
17 27 35 45
A1
A2
18 28 36 46
17 27 35 45
A1
A2
18 28 36 46
XVI © Festo Didactic 551153

Allocation of components to exercises
Equipment sets TP 601 and TP 602
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Component
4/3-way solenoid valve, working lines

1 1 1
relieved in mid-position
Pressure relief valve, compensated 1 1
Hydraulic motor 1 1
Diaphragm accumulator with shut-off block 1 1
Proximity switch, inductive, M12 1 1
Emergency stop pushbutton, electrical 1 1 1
Relay, 3-way 1 2 1 1 1 1 2 2
Piloted non-return valve 1 1 1
T-distributor 1 1 1 1 1
Electrical preset counter, cumulative 1
Time relay, 2-way 1 1
2-way flow control valve 1 1 1 1 1 1 1 1 1 1
4/2-way solenoid valve with spring return 1 1 1 1 1 1 1
4/2-way double solenoid valve, detenting 1 1 1 1
4/3-way solenoid valve, mid-position closed 1 1 1 1
On-off valve 1 1 1 1 1 1 1 1 1 1 1 1
Mounting kit for cylinders 1 1 1 1 1 1 1
Double-acting cylinder, 16/10/200, with cover 1 1 2 1 1 1 1 1 1 1 1 2
One-way flow control valve 1 1 1 1 1 1 1 1 1 1
Pressure relief valve 1 1 1 1 1 1 1 1
Pressure gauge 2 2 2 2 2 2 2 2 1 1 2 2
Pressure switch, electronic 1 1 1 1 1 1
9 kg weight for cylinder 1 1 1 1 1
Electrical limit switch 1 2 2 2 2 2 2
Proximity switch, electronic 2 1 2 2 2 1 1
Relay, 3-way 2 2 2 2 2 2 2 2 2 2 2 2
Non-return valve in the hose, opening pressure: 0.6 MPa 1 1 1 1
Signal input, electrical 1 1 1 1 1 1 1 1 1 1 1 1
T-distributor 2 2 1 2 2 2 2 1 2
4-way manifold plate with pressure gauge 2 2 2 2 2 2 2 2 2 2 2 2
* Components with grey background come from equipment set TP 601.
© Festo Didactic 551153 XVII

Required accessories
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Component
Cover for weight 1 1 1 1 1
Hydraulic power unit 1 1 1 1 1 1 1 1 1 1 1 1
Power pack, 24 V DC 1 1 1 1 1 1 1 1 1 1 1 1
Hose line, 600 mm 3 8 8 5 6 5 5 5 5 7 8 8
Hose line, 1000 mm 2 3 4 2 3 2 4 3 2 2 4
Hose line, 1500 mm 2 2 2 2 2 2 2 2 2 2 2 2
Notes for the teacher/trainer
Learning objectives
The basic learning objective of this workbook is to understand, plan, set up and safely commission
advanced electro-hydraulic circuits. The advanced circuits include step sequences, time and counting
functions, operating modes and emergency stop functions. This knowledge is gained by means of
theoretical questions and by actually setting up the circuits on the slotted profile plate. Direct interplay of
theory and practice ensures fast progress and long-lasting learning. The more specific learning objectives
are documented in the matrix. Concrete, individual learning objectives are assigned to each exercise.
Required time
The time required for working through the exercises depends on the learner’s previous knowledge of the
subject matter. Each exercise should take approximately 1 to 1½ hours.
Equipment set components

The textbook, the workbook and the equipment set are matched to each other. All 12 exercises can be
completed using components from one TP 601 and one TP 602 equipment set.
Each exercise can be set up on a slotted profile plate with a width of 1100 mm.
Standards
The following standards are applied in this workbook:
ISO 1219-1 Fluid power systems and components – Graphic symbols and circuit diagrams
EN 60617-2 to EN 60617-8 Graphic symbols for diagrams
EN 81346-2 Industrial systems, installations and equipment and industrial products;
structuring principles and reference designations
Identification in the workbook

Solutions and supplements in graphics or diagrams appear in red.
XVIII © Festo Didactic 551153

Identification in the set of exercises
Texts which require completion are identified with a grid or grey table cells.
Graphics and diagrams which require completion include a grid.
Notes for the lesson

Additional information is provided here regarding the didactic-methodological procedure, the individual
components and the completed controllers. These notes are not included in the set of exercises.
Solutions
The solutions specified in this workbook result from test measurements. The results of your measurements
may vary from these data.
Learning topics
The table below contains an overview of the learning topics offered by educational institutions for selected
professions on the subject matter of “advanced electro-hydraulic circuits”.
Vocation Subject
Mechatronics technician Examination of the flow of energy and information in electrical, pneumatic and hydraulic
assemblies
Implementation of mechatronic subsystems
Commissioning, troubleshooting and repair
Industrial mechanic Installation and commissioning of technical control systems
Electronics engineer for automation Analysing and adapting control systems

technology
Systems implementation and safety testing
Implementing automation systems
Structure of the exercises
All 12 exercises have the same structure and are broken down into:
• Title
• Learning objectives
• Problem description
• Layout
• Project assignments
• Work aids
• Worksheets
The workbook includes the solutions for all of the worksheets for all 12 exercises.
© Festo Didactic 551153 XIX

Component designations
Components are designated in circuit diagrams in accordance with DIN ISO 1219-2. All of the components
included in any given circuit have the same primary identifying number. Letters are assigned depending on
each respective type of component. Consecutive numbers are assigned if several components of the same
type are included within a single circuit.
Cylinders: 1A1, 2A1, 2A2 ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 …
Sensors: 1B1, 1B2 ...
Signal input: S1, S2 …
Accessories: 0Z1, 0Z2, 1Z1 …
Contents of the CD-ROM
The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional
media.
The CD-ROM contains the following folders:

• Operating instructions
• Illustrations
• Data sheets
• FluidSIM® circuit diagrams
• Presentations
Operating instructions
Operating instructions are provided for various components included in the training package. These
instructions are helpful when using and commissioning the components.
Illustrations
Photos and graphics of components and industrial applications are made available. These can be used to
illustrate individual tasks or to supplement project presentations.
Data sheets
The data sheets for the components included in the training package are supplied along with the equipment
set, and are additionally available as PDF files.
FluidSIM® circuit diagrams

The FluidSIM® circuit diagrams for all 12 exercises included in the technology package are contained in this
directory.
Presentations
Short presentations for components included in the training package are included in this directory. They can
be used, for example, for the creation of project presentations.
XX © Festo Didactic 551153

Table of Contents
Exercises and solutions

© Festo Didactic 551153 1

2 © Festo Didactic 551153
Exercise 1:
Clamping valve manifolds
Learning objectives
After completing this exercise:
• You will be familiar with the modes of operation of various proximity switches.
• You will know how to select proximity switches according to technical control requirements.
• You will know how to expand electro-hydraulic control systems and accordingly update the
documentation.
Problem description
Valve manifolds are surface milled at an assembly unit. The valve manifolds are clamped before they are
milled. Clamping is triggered by actuating a pushbutton.
Supplement the clamping device’s controller. Clamping must not be triggered until a valve manifold is
automatically detected in the workpiece holding fixture.
Layout
Clamping device for valve manifolds

Exercise 1 – Clamping valve manifolds
Description of the process

1. The clamping cylinder is in the rear end-position. A valve manifold is located in the workpiece holding
fixture. The valve manifold is detected by a suitable proximity switch.
2. After briefly activating pushbutton S1 used for clamping, the clamping cylinder’s piston rod advances
until it reaches the valve manifold. The valve manifold is clamped.
3. The valve manifold is machined.
4. After briefly activating pushbutton S2 used for opening the clamping device, the piston rod is once
again retracted.
Project assignments
1. Describe the essential characteristics of inductive, capacitive and optical proximity switches.
2. Select a suitable proximity switch for detecting the valve manifold.
3. Supplement the hydraulic and electrical circuit diagrams for the clamping device.
4. Complete the equipment list.
5. Set up the controller.
6. Double check the controller configuration.
7. Describe the controller’s working sequence.
Visual inspection
Continuous visual inspection for defects in hoses and hydraulic devices is an essential part of
hydraulic safety standards.
Work aids
• Data sheets, operating instructions
• Electro-hydraulics textbook
• Web-based training, electro-hydraulics
• FluidSIM® Hydraulic simulation software

1. Describing the essential characteristics of proximity switches
Information
Electronic sensors include inductive, optical and capacitive proximity switches. No movable contact
is switched over with these sensors. Instead, the output is either electronically connected to supply
voltage or to ground (= output voltage of 0 V).
a) Complete the circuit symbol for the inductive proximity switch.
Prerequisite
• The switch is laid out as an NO contact.
Inductive proximity switch – circuit symbol
b) Describe the mode of operation of the inductive proximity switch.
Inductive proximity switches are equipped with an oscillator circuit. When voltage is applied to the
terminals, the oscillator circuit generates a high-frequency electromagnetic field which is emitted from
the front of the proximity switch. If an electrically conductive material is brought within the range of
the electromagnetic stray field, oscillation is attenuated. Attenuation of the oscillator is evaluated
electronically, and provides the output signal.
c) Describe the type of material which is detected by an inductive proximity switch.
Inductive proximity switches can be used to detect all good electrical conductors, for example graphite
as well as metals.

d) Complete the table with entries for the inductive proximity switch’s technical data. Use the required
data from the data sheet for the inductive proximity switch.
Parameter Value
Operating voltage 10 to 30 V DC
Sensing range 0 to 4 mm
Switching frequency Max. 2000 Hz
Switching output PNP, NO contact
Switching current Max. 200 mA
Connection Sockets for 4 mm safety plugs
Protection IP 67
Inductive proximity switch – excerpt from the technical data
e) Explain the meaning of “PNP switching output”.
PNP switching output means: The proximity switch’s signal line is switched to positive potential in the
actuated state. These proximity switches are also called positive switching proximity switches or
sensors.
f) Supplement the circuit. Connect the inductive proximity switch to supply power and connect its output
to a relay which serves as a load. Designate the proximity switch’s terminals.
Inductive proximity switch – connection in the circuit diagram

g) Explain how you determine the switching status of the proximity switch.
A yellow LED indicates the switching status of the inductive proximity switch.
h) Capacitive and optical proximity switches are also used in controllers.

Name the proximity switches shown below.
Capacitive proximity switch Optical proximity switch
i) Describe the type of material which is detected by a capacitive proximity switch.
Capacitive proximity switches not only respond to materials with good electrical conductivity, i.e.
metals, but rather to all insulators with high dielectric constants as well such as plastics, glass,
ceramic, liquids and wood.
j) Optical proximity switches make use of optics and electronics in order to detect objects. Red or infrared
light is utilised to this end.
Describe the mode of operation of the reflex light sensor as an example of an optical proximity switch.
Optical proximity switches consist of two main modules: the emitter and the receiver. In the case of
reflex light sensors, both are located in a single housing. If the light emitted by the proximity switch
strikes a reflective surface, it is redirected to the receiver. The proximity switch’s output is switched.
This mode of operation means that reflex light sensors can only be used if the workpiece or machine
part to be detected is highly reflective.

k) List material surfaces which are highly reflective.
For example, metallic surfaces and surfaces with bright colours are highly reflective.
2. Selecting a suitable proximity switch for detecting valve manifolds

The proximity switch has to detect whether or not a workpiece (valve manifold) is located in the clamping
device’s workpiece holding fixture.
Requirements for the proximity switch include:

• The workpiece to be detected is made of metal with a reflective surface.
• As a result of machining processes which take place close to the clamping device, the surrounding air
contains lots of material and contamination particles. For this reason, the proximity switch should be
insensitive to dust and vibration.
• The workpiece has to be sensed in a contactless fashion.
– Select a suitable proximity sensor and explain why it fulfils the specified requirements.
 Mechanical limit valve

 Capacitive proximity switch
 Inductive proximity switch
 Optical proximity switch
The mechanical limit switch does not fulfil the requirements because it is not contactless.
The capacitive proximity switch does not fulfil the requirements because it does not function correctly
in environments with large amounts of particles and other contamination.
The inductive proximity switch fulfils the requirements. It works in a contactless fashion and is
The optical proximity switch does not fulfil the requirements because it does not function correctly in
environments with large amounts of particles and other contamination.

3. Supplementing the hydraulic and electrical circuit diagrams for the clamping device
a) Determine whether or not supplementing the controller with an additional proximity switch will
influence the hydraulic circuit, and explain your conclusions.
1A1 1B1
1Z1 1Z2
1V2 B
1V1 A B
1M1 1M2
P T
0Z1
0V1
5 MPa
(50 bar)
Hydraulic circuit diagram for the clamping device
Functions of the hydraulic power section
Clamping speed is adjustable.
The clamping device is opened in an unthrottled manner.
Two pressure gauges are included on the cylinder for maintenance personnel.
The clamping cylinder is retracted in its initial position.
Safe commissioning is supported by a pump bypass circuit.
The changes to the signal control section of the clamping device do not have any effect on its
hydraulic circuit.

b) Complete the list of conditions for electrical signal control at the clamping device.
Conditions for electrical signal control
Two pushbuttons are provided for operating the clamping device:

– Pushbutton S1 for clamping
– Pushbutton S2 for releasing
The initial position of the clamping cylinder is detected by limit switch 1B1.
The workpiece needs to be detected by inductive sensor B1.
The control circuit and the power circuit are isolated within the clamping device’s controller.
The valve does not change its current switching position in the event that electrical control energy should fail.
c) Supplement the electrical circuit diagram for the clamping device. Add any missing circuit symbols.
Identify the individual components and enter the missing port designations. Complete the switching
element tables.
S1: clamp S2: release

Electrical circuit diagram for the clamping device

d) Specify the current paths which are used for signal input, signal logic and signal output.
Function Current path
Signal input 1–5
Signal logic 6
Signal output 7–8
4. Completing the equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Complete the equipment list. Enter quantity, identification and designation of the required components.
Quantity Identification Designation
1 1A1 Double-acting cylinder with cover
2 1Z1, 1Z2 Pressure gauge
1 1V2 One-way flow control valve
1 1V1 4/2-way double solenoid valve, detenting
1 0V1 On-off valve
3 — Hose line, 600 mm
2 — 4-way manifold plate with pressure gauge
1 — Hydraulic power unit
Hydraulic components
2 S1, S2 Pushbutton (normally open)
1 B1 Proximity sensor, inductive
1 1B1 Limit switch, electrical, actuated from the right
5 K1, K2, K3, K4, K5 Relay
2 1M1, 1M2 Solenoid coils for 4/2-way double solenoid valve 1V1
1 — Power pack, 24 V DC

5. Setting up the controller

Observe the following points when setting up the controller:
• Set the pressure-relief valve at the hydraulic power unit to a pressure of 6 MPa (60 bar) before setting
up the circuit.
• Use the circuit diagram.
• Designate the components.
pressure! Couplings must be connected in the unpressurised state.
• Selecting and laying hose lines
– Select the hose line length such that adequate leeway is available
in order to accommodate changes in length which result from pressure.
– Avoid mechanical stressing of the hose line.
– Do not bend the hose line into a radius of less than its specified minimum bending radius of 51 mm.
– Do not twist the hose line during installation.
– Make sure that hose lines do not become kinked.
• Position the inductive proximity switch on the slotted assembly board such that the output signal can
be safely triggered with a metallic object.
A screwdriver, for example, can be used as a metal object by means of which the output signal is briefly
generated. If the proximity switch is mounted such that it detects a valve manifold, the output signal will
be continuously generated.
• Mark the completed hose connections in the hydraulic circuit diagram.
• Mark the installed connecting lines in the hydraulic circuit diagram.
6. Double checking the controller setup
a) Safe commissioning is supported by protection circuits and safety measures. Explain the advantage of a
tank bypass circuit during commissioning.
Advantages of the tank bypass circuit:

• If the system should malfunction, it can be rendered pressure-free immediately, without
having to shut down the hydraulic power unit.
• Pressure can be built up gradually within the system, until the desired maximum pressure is
reached.

b) What needs to be taken into consideration with regard to commissioning the 4/2-way double solenoid
valve?
Double solenoid valves do not have a defined initial position. As a result, cylinders may advance or
retract automatically when the system is pressurised with hydraulic fluid.
In order to assure that the 4/2-way double solenoid valve is in the switching position which is
depicted as the initial position in the circuit diagram, the solenoid in coil 1M2 must be briefly
activated.
c) Explain your procedures for commissioning the controller.
1. Make sure that all tank lines have been connected and that all couplings have been securely
fitted.
2. Make sure that the cover has been correctly mounted to the cylinder.
3. Fully close the one-way flow control valve, and then open the restrictor by one half of one
revolution.
4. Switch to pump recirculation by opening the on-off valve.
5. Switch 24 V DC control voltage on.
6. Switch the hydraulic power unit on.
7. Check the system’s initial position. Use the components’ status indicators to this end.
8. Slowly close the on-off valve until a circulating pressure of approximately 1.5 MPa (15 bar)
prevails.
Immediately set the pump back to recirculation in the event of leaks.
9. Run the sequence once and watch for leaks.
In doing so, trigger a signal from inductive proximity switch B1.
The signal indicates the presence of a workpiece.
10. Fully close the on-off valve and set the pressure limit at the hydraulic power unit to the
specified value of 5 MPa (50 bar).
11. Allow the controller to run through several complete cycles.
12. Select the desired advancing speed by closing the one-way flow control valve to the required
extent.
d) What has to be assured when setting up the circuit for the one-way flow control valve?
The one-way flow control valve must be opened all the way before setting up the circuit.

7. Describing the controller sequence
– Describe the individual steps of the controller sequence.
Initial position
In its initial position, cylinder 1A1 is in the rear end-position. Limit switch 1B1 (NO contact) is
actuated, relay K3 is picked up, changeover contact K3 (connected as an NO contact) in current path 6
is closed.
Inductive proximity switch B1 (NO contact) has detected a workpiece, relay K4 is picked up,
changeover contact K4 (connected as an NO contact) in current path 6 is closed.
Step 1-2 (clamping)

When pushbutton S1 (NO contact) is activated, relay K1 is picked up. Changeover contact K1
(connected as an NO contact) in current path 6 is closed. Relay K5 is picked up, changeover contact K5
(connected as an NO contact) in current path 7 is closed. The electrical circuit of solenoid coil 1M1 at
4/2-way double solenoid valve 1V1 is closed. Double solenoid valve 1V1 is reversed as a result.
Cylinder 1A1 advances.
As soon as pushbutton S1 or limit switch 1B1 is no longer activated, relay K5 is released and
changeover contact K5 in current path 7 is opened. As a result, the flow of current to solenoid coil 1M1
is interrupted. Valve 1V1 is retained in its current switching position by the detent.
Step 2-3 (release)

When pushbutton S2 (NO contact) is activated, relay K2 is picked up. Changeover contact K2
(connected as an NO contact) in current path 8 is closed. The electrical circuit of solenoid coil 1M2 at
4/2-way double solenoid valve 1V1 is closed. Double solenoid valve 1V1 is reversed as a result.
Cylinder 1A1 is retracted.
As soon as pushbutton S2 is no longer activated, relay K2 is released and changeover contact K2 in

current path 8 is opened. As a result, the flow of current to solenoid coil 1M2 is interrupted. Valve 1V1
is retained in its current switching position by the detent.

Table of Contents
Exercises and worksheets


Exercise 1:
Clamping valve manifolds
Learning objectives
After completing this exercise:
• You will be familiar with the modes of operation of various proximity switches.
• You will know how to select proximity switches according to technical control requirements.
• You will know how to expand electro-hydraulic control systems and accordingly update the
documentation.
Problem description
Valve manifolds are surface milled at an assembly unit. The valve manifolds are clamped before they are
milled. Clamping is triggered by actuating a pushbutton.
Supplement the clamping device’s controller. Clamping must not be triggered until a valve manifold is
automatically detected in the workpiece holding fixture.
Layout
Clamping device for valve manifolds

Description of the process

1. The clamping cylinder is in the rear end-position. A valve manifold is located in the workpiece holding
fixture. The valve manifold is detected by a suitable proximity switch.
2. After briefly activating pushbutton S1 used for clamping, the clamping cylinder’s piston rod advances
until it reaches the valve manifold. The valve manifold is clamped.
3. The valve manifold is machined.
4. After briefly activating pushbutton S2 used for opening the clamping device, the piston rod is once
again retracted.
Project assignments
1. Describe the essential characteristics of inductive, capacitive and optical proximity switches.
2. Select a suitable proximity switch for detecting the valve manifold.
3. Supplement the hydraulic and electrical circuit diagrams for the clamping device.
4. Complete the equipment list.
5. Set up the controller.
6. Double check the controller configuration.
7. Describe the controller’s working sequence.
Visual inspection
Continuous visual inspection for defects in hoses and hydraulic devices is an essential part of
hydraulic safety standards.
Work aids
• Data sheets, operating instructions
• Electro-hydraulics textbook
• Web-based training, electro-hydraulics
• FluidSIM® Hydraulic simulation software
4 Name: __________________________________ Date: ____________ © Festo Didactic 551153

1. Describing the essential characteristics of proximity switches
Information
Electronic sensors include inductive, optical and capacitive proximity switches. No movable contact
is switched over with these sensors. Instead, the output is either electronically connected to supply
voltage or to ground (= output voltage of 0 V).
a) Complete the circuit symbol for the inductive proximity switch.
Prerequisite
• The switch is laid out as an NO contact.
Inductive proximity switch – circuit symbol
b) Describe the mode of operation of the inductive proximity switch.
c) Describe the type of material which is detected by an inductive proximity switch.
© Festo Didactic 551153 Name: __________________________________ Date: ____________ 5

d) Complete the table with entries for the inductive proximity switch’s technical data. Use the required
data from the data sheet for the inductive proximity switch.
Parameter Value
Operating voltage
Sensing range
Switching frequency
Switching output
Switching current
Connection
Protection
Inductive proximity switch – excerpt from the technical data
e) Explain the meaning of “PNP switching output”.
f) Supplement the circuit. Connect the inductive proximity switch to supply power and connect its output
to a relay which serves as a load. Designate the proximity switch’s terminals.
Inductive proximity switch – connection in the circuit diagram

g) Explain how you determine the switching status of the proximity switch.
h) Capacitive and optical proximity switches are also used in controllers.

Name the proximity switches shown below.
i) Describe the type of material which is detected by a capacitive proximity switch.
j) Optical proximity switches make use of optics and electronics in order to detect objects. Red or infrared
light is utilised to this end.
Describe the mode of operation of the reflex light sensor as an example of an optical proximity switch.

k) List material surfaces which are highly reflective.
2. Selecting a suitable proximity switch for detecting valve manifolds

The proximity switch has to detect whether or not a workpiece (valve manifold) is located in the clamping
device’s workpiece holding fixture.
Requirements for the proximity switch include:

• The workpiece to be detected is made of metal with a reflective surface.
• As a result of machining processes which take place close to the clamping device, the surrounding air
contains lots of material and contamination particles. For this reason, the proximity switch should be
• The workpiece has to be sensed in a contactless fashion.
– Select a suitable proximity sensor and explain why it fulfils the specified requirements.
 Mechanical limit valve

 Capacitive proximity switch
 Inductive proximity switch
 Optical proximity switch

3. Supplementing the hydraulic and electrical circuit diagrams for the clamping device
a) Determine whether or not supplementing the controller with an additional proximity switch will
influence the hydraulic circuit, and explain your conclusions.
1A1 1B1
1Z1 1Z2
1V2 B
1V1 A B
1M1 1M2
P T
0Z1
0V1
5 MPa
(50 bar)
Hydraulic circuit diagram for the clamping device
Functions of the hydraulic power section
Clamping speed is adjustable.
The clamping device is opened in an unthrottled manner.
Two pressure gauges are included on the cylinder for maintenance personnel.
The clamping cylinder is retracted in its initial position.
Safe commissioning is supported by a pump bypass circuit.

b) Complete the list of conditions for electrical signal control at the clamping device.
Conditions for electrical signal control
Two pushbuttons are provided for operating the clamping device:

– Pushbutton S1 for clamping
– Pushbutton S2 for releasing
The initial position of the clamping cylinder is detected by limit switch 1B1.
The control circuit and the power circuit are isolated within the clamping device’s controller.
The valve does not change its current switching position in the event that electrical control energy should fail.
c) Supplement the electrical circuit diagram for the clamping device. Add any missing circuit symbols.
Identify the individual components and enter the missing port designations. Complete the switching
element tables.
24 V 1 2 3 4 5 6 7 8
13 13 2 4
S1 S2 1B1
14 14 1
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 1M1 1M2
A2 A2 A2 A2 A2
0V 12 12 12 12 12
11 14 11 14 11 14 11 14 11 14 1A1+ 1A1-
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
S1: clamp S2: release

Electrical circuit diagram for the clamping device

d) Specify the current paths which are used for signal input, signal logic and signal output.
Function Current path
Signal input
Signal logic
Signal output
4. Completing the equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Complete the equipment list. Enter quantity, identification and designation of the required components.
1 1A1 Double-acting cylinder with cover
2 1Z1, 1Z2 Pressure gauge
1 1V2 One-way flow control valve
1 1V1 4/2-way double solenoid valve, detenting
1 0V1 On-off valve
2 — 4-way manifold plate with pressure gauge
1 — Hydraulic power unit
Hydraulic components
2 S1, S2 Pushbutton (normally open)
1 1B1 Limit switch, electrical, actuated from the right
2 1M1, 1M2 Solenoid coils for 4/2-way double solenoid valve 1V1
1 — Power pack, 24 V DC

5. Setting up the controller

Observe the following points when setting up the controller:
• Set the pressure-relief valve at the hydraulic power unit to a pressure of 6 MPa (60 bar) before setting
up the circuit.
• Use the circuit diagram.
• Designate the components.
pressure! Couplings must be connected in the unpressurised state.
• Selecting and laying hose lines
– Select the hose line length such that adequate leeway is available
in order to accommodate changes in length which result from pressure.
– Avoid mechanical stressing of the hose line.
– Do not bend the hose line into a radius of less than its specified minimum bending radius of 51 mm.
– Do not twist the hose line during installation.
– Make sure that hose lines do not become kinked.
• Position the inductive proximity switch on the slotted assembly board such that the output signal can
be safely triggered with a metallic object.
A screwdriver, for example, can be used as a metal object by means of which the output signal is briefly
generated. If the proximity switch is mounted such that it detects a valve manifold, the output signal will
be continuously generated.
• Mark the completed hose connections in the hydraulic circuit diagram.
• Mark the installed connecting lines in the hydraulic circuit diagram.
6. Double checking the controller setup
a) Safe commissioning is supported by protection circuits and safety measures. Explain the advantage of a
tank bypass circuit during commissioning.

b) What needs to be taken into consideration with regard to commissioning the 4/2-way double solenoid
valve?
c) Explain your procedures for commissioning the controller.
d) What has to be assured when setting up the circuit for the one-way flow control valve?

7. Describing the controller sequence
– Describe the individual steps of the controller sequence.
Initial position
Step 1-2 (clamping)
Step 2-3 (release)

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© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

Use for intended purpose ____________________________________________________________________ V

Exercises and solutions

Exercise 1: Clamping valve manifolds _______________________________________________________ 3

© Festo Didactic 551153 III

Exercise 1: Clamping valve manifolds _______________________________________________________ 3

IV © Festo Didactic 551153

© Festo Didactic 551153 V

VI © Festo Didactic 551153

Within the software, the following programmes are available:

Do you have tips, feedback or suggestions for improving this workbook?

If so, please send us an e-mail at [email protected].

© Festo Didactic 551153 VII

Technical prerequisites for setting up the controllers include:

VIII © Festo Didactic 551153

© Festo Didactic 551153 IX

X © Festo Didactic 551153

Important TP 602 components

Textbooks Hydraulics, basic level

Workbooks Electro-hydraulics, basic level (TP 601)

DVD Electro-pneumatics and electro-hydraulics, basic level

Set of posters Hydraulics

Simulation programme FluidSIM® Hydraulic

Digital training programmes Web-based training, hydraulics – basic hydraulics principles

Overview of media for training packages TP 601 and TP 602

© Festo Didactic 551153 XI

XII © Festo Didactic 551153

You will become familiar with the modes of operation of

You will learn how to select proximity switches according to

You will learn how to expand electro-hydraulic control systems

You will learn how to utilise 4/3-way solenoid valves with

You will learn how to represent control sequences as a

You will learn how to plan and set up control sequences as

You will learn to recognise overlapping signals in control

You will learn how to plan and set up pressure dependent

You will become familiar with options for querying time in

You will learn how to represent a time-dependent controller in

You will become familiar with the function of an electrical

You will become familiar with simple operating modes and

You will become familiar with the inching mode as a manual

© Festo Didactic 551153 XIII

You will become familiar with the essential characteristics of

You will become familiar with various emergency stop

You will learn how to plan and set up an emergency stop

You will learn how to detect and eliminate errors in complex

You will learn how to approach error detection and

Designation Order number Quantity

4/3-way solenoid valve, working lines relieved in mid-position 544348 1

Pressure relief valve, compensated 567237 1

Hydraulic motor 152858 1

Diaphragm accumulator with shut-off block 152859 1

Proximity switch, inductive, M12 548643 1

Emergency stop pushbutton, electrical 183347 1

Relay, 3-way 162241 2

Piloted non-return valve 544339 1

Electrical preset counter, cumulative 1677856 1

Time relay, 2-way 162243 1

XIV © Festo Didactic 551153