Workbook Electropneumatics Advanced Level

Electropneumatics
Advanced level
Workbook
TP 202
With CD-ROM
+24 V 8 9 10 11 12 13 14 15 16 17
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K1 K6 K2 K7 K4 K8 K3 K9 K1 K10
11 11 11 11 11 11 11 11 21 21
12 14
K5
11
12 14 22 24 22 24 22 24 22 24
K10 K6 K7 K8 K9
11 21 21 21 21
A1 A1 A1 A1 A1
K6 K7 K8 K9 K10
A2 A2 A2 A2 A2
... ...
0V 12 12 12 12 12
11 14 .9 11 14 .11 11 14 .13 11 14 .15 11 14 .8
22 22 22 22 22
21 24 .10 21 24 .12 21 24 .14 21 24 .16 21 24 .17
32 32 32 32 32
31 34 .18 31 34 .18 31 34 .19 31 34 .20 31 34 .21
42 42 42 42 42
41 44 41 44 .19 41 44 .20 41 44 .21 41 44
1A1+ 2A1+ 2A1- 1A1-
Festo Didactic
541091 EN
Order No.: 541091
Edition: 04/2012
Authors: Wolfgang Haring, Michel Metzger, Ralph-Christoph Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 09/2015, Susanne Durz
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

All rights reserved.
+49 711 3467-0 www.festo-didactic.com
+49 711 34754-88500 did@de.festo.com
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
Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Work instructions and safety precautions ____________________________________________________ VIII
Technology package for electro-pneumatics (TP 200) ____________________________________________X
Learning objectives for the advanced level (TP 202) _____________________________________________ XI
Allocation of learning objectives per exercise _________________________________________________ XII
Equipment set for the advanced level (TP 202) ________________________________________________ XIV
Allocation of components per exercise ______________________________________________________ XVII
Tools for the trainer _____________________________________________________________________ XVIII
Structure of the exercises ________________________________________________________________ XVIII
Designations of the components____________________________________________________________ XIX
CD-ROM contents ________________________________________________________________________ XIX
Learning goals for the basic level (TP 201) ____________________________________________________ XXI
Exercises and solutions
Exercise 1: Implementing a diverting device ____________________________________________________1

Exercise 2: Placing beverage bottles _________________________________________________________ 11
Exercise 3: Implementing a sorting station____________________________________________________ 19
Exercise 4: Machining key blanks ___________________________________________________________ 31
Exercise 5: Bending mounting brackets ______________________________________________________ 41
Exercise 6: Sorting out empty jars from a filling system _________________________________________ 51
Exercise 7: Bonding components ___________________________________________________________ 61
Exercise 8: Selecting operating modes _______________________________________________________ 69
Exercise 9: Machining key blanks with emergency stop function __________________________________ 79
Exercise 10: Bending mounting brackets with emergency stop function ____________________________ 89
Exercise 11: Transporting chocolate bars with emergency stop function ____________________________ 97
Exercise 12: Eliminating a malfunction at a machining station ___________________________________ 107
© Festo Didactic 541091 III

Exercises and worksheets

IV © Festo Didactic 541091

Use for intended purpose
The training package for electropneumatics 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 laid out 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 improperly.
The training system from Festo Didactic has been developed and manufactured exclusively for training and
vocational education in the field of automation technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment 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 541091 V

Preface
Festo Didactic’s training system for automation technology is geared towards various educational
backgrounds and vocational requirements. The training system is therefore broken down as follows:
• Technology-oriented training packages
• Mechatronics and factory automation
• Process automation and control technology
• Robotino® – training and research with mobile robots
• Hybrid learning factories
The technology packages deal with various technologies including pneumatics, electro-pneumatics,
hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,
electrical engineering and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual packages, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.
VI © Festo Didactic 541091

All training modules have the same structure:
• Hardware
• Teachware
• Software
• Seminars
The hardware is comprised of industrial components and systems that are specially designed for training
purposes.
The structure of the teachware corresponds to that of the hardware. It includes:

• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, supplementary instructions and solutions)
• Transparencies and videos (for dynamic instruction)
The teaching and learning media are available in several languages. They’re intended for use in classroom
instruction, but are also suitable for self-study.
Where software is concerned, computer training programs, as well as simulation, visualisation, project
engineering, design engineering and programming software, are made available.
A wide range of seminar offerings covering the contents of the training packages round off the programme
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 did@de.festo.com.

The authors and Festo Didactic look forward to your feedback.
© Festo Didactic 541091 VII

Introduction
This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic.
This system provides a solid basis for practice-oriented vocational and further training. Technology package
TP 200 is comprised exclusively of electropneumatic control systems.
Advanced Level TP 202 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.
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.
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 TP 201 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
• Pneumatics/Electropneumatics
Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices,
etc.).
VIII © Festo Didactic 541091

Work instructions and safety precautions
General
• Trainees should only work with the circuits under the supervision of a trainer.
• Observe specifications included in the data sheets for the individual components and in particular all
safety instructions!
• Faults which may impair safety must not be generated in the training environment and must be
eliminated immediately.
Mechanical setup
• Mount all the components securely onto the profile plate.
• Adhere to instructions regarding positioning of the components.
Electrical setup
• Use low voltage only (max. 24 V DC).
• Electrical connections must only be established and interrupted in the absence of voltage!
• Only use connecting cables with safety plugs for electrical connections.
• Only pull the plug when disconnecting connecting cables – never pull the cable.
Pneumatics
• Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
• Do not switch on the compressed air until all of the tubing connections have been completed and
secured.
• Do not disconnect tubing while under pressure.
• Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
• Danger of accident due to tubing slipping off!
– Use shortest possible tubing connections.
– Wear safety glasses.
– In the event that tubing slips off:
Switch compressed air supply off immediately.
• Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
• Switch compressed air supply off before dismantling the circuit.
• Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.
© Festo Didactic 541091 IX

Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
• Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply
clip the components into the slots on the profile plate. Release the components from the slots by
turning the blue lever.
• Variant B, bolt system
Components with medium load capacity (e.g. pneumatic cylinders). These components are clamped to
the profile plate with T-head bolts. The blue, knurled nut is used for clamping and loosening.
• Variant C, screw system
For components with high load capacity and components which are seldom removed from the profile
plate (e.g. on-off valve with filter regulator). The components are secured with socket head screws and
T-head bolts.
X © Festo Didactic 541091

Technology package for electro-pneumatics (TP 200)
The TP 200 technology package consists of a multitude of training materials and seminars. The subject
matter of this package is electro-pneumatic controllers. The individual components included in the TP 200
technology package can also be included in other modules.
Important elements of the TP 200

• Permanent workstation with Festo Didactic profile plate
• Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)
• Equipment sets or individual components
• Visual training materials
• Practical training models
• Complete laboratory setups
Training documentation
Textbook Fundamentals of pneumatics and electropneumatics

Maintenance of pneumatic components and systems
Workbooks TP 201 basic level

TP 202 advanced level
Optional teachware Set of transparencies and overhead projector

Magnetic symbols, drawing template
Electro-pneumatics WBT, pneumatics WBT
Electrical engineering WBTs 1 and 2, electronics WBTs 1 and 2
Set of cutaway models with storage case
FluidSIM® Pneumatik simulation software
Seminars
P100 Basic pneumatics knowledge for machine operators
P111 Fundamentals of pneumatics and electro-pneumatics
P121 Maintenance and troubleshooting for pneumatic and electro-pneumatic systems
P-OP Tracking down waste – economic use of pneumatics
P-NEU Pneumatics refresher and update
IW-PEP Repair and maintenance in the field of control technology – pneumatic and electro-pneumatic systems
P-AL Pneumatics for vocational education
P-AZUBI Pneumatics and electro-pneumatics for trainees
Please refer to the current seminar schedule for event locations, dates and prices.
You’ll find further training materials in our catalogue and on the Internet. The training system for automation
technology is continuously updated and expanded. Transparency sets, videos, CD-ROMs and DVDs, as well
as textbooks, are offered in several languages.
© Festo Didactic 541091 XI

Learning objectives for the advanced level (TP 202)
• Become familiar with the setup and function of valve terminals.

• Be able to use valve terminals in accordance with specified requirements.
• Be able to create a displacement-step diagram for sequence controls.
• Be able to convert a function chart into a GRAFCET chart.
• Be able to resolve overlapping signals in sequence controls using the group method.
• Recognise overlapping signals in sequence controls.
• Be able to setup a step sequence using valves with spring return.
• Be able to setup a step sequence using double pilot valves.
• Become familiar with the modes of operation of various proximity switches.
• Be able to select proximity switches which are appropriate for the conditions.
• Become familiar with logic operations and implement them.
• Become familiar with the setup and function of a pneumatic-electric converter.
• Become familiar with options for querying pressure and time in electro-pneumatic controllers.
• Become familiar with the possible uses of an on-delay timing relay.
• Become familiar with operating modes and learn to set up circuits with which single cycle and
continuous cycle operating modes can be implemented.
• Become familiar with the function of an electrical preset counter and learn to use it in circuits.
• Be able to develop and set up the emergency stop function for a controller using valves with spring
return.
• Be able to develop and set up the emergency stop function for a controller using double pilot valves.
• Be able to develop and set up a specified motion sequence in the event of an emergency stop.
• Be able to set up the following emergency stop condition: “cylinder remains in its momentary position
in the event of an emergency stop”.
• Become familiar with the setup and mode of operation of a 5/3-way solenoid valve.
• Be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.
• Be able to integrate the reset operating mode into a controller.
• Learn to detect and eliminate errors in complex electro-pneumatic controllers.
XII © Festo Didactic 541091

Allocation of learning objectives per exercise
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning objectives
Become familiar with the setup and function of valve • •

terminals.
Be able to use valve terminals in accordance with • •

specified requirements.
Be able to resolve overlapping signals in sequence •

controls using the group method.
Be able to create a displacement-step diagram for • • •

sequence controls.
Be able to convert a function chart into a GRAFCET •

chart.
Be able to setup a step sequence using valves with •

spring return.
Recognise overlapping signals in sequence controls. •
Be able to setup a step sequence using double pilot •

valves.
Become familiar with the modes of operation of •

various proximity switches.
Be able to select proximity switches which are •

appropriate for the conditions.
Become familiar with logic operations and implement •

them.
Become familiar with options for querying pressure •

and time in electro-pneumatic controllers.
Become familiar with the setup and function of a •

pneumatic-electric converter.
Become familiar with the possible uses of an on-delay •

timing relay.
© Festo Didactic 541091 XIII

Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Learning goals
Become familiar with operating modes and learn to set • •

up circuits with which single cycle and continuous
cycle operating modes can be implemented.
Become familiar with the function of an electrical •

preset counter and learn to use it in circuits.
Be able to develop and set up the emergency stop •

function for a controller using valves with spring
return.
Be able to develop and set up the emergency stop •

function for a controller using double pilot valves.
Be able to develop and set up a specified motion •

sequence in the event of an emergency stop.
Be able to set up the following emergency stop •

condition: “cylinder remains in its momentary position
in the event of an emergency stop”.
Become familiar with the setup and mode of operation •

of a 5/3-way solenoid valve.
Be able to replace a 5/3-way solenoid valve with 3/2- •

way solenoid valves.
Be able to integrate the reset operating mode into a •

controller.
Be able to detect and eliminate errors in complex •

electro-pneumatic controllers.
XIV © Festo Didactic 541091

Equipment set for the advanced level (TP 202)
The equipment set for the advanced level has been put together for vocational training in the field of electro-
pneumatic control technology. The two equipment sets (TP 201 and TP 202) include components which are
necessary for mastering the predefined learning objectives and can be supplemented with other equipment
sets for the training system for automation technology as desired.
Equipment set for the advanced level (TP 202, order no. 540713)
Designation Order no. Quantity
Proximity switch, inductive 548643 1
Proximity switch, capacitive 548651 1
Emergency-stop button 183347 1
Relay, 3-way 162241 2
Non-return valve, piloted 540715 2
Signal input, electrical 162242 1
Valve terminal with 4 valve slices (MMJJ) 540696 1
Preset counter, electrical 1677856 1
Time relay, 2-way 162243 1
© Festo Didactic 541091 XV

Equipment set symbols
Designation 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
Signal input, electrical

13 21
14 22
13 21
14 22
13 21
14 22
13 21
14 22
XVI © Festo Didactic 541091

Designation Symbol
Time relay, 2-way
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
Preset counter, electrical
A1 1 R1
A2 R2
4 2
Proximity switch, inductive
Proximity switch, capacitive
Emergency-stop button
13 21
14 22
Non-return valve, piloted

2
1 21
© Festo Didactic 541091 XVII

Allocation of components per exercise
TP 202 equipment set
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Component
Proximity switch, inductive 1
Proximity switch, 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
Preset counter, electrical 1
Time relay, 2-way 1
XVIII © Festo Didactic 541091

Tools for the trainer
Learning objectives
The basic learning objectives for these exercises are the systematic drafting of circuit diagrams, as well as
the practical setup of the controller on the profile plate. This direct interaction involving both theory and
practice ensures faster progress and longer-lasting learning. Concrete, individual learning objectives are
assigned to each exercise. Important learning objectives are in parentheses in the revision sections.
Required time
The time required for working through the exercises depends on the student’s previous knowledge of the
subject matter. For a skilled labourer in the field of metalworking or electrical installation the time required
is approx. 2 weeks. For a technician or engineer it is approx. 1 week.
Equipment set elements

The exercise book and the equipment set match each other. For all 12 exercises, you’ll need the components
included in the equipment set for the TP 201 basic level.
Each exercise in the basic level can be set up on a profile plate.
Structure of the exercises
All 12 exercises in part A have the same structure and are broken down into:
• Title
• Learning objectives
• Presentation of the problem
• Layout
• Parameters
• Project assignment
• Worksheets
The trainer’s manual includes the solutions for all 12 exercises.
© Festo Didactic 541091 XIX

Designations of the components
Pneumatic components are designated in circuit diagrams in accordance with DIN ISO 1219 2. All the
components included in any given circuit have the same primary identifying number. Letters are assigned
depending on each respective type of component. Consecutive numbers are assigned if several components
of the same type are included within a single circuit. Pressure lines are designated with a P and are
numbered separately.
Drives: 1A1, 2A1, 2A2 ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
Sensors: 1B1, 1B2 ...
Signal inputs: 1S1, 1S2 ...
Accessories: 0Z1, 0Z2, 1Z1 ...
Pressure lines: P1, P2 ...
CD-ROM contents
The CD-ROM supplied provides you with additional media. The contents of parts A (exercises) and C
(solutions) have been saved as PDF files.
The CD-ROM contains the following folders:
• Demo
• FluidSIM® circuit diagrams
• Industrial applications
• Presentations
• Videos
Demo
A demo version of the FluidSIM® pneumatics software package is included on the CD-ROM. This demo
version is also suitable for testing controllers developed by the user.
FluidSIM® circuit diagrams

The FluidSIM® circuit diagrams for all 12 exercises included in the technology package are contained in this
directory.
XX © Festo Didactic 541091

Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks or to supplement project presentations.
Presentations
This directory contains short presentations for the components included in the technology package. These
can be used, for example, to create project presentations.
Videos
Several short videos of industrial applications in their actual environments round off the media provided
with the technology package.
© Festo Didactic 541091 XXI

Learning goals for the basic level (TP 201)
• Become familiar with the setup and mode of operation of a single-acting cylinder.
• Become familiar with the setup and mode of operation of a double-acting cylinder.
• Be able to calculate piston forces based on specified values.
• Become familiar with the setup and mode of operation of a 3/2-way solenoid valve.
• Become familiar with the setup and mode of operation of a double solenoid valve.
• Be able to select solenoid valves based on the specified requirements.
• Be able to recognise and sketch the various types of actuation for directional control valves.
• Be able to convert solenoid valves.
• Be able to explain and set up direct actuation.
• Be able to explain and set up indirect actuation.
• Become familiar with logic operations and set them up.
• Become familiar with various types of end-position control and learn to select the appropriate type.
• Be able to calculate characteristic electrical values.
• Become familiar with latching circuits with varying performance features.
• Be able to explain and set up an electrical latching circuit with dominant breaking signal.
• Be able to set up a pressure dependent controller.
• Become familiar with the setup and mode of operation of magnetic proximity switches.
• Become familiar with displacement-step diagrams and learn to create them for specific problems.
• Be able to implement sequence control with two cylinders.
• Be able to detect and eliminate errors in simple electro-pneumatic controllers.
XXII © Festo Didactic 541091

TP 201 equipment set
Designation Order no. Quantity
2 x 3/2-way solenoid valve, normally closed 567198 1
5/2-way double solenoid valve 567200 2
5/2-way solenoid valve 567199 1
Blanking plug 153267 10
Double-acting cylinder 152888 2
One-way flow control valve 193967 4
Pressure sensor 572745 1
Single-acting cylinder 152887 1
On-off valve with filter regulator 540691 1
Limit switch, electrical, actuated from left 183322 1
Limit switch, electrical, actuated from right 183345 1
Plastic tubing, 4 x 0.75, 10 m 151496 2
Proximity switch, electronic 540695 2
Proximity switch, optical 572744 1
Relay, 3-way 162241 2
Signal input, electrical 162242 1
Push-in sleeve 153251 10
Push-in T-connector 153128 20
Distributor block 152896 1
© Festo Didactic 541091 XXIII

XXIV © Festo Didactic 541091
Contents
Exercises and solutions

© Festo Didactic 541091 XXV

XXVI © Festo Didactic 541091
Exercise 1:
Implementing a diverting device
Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of valve terminals.
• You’ll be able to use valve terminals in accordance with specified requirements.
Presentation of the problem

Beverage bottles will be diverted from one conveyor to another by means of a diverting device. The diverting
panel is advanced when one of the pushbuttons is activated. The bottle is transferred and transported in the
opposite direction. The diverting panel is returned to its initial position when another pushbutton is
activated.
Layout
Diverting device for beverage bottles
© Festo Didactic 541091 1

Exercise 1: Implementing a diverting device
Parameters
• A double-acting cylinder will be used.
• The cylinder will be controlled indirectly via pushbutton.
• In the event of a power failure, the cylinder’s piston rod should remain in its current position.
Project assignment
1. Answer the questions and complete the tasks relating to the learning content.
2. Draw the pneumatic and electrical circuit diagrams.
3. Create an equipment list.
4. Set up the pneumatic and electrical circuits.
5. Check the circuit sequence.
Control sequence
1. Cylinder 1A1 is in the rear end-position.
2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the cylinder travels
to the front end-position.
3. After activating pushbutton S2, 5/2-way double solenoid valve 1V1 is reversed again and the cylinder
travels to the rear end-position.
2 © Festo Didactic 541091

Fundamentals: installation
The layout, tubing and wiring of the components of an electro-pneumatic controller should be selected so
that the total costs for the components, installation and maintenance are as low as possible. With regard to
wiring, selection is made between:
• Conventional wiring technology, e.g. terminal strips
• Modern installation concepts, e.g. wiring with multi-pin plug connection
With regard to layout and the number of drives, as well as tubing, a selection is made between:
• Individual mounting for solenoid operated directional control valves
• Block-type mounting (manifold block or valve terminal)
Comparison of required tubing connections
– Compare the concepts listed above using the controller for this exercise as an example with regard to
minimising tubing connections.
Note
Use the individual valves from TP 201 and the MPA valve terminal from TP 202, as well as the
associated technical descriptions.
Components Individual mounting of Block-type mounting of Savings with block-type

directional control valves directional control valves mounting
Tubing
Number of compressed air 1 0 1

distributors
Number of tubes for supplying 1 0 1

compressed air distributor
Number of tubes for compressed 3 1 2

air supply to the control loops
Number of tubes between 6 6 -

directional control valves and
cylinder
Silencers
Number of silencers for control 6 1 5

loops

Reducing required tube connections
– Which concept enables a reduction of the required tubing connections? Place an X next to your selection
and justify your decision.
Individual mounting of Block-type mounting Reason

directional control of directional control
valves valves
If the directional control valves in the control loops are mounted on a valve
terminal, one length of tubing is adequate for compressed air supply to all control
loops, and one silencer vents all of the exhaust air.
X
Compared with individual mounting, this solution eliminates numerous tubing
connections and silencers, as well as the need for a compressed air distributor.
The amount of work required for tubing is reduced correspondingly.
Note

Comparison of required wiring
– Compare the concepts listed above using the controller for this exercise as an example with regard to
minimising wiring.
Components Cables Number of Number of

terminals/components with terminals/components with
conventional wiring multi-pin plug
Control cabinet 1 1
Terminal strip 1 in the control Earth cable 1 2

cabinet
Supply power (24 V) 1 2
PLC outputs (actuation of 6 6

solenoid coils)
PLC inputs (evaluation of 6 6

proximity switches)
Terminal strip 1 in the control cabinet, total 14 16
Cables from control cabinet to Cables between terminal Cable harness or single cable Cable harness or single cable
terminal box strips 1 and 2 with 14 cores with 8 cores
Terminal strip 2 Proximity switch (3 cores 18 18

(in the control cabinet) per proximity switch)
Solenoids 12 -
(2 cores per solenoid)
Terminal strip 2, total 30 18
Cables to directional control 30 18

valves and sensors
Connection of the solenoid 6 cables with 2 cores each -
coils
Wiring table
Note

Reducing required wiring
– Which concept enables you to reduce the wiring? Place an X next to your selection and justify your
decision.
Conventional wiring Multi-pin plug

Reason
technology
All valves included in the controller are arranged on the MPA valve terminal (with MP
connection).
As compared with conventional wiring, many of the terminals at terminal strip 2 and
X
the cables to the solenoid coils are eliminated when the valve terminal is connected
with a multi-pin plug.
Wiring is thus reduced, and maintenance and troubleshooting are simplified.
Note

Completing the pneumatic circuit diagram with individual valves
– Complete the pneumatic circuit diagram for the diverting device with individual valves.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Pneumatic circuit diagram with individual
Completing the pneumatic circuit diagram with valve terminal
– Complete the pneumatic circuit diagram for the diverting device with valve terminal.
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

Completing the electrical circuit diagram
– Complete the electrical circuit diagram for the diverting device.
+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

Sequence description
– Describe the controller’s working sequence.
Initial position
In its initial position, cylinder 1A1 is in the rear end-position.
Step 1-2
When pushbutton S1 (NO contact) is activated, relay K1 is picked up and changeover contact K1 in
current path 3 is closed.
The electrical circuit of solenoid coil 1M1 is closed. 5/2-way double solenoid valve 1V1 is reversed
as a result.
The piston end of cylinder 1A1 is pressurised while the piston rod end is exhausted. The piston rod
in cylinder 1A1 advances.
As soon as pushbutton S1 (NO contact) is no longer activated, relay K1 is released and changeover
contact K1 in current path 3 is opened.
The electrical circuit of solenoid coil 1M1 is opened.
Step 2-3
When pushbutton S2 (NO contact) is activated, relay K2 is picked up and changeover contact K2 in
current path 4 is closed.
The electrical circuit of solenoid coil 1M2 is closed. As a result, 5/2-way double solenoid valve 1V1
is returned to its initial position.
The piston rod end of cylinder 1A1 is pressurised while the piston end is exhausted. The piston rod
in cylinder 1A1 travels to the rear end-position.
contact K2 opens.
The electrical circuit of solenoid coil 1M2 is opened.

Creating an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Create an equipment list by entering the required devices to the table below.
Quantity Designation
1 Cylinder, double-acting
2 One-way flow control valve
1 5/2-way double solenoid valve (slice J in the valve terminal)
2 Pushbutton (normally open)
2 Relay
1 Distributor block
1 On-off valve with filter regulator
1 Compressed air source
1 24 V DC power supply unit
Equipment list

Exercise 2:
Placing beverage bottles
Learning goals
• You’ll be familiar with the setup and function of valve terminals.
• You’ll be able to use valve terminals in accordance with specified requirements.

Beverage crates need to be filled individually. The beverages crates are pushed to the loading station by
means of a conveyor. Then they’re brought into the loading position and are lifted in a retaining frame.
Layout
Loading station for beverage bottles

Exercise 2: Placing beverage bottles
Parameters
• The cylinders’ end positions should be monitored with limit switches and proximity switches.
• The beverage crates should be detected by means of a proximity switch.
Project assignment
Control sequence
1. Cylinder 1A1 advances. The beverage crate is moved into the loading position as a result.
2. Cylinder 2A1 advances and lifts the beverage crate in the loading station’s retaining frame.
3. 20 bottles are placed into the crate.
4. Cylinder 1A1 is subsequently retracted, followed by cylinder 2A1.
5. The overall sequence is thus as follows:
1A1+ 2A1+ 1A1– 2A1–

Fundamentals: block-type valve assembly

When comparing individual valves with a valve terminal in actual industrial practice, various advantages and
disadvantages become apparent due to differing layouts for electromagnetic controllers.
– Compare the concepts of individual mounting with block-type mounting of directional control valves
with regard to tubing connections for spatially distributed controllers.
Which concept is most advantageous? Give reasons for you selection.
Individual mounting of Block-type mounting of

Reason
directional control valves directional control valves
Despite undisputed advantages (reduced wiring and tubing

connections), block-type valve mounting leads to undesirable side
effects for cylinder drive units which are considerable distances
apart.
Long lengths of tubing are required between the directional control

valves and the cylinders.
This results in long signal running times (for example roughly 30 ms

for a tubing length of 10 metres). and delayed cylinder response.
X The electro-pneumatic controller is correspondingly sluggish.
The large volume represented by the tubing between valve and

cylinder results in increased compressed air consumption.
The overall layout becomes confusing due to numerous, long

lengths of tubing. Tubing replacement is time-consuming in the
event of a defect.
Directional control valves should thus only be block mounted when

the cylinder drive units used are relatively close-by, or when the
above mentioned disadvantages are acceptable.

Fundamentals: current reduction for solenoid coils

The directional control valves from TP 201 and the MPA valve terminal from TP 202 are equipped with
current reduction (see technical descriptions of the individual valves from TP 201 and the MPA valve
terminal from TP 202).
– Describe what is meant by current reduction.
After the high current phase (switching operation, 20 ms switch-on time), nominal current through
the solenoid coils is electronically reduced to the point at which the preliminary stage (piloting of
the solenoid operated directional control valve) can just barely be held against the force of the
return spring. Electrical power consumption is significantly reduced during this phase as a result.
Nominal pick-up current (up to 20 ms) amounts to 24 V DC at 80 mA, whereas nominal current
during current reduction (after 20 ms) is only 20 mA. Due to the fact that the holding phase is
considerably longer than the reversing phase, a great deal less electrical energy is required on the
whole to operate the solenoid coil.
– Describe the advantages which result from current reduction.
The directional control valves and the MPA valve terminal have reduced energy consumption.
Depending on the actual application, the power supply unit for supplying power to the directional
control valves and the MPA valve terminal can be laid out more economically.
Minimal current flow through the solenoid coils means less waste heat. In particular where large
numbers of solenoid coils are arranged next to each other, this is advantageous (overheating of the
coil windings and blown coil wires).
The solenoid coils lose less power.

Completing the pneumatic circuit diagram with individual valves
– Complete the pneumatic circuit diagram for the loading station with individual valves.
1A1 2A1
1B1 2B2
1B1 1B2
1V2 1 1 1V3
1V2 1V3
2V2
1V2 1 1 2V3
1V3
2V2
1V2
2 2 2 2
2V3
1V3
2V2
1V2
1V1
2V1 4 2 1V3
2V3
2V2
1V2
2V1 4 2
1M1 1M2 2M1 2M2

5 3 5 3
1 1
Pneumatic circuit diagram with individual valves
Completing the pneumatic circuit diagram with valve terminal
– Complete the pneumatic circuit diagram for the loading station with valve terminal.
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

– Complete the electrical circuit diagram for the loading station.

Initial position
In their initial positions, cylinders 1A1 and 2A1 are in the rear end-position. Limit switch 1B1 is
actuated, and relay K1 is picked up and closes changeover contact K1 in current path 10. Proximity
switch 2B1 is actuated, and relay K3 is picked up and closes changeover contact K3 in current
path 10.
Optical proximity switch 1B3 has detected a beverage crate, and relay K5 is picked up and closes
changeover contact K5 in current path 10.
Step 1-2
When pushbutton S1 (NO contact) is activated, relay K6 is picked up. Changeover contact K6 is
closed in current path 10. The electrical circuit in solenoid coil 1M1 at 5/2-way double solenoid
valve 1V1 is closed. Double solenoid valve 1V1 is reversed as a result. Cylinder 1A1 advances.
contact K6 opens. The electrical circuit of solenoid coil 1M1 is opened.
Step 2-3
When cylinder 1A1 reaches its front end-position, limit switch 1B2 (NO contact) is switched and
relay K2 is picked up. Changeover contact K2 in current path 11 closes. The electrical circuit in
solenoid coil 2M1 at 5/2-way double solenoid valve 2V1 is closed. Double solenoid valve 2V1 is
reversed. Cylinder 2A1 advances.
Step 3-4
When cylinder 2A1 reaches the front end-position, proximity switch 2B2 is actuated (NO contact)
and relay K4 is picked up. Changeover contact K4 in current path 12 closes. The electrical circuit of
solenoid coil 1M2 is closed. As a result, double solenoid valve 1V1 is returned to its initial position.
Cylinder 1A1 travels to its rear end-position.
Step 4-5
When cylinder 1A1 reaches its rear end-position, limit switch 1B1 is switched and relay K1 is picked
up. Changeover contact K1 in current path 13 closes. The electrical circuit of solenoid coil 2M2 is
closed. As a result, double solenoid valve 2V1 is returned to its initial position. Cylinder 2A1 travels
to its rear end-position.

Creating an equipment list

– Create an equipment list by entering the required components in the table below.
2 5/2-way double solenoid valve (slice J in the valve terminal)
2 Electrical limit switch
2 Proximity switch, electronic
1 Proximity switch, optical
6 Relay
1 Distributor block
Equipment list

Exercise 3:
Implementing a sorting station
Learning objectives
• You’ll be able to resolve overlapping signals in sequence controls using the group method.

Similar workpieces of different lengths are transported on a conveyor belt. If a long workpiece is detected, a
cylinder lifts the stopper plate. The workpiece is thus retained in the push-in position, and a second cylinder
pushes it into the vertical carousel. The short workpieces are not stopped, and they fall into the basket.
Layout
Sorting station

Exercise 3: Implementing a sorting station
Parameters
• Overlapping signals occur within this sequence controller. These will be resolved by means of the group
method.
Project assignment
2. Draw the displacement-step diagram.
3. Create the associated function diagram.
4. Draw the pneumatic and electrical circuit diagrams for the sorting device.
Control sequence
1. If a long workpiece is detected, cylinder 1A1 lifts the stopper plate. The workpiece is retained in the
push-in position as a result.
2. Cylinder 2A1 pushes the workpiece into the vertical carousel.
3. Cylinder 2A1 is then retracted, followed by cylinder 1A1.
4. Abbreviated notation for the entire sequence is:
1A1+ 2A1+ 2A1– 1A1–

Fundamentals: overlapping signals

Displacement-step diagrams are a tool for the systematic development of circuit diagrams, but they’re also
helpful for machine troubleshooting and maintenance.
Sequence
1. Cylinders 1A1 and 2A1 are retracted in their initial positions, and limit switch 1B1 and proximity switch
2B1 are actuated.
2. If pushbutton S1 is activated AND limit switch 1B1 is actuated, cylinder 1A1 advances to the front end-
position.
3. Limit switch 1B2 is actuated and cylinder 2A1 advances. Limit switch 2B2 is actuated when the front
end-position is reached.
4. Cylinder 2A1 returns to the rear end-position and actuates proximity switch 2B1.
5. Cylinder 1A1 is retracted.
– Draw a displacement-step diagram for the sequence described above.
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
Displacement-step diagram

Fundamentals: overlapping signals

Overlapping signals occur due to the power section and the above described work sequence of the sorting
station.
– Describe the problem.
Overlapping signals are caused by simultaneous signals to the control ports of a bistable final
control element. The interfering signal must be switched away. If the corresponding signalling
element is deprived of energy, the interfering signal is also switched off. Several overlapping
signals occur: from the displacement-step diagram for the sorting station it becomes clear that
signalling element 2B1 at the rear end-position of cylinder 2A1 causes return motion of cylinder 1A1
(see sequence status 4). 2B1 is actuated in the initial position, and thus applies a continuous signal
(logic 1) to reset input 1M2. And thus a start signal (logic 1) to 1M1 generates an overlapping signal
for final control element 1V1 at cylinder 1A1. The sequence cannot be started for this reason. In
sequence status 2, signalling element 1B2 triggers motion 2A1+ by energising solenoid coil 2M1.
However, since 1B2 remains actuated until sequence status 4 is reached, 2M1 receives a
continuous signal (logic 1). Signalling element 2B2 should then initiate motion 1A1– by energising
solenoid coil 2M2. This results in a standstill at the machine, because final control element 2V1
remains in the depicted position, thus causing cylinder 2A1 to stop in the advanced position.
– Explain how this problem can be eliminated.
The interfering signal must be switched away. If the corresponding signalling element is deprived of
energy, the interfering signal is also switched off. These switching functions can be selected so that
pending signals (logic 1) are switched off (set to logic 0) when they interfere with correct
sequencing, or at an earlier point in time. It’s advisable to combine these signal deactivating
functions so that each signalling element switches two interfering signals off. This simplifies the
circuit diagram, making it more clear-cut, and fewer switching functions are required. The correct
locations for these signal switch-offs can be determined by assigning individual motions to groups
(control loop generation).

Group method fundamentals: assignment to groups

Overlapping signals can be prevented by assigning individual motions to groups (control loop generation).
• Create groups for the above described work sequence.

• Designate the associated solenoid coils.
• Designate the signalling elements / memory inputs at the group separator.
• Indicate which solenoid coil the respective memory output affects.
• Designate the signalling elements within the groups.
Indicate which solenoid coil(s) the respective signalling elements affect.
Note
Signalling elements at the group separator must act upon a memory input (e.g. relay with latching
circuit or RS flip-flop); the memory output allocated to the memory input initiates subsequent
motion.
Signalling elements within the group initiate subsequent motion directly.
– Create groups of motions and enter the associated solenoid coils.
Group 1 Group 2
1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–

Group method fundamentals: memory
– Designate the signal generators and the memory inputs at the group separator and sketch in allocation
of memory outputs to their corresponding solenoid coils. Copy your entries from the previous
worksheet to this end.
Group 1 Group 2
1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–
START 2B2
+ 1B1
Memory Memory
Group method fundamentals: allocation of signalling elements within a group
– Designate the signalling elements within a group, as well as their allocation to the corresponding
solenoid coils. Copy your entries from the previous worksheet to this end.
Group 1 Group 2
1B2 2B1
1M1 1A1+ 2M1 2A1+ 2M2 2A1– 1M2 1A1–
START 2B2
+ 1B1
Memory Memory

Fundamentals: displacement-step diagram – group creation
– Create a displacement-step diagram based on the cylinder motions shown in the graphic. Then create
groups and add them to the graphic.
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
Note
If you combine as many motions as possible into each group, the controller is less complicated.
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–

1A1+ 2A1+ 2A1– 3A1+ 1A1– 3A1–


Fundamentals: displacement-step diagram – group creation
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–

3A1– 1A1+ 3A1+ 2A1+ 2A1– 1A1–

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+

1A1+ 3A1+ 1A1– 2A1– 3A1– 2A1+


Fundamentals: creating a function diagram

Function diagrams and/or function charts are helpful in many ways. They are a tool for the systematic
development of circuit diagrams, as well as for machine troubleshooting and maintenance.
– Create a function diagram for the sorting station.
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
Note
Combine the signal switching functions and signal switch-off functions so that each signalling
element switches two interfering signals off. This simplifies the circuit diagram.

Pneumatic circuit diagram
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
– Complete the electrical circuit diagram.

– Set up the controller and describe the sequence used.
Initial position
In their initial positions, cylinders 1A1 and 2A1 are in the rear end-position. The limit switches and
proximity switches, namely 1B1 and 1B2 at cylinder 1A1, and 2B1 and 2B2 at cylinder 2A1, are
connected to relays K1, K2, K3 and K4 in the electrical circuit diagram.
Group 1
If start button S1 is actuated (NO contact actuated, relay K5 picked up) AND cylinder 1A1 is in its
rear end-position (NO contact 1B1 actuated, relay K1 picked up) AND cylinder 2A1 is in the rear end-
position (NO contact 2B1 actuated, relay K3 picked up, NO contact 2B2 unactuated, relay K4
released), relay K6 in current path 8 is picked 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 is closed and activates group 1. Also at
the same time, changeover contact K6 in current path 12 is opened and deactivates group 2; the
electrical circuits in solenoid coils 1M2 and 2M2 are open.
If changeover contact K6 in current path 10 is closed, the electrical circuit in solenoid coil 1M1 at
double solenoid valve 1V1 is closed. Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
When cylinder 1A1 reaches its front end-position, proximity switch 1B2 (NO contact actuated) is
switched and relay K2 is picked up. Changeover contact K2 in current path 11 closes. The electrical
circuit in solenoid coil 2M1 at double solenoid valve 2V1 is closed. The valve is reversed and
cylinder 2A1 advances.
Group 2
When cylinder 2A1 reaches the front end-position, proximity switch 2B2 is switched (NO contact
actuated) and relay K4 is picked up. Changeover contact K4 in current path 8 opens and clears self-
latching at relay K6.
At the same time, changeover contact K6 in current path 10 is opened and deactivates group 1; the
electrical circuits in solenoid coils 1M1 and 2M1 are open. Also at the same time, changeover
contact K6 in current path 12 is closed and activates group 2. The electrical circuit in solenoid coil
2M2 at double solenoid valve 2V1 is closed. Double solenoid valve 2V1 is reset. Cylinder 2A1 is
once again retracted.
When cylinder 2A1 reaches its rear end-position, limit switch 2B1 (NO contact actuated) is switched
and relay K3 is picked up. Changeover contact K3 in current path 13 closes. The electrical circuit in
solenoid coil 1M2 at double solenoid valve 1V1 is closed. Valve 1M1 is reset and cylinder 1A1 is
retracted again.

Completing the equipment list

– Complete the device list by entering the quantities of the required components in the table below.
2 5/2-way double solenoid valve (slice J on the valve terminal)
6 Relay
1 Distributor block
Equipment list

Exercise 4:
Machining key blanks
Learning objectives
• You’ll be able to create a displacement-step diagram for sequence controls.
• You’ll be able to convert a function chart into a GRAFCET chart.
• You’ll be able to setup a step sequence using valves with spring return.

Key blanks have to be fed to a milling machine. A handling unit is used to this end. First of all, the key blanks
are picked up by a gripper. A lifting cylinder lifts the key blanks up to the milling tool. A feed cylinder moves
the blank into the machining position.
Layout

Exercise 4: Machining key blanks
Parameters
• Double-acting cylinders and solenoid valves with spring return will be used.
Project assignment
2. Create the associated function diagram.
3. Convert the function chart into a GRAFCET chart.
4. Draw the pneumatic and electrical circuit diagrams for the separating and turning station.
5. Check the equipment list.
Control sequence
1. Lifting cylinder 1A1 is in the lower end-position.
2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the lifting cylinder
travels to the upper end-position.
3. When lifting cylinder 1A1 is advanced, feed cylinder 2A1 advances to its front end-position.
4. After cylinder 2A1 has reached its front end-position, cylinder 2A1 is retracted first. Lifting cylinder 1A1
is then lowered.
5. The sequence is as follows: 1A1+ 2A1+ 2A1– 1A1–
Note
The gripper is not taken into consideration in the setup.
Machining time (cylinder 2A1 in front end-position) is not taken into consideration.

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

Creating the displacement-step diagram
Sequence:
1. Cylinders 1A1 and 2A1 are retracted in their initial positions, and limit switches 1B1 and 2B1 are
actuated.
2. If pushbutton S1 is activated AND limit switch 1B1 is actuated, cylinder 1A1 advances to the front end-
position. Proximity switch 1B2 is actuated.
3. Cylinder 2A1 advances. Limit switch 2B2 is actuated when the front end-position is reached.
4. Cylinder 2A1 returns to the rear end-position and actuates limit switch 2B1.
5. Cylinder 1A1 is retracted.
6. The entire sequence is thus: 1A1+ 2A1+ 2A1– 1A1–
– Draw a displacement-step diagram for the sequence 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

Fundamentals: creating a function diagram

Function diagrams and/or function charts are helpful in many ways, for example as a tool for the systematic
development of circuit diagrams, as well as for machine troubleshooting and maintenance.
– Create a function diagram for the task described above.
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

Fundamentals: creating a GRAFCET chart
– Convert the function chart into a GRAFCET chart.
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
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

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 A3 format)
– Complete the electrical circuit diagram for the handling unit.
Electrical circuit diagram (circuit diagram in A3 format)

Initial position
In their initial positions, cylinders 1A1 and 2A1 are in the rear end-position. Limit switches 1B1 and
2B1, as well as proximity switches 1B2 and 2B2, are connected to relays K1, K2, K3 and K4 in the
electrical circuit diagram.
Step 1-2
If cylinder 1A1 is in its rear end-position (NO contact 1B1 actuated, relay K1 picked up) AND start
button S1 is activated (relay K5 is picked up), relay K6 in current path 8 is picked 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 is closed and initialises step 2.
Also at the same time, changeover contact K6 in current path 16 is closed. The electrical circuit in
solenoid coil 1M1 is closed. Solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
Step 2-3
After cylinder 1A1 reaches the front end-position (NO contact 1B2 actuated, relay K2 picked up)
AND step 1 has been set (relay K6 is picked up), relay K7 in current path 10 is picked up and the
self-latching loop (changeover contact K7 in current path 11) is activated.
Step 3-4
AND step 2 has been set (relay K7 is picked up), relay K8 in current path 12 is picked up and the
self-latching loop (changeover contact K8 in current path 13) is activated.
Also at the same time, changeover contact K8 in current path 17 is opened. The electrical circuit in
solenoid coil 2M1 is opened. Solenoid valve 2V1 is reversed by means of spring return. Cylinder 2A1
is retracted.

Step 4-5
After cylinder 2A1 reaches the rear end-position (NO contact 2B1 actuated, relay K3 picked up) AND
step 3 has been set (relay K8 is picked up), relay K9 in current path 14 is picked up and the self-
At the same time, changeover contact K9 in current path 16 is opened. The electrical circuit in
is retracted.
Also at the same time, changeover contact K9 in current path 8 opens and clears self-latching at
relay K6 (step 1). As a result, changeover contact K6 in current path 10 opens and clears self-
latching at relay K7 (step 2). Changeover contact K7 in current path 12 opens and clears self-
latching at relay K8 (step 3), changeover contact K8 in current path 14 opens and stops self-latching
at relay K9 (step 4).
And thus all steps have been cleared.


– Complete the equipment list by entering the necessary quantities of required devices to the table
below.
2 5/2-way solenoid valve (slice M in the valve terminal)
9 Relay
1 Distributor block
Equipment list

Exercise 5:
Bending mounting brackets
Learning objectives
• You’ll be able to recognise overlapping signals in sequence controls.
• You’ll be able to setup a step sequence using double pilot valves.

Sheet metal strips are bent to form mounting brackets using a pneumatic bending device. The sheet metal
strips are placed into the bending device manually. The bending cylinders are actuated by means of double
solenoid valves. Operating safety must be ensured for the bending device.
Note
Safety devices which are required in actual practice are not taken into consideration for this
exercise.
Only one of the horizontally mounted cylinders will be taken into consideration.
Layout
Bending device for sheet metal strips

Exercise 5: Bending mounting brackets
Parameters
• It must be possible to adjust the advance and return stroke speed independently for the bending
process.
Project assignment
2. Create the associated function diagram and the GRAFCET chart.
Control sequence
1. Bending cylinders 1A1 and 2A1 are retracted.
2. When start button S1 is activated, cylinder 1A1 advances.
3. After bending cylinder 1A1 has reached the front end-position, bending cylinder 2A1 advances and
finishes bending the bracket.
4. Bending cylinder 2A1 is subsequently retracted, followed by bending cylinder 1A1.
5. The motion sequence is as follows:
1A1+ 2A1+ 2A1– 1A1–

Creating the displacement-step diagram
Sequence
• Cylinders 1A1 and 2A1 are retracted in their initial positions, and limit switches 1B1 and 2B1 are
actuated.
• If start button S1 is activated AND limit switch 1B1 is actuated, cylinder 1A1 advances to the front end-
position. Proximity switch 1B2 is actuated.
• Cylinder 2A1 advances. Limit switch 2B2 is actuated when the front end-position is reached.
• Cylinder 2A1 returns to the rear end-position and actuates limit switch 2B1.
• Cylinder 1A1 is retracted.
– Draw a displacement-step diagram for the sequence described above.
START
1 2 3 4 5=1
(1M2)
1
1B2
1A1
0
(1M1) 1B1
2B2 (2M2)
1
2A1
2B1
0
(2M1)

Creating a function diagram
– Create a function diagram for the bending device described above.
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

Creating a GRAFCET chart
– Create a GRAFCET chart for the above described sequence.
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

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
– Complete the electrical circuit diagram for the bending device.

An additional control step (step 5) must be implemented for the circuit with double solenoid valves,
in order to clear the step sequence.
Initial position
Step 1-2
button S1 is activated (relay K5 is picked up), relay K6 is picked up and the self-latching loop
(changeover contact K6 in current path 9) is activated.
solenoid coil 1M1 is closed. Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
Step 2-3
AND step 1 has been set (relay K6 is picked up), relay K7 is picked up and the self-latching loop
solenoid coil 1M1 is opened.
Step 3-4
AND step 2 has been set (relay K7 is picked up), relay K8 is picked up and the self-latching loop
solenoid coil 2M2 is closed. Double solenoid valve 2V1 is reset. Cylinder 2A1 is retracted.

Step 4-5
step 3 has been set (relay K8 is picked up), relay K9 is picked up and the self-latching loop
Step 5-6 (control step)

step 4 has been set (relay K9 is picked up), relay K10 is picked up and the self-latching loop
latching at relay K10 (step 5).
And thus all steps have once again been cleared.


– Complete the equipment list by entering the quantities of the required components in the table below.
10 Relay
1 Distributor block
Equipment list


Exercise 6:
Sorting out empty jars from a filling system
Learning goals
• You’ll be familiar with the modes of operation of various proximity switches.
• You’ll be able to select proximity switches which are matched to prevailing conditions.
• You’ll be familiar with logic operations and be able implement them.

Filled jars are sealed with lids in a filling system. Jars and lids are fed to the process independent of each
other. Filled jars have to be sealed with lids. Jars which have not been properly filled need to be sorted out.
Layout
Filling jam jars

Exercise 6: Sorting out empty jars from a filling system
Project assignment
1. Answer the questions and complete the tasks covering the fundamentals of the included learning
content.
Control sequence
1. Inductive proximity switch B1 is located at the lid feeder.
2. The following devices are located at the jar feeder:
3. Capacitive proximity switch B2 which detects whether or not a jar is present
4. Optical proximity switch B3 which detects whether or not the jar has been filled to the correct level
5. Cylinder 1A1 seals correctly filled jars with lids.
6. Jars which have not been correctly filled are sorted out by cylinder 2A1.

Fundamentals: logic operations

The following logic operations result from the description of the control task:
a) B1 AND B2 AND B3 = 1M1 (advance cylinder 1A1)
and
b) B1 AND B2 AND (NOT B3) = 2M1 (advance cylinder 2A1)
– Create the associated Boolean equations.
a) B1 ^ B2 ^ B3 = 1M1
b) B1 ^ B2 ^ B3 = 2M1
– Create the associated logic symbols.
a) b)
B1 & 1M1 B1 & 2M1

B2 B2
B3 B3
– Create the associated ladder diagrams.
a) b)
B1 B2 B3 1M1 B1 B2 B3 2M1

Fundamentals: inductive, optical and capacitive proximity switches

Inductive, optical and capacitive proximity switches are electronic sensors. These sensors do not include a
moving contact which can be switched. Instead, the output is electronically connected to either supply
power or earth (= output voltage of 0 V).
– Describe the setup and function of an inductive proximity switch.
Circuit symbol Design and function
An inductive proximity switch consists of an electrical resonant circuit, a flip-flop and an amplifier.
When voltage is applied to the terminals, the resonant circuit generates a high-frequency, alternating
magnetic field which is emitted from the front of the sensor. If an electrical conductor is moved into this
field, the resonant circuit is attenuated.
The downstream electronics, consisting of the flop-flop and the booster, evaluate the characteristics of
the resonant circuit, and activate the output. All highly, electrically conductive materials can be
detected with inductive proximity switches.
Fundamentals: optical proximity switches

Optical proximity sensors make use of optics and electronics in order to detect objects. Basically,
differentiation is made amongst three types of optical proximity switches:
• Through-beam sensor
• Retro-reflective sensor
• Diffuse sensor
– Describe the setup and function of a diffuse optical sensor.
The emitter and the receiver of the diffuse sensor are situated next to each other in a single component.
If the emitted light strikes a reflective surface, it is redirected to the receiver and the sensor’s output is
switched. As a result of this mode of operation, diffuse sensors can only be used if the workpiece or
machine component to be detected demonstrates good reflectivity (e.g. metallic surfaces, bright
colours).

Fundamentals: capacitive proximity switches
– Describe the setup and function of a capacitive proximity switch.
A capacitive proximity switch consists of a capacitor and an electrical resistor which combine to form a
resonant circuit, as well as an electronic circuit for evaluating oscillation.
An electrostatic field is generated between the capacitor’s active and ground electrodes. A stray field is
generated at the front of the sensor (active sensing surface). If an object penetrates this stray field, the
capacitance value of the capacitor is changed. The resonant circuit is attenuated.
The downstream electronics activate the sensor’s output. Not only do capacitive proximity switches
react to materials with good electrical conductivity (e.g. metals), they also react to all insulators with
large dielectric constants such as plastics, glass, ceramics, liquids and wood.
Conductive materials located within the stray field of the active sensing surface create a counter-
electrode.
Non-conductive materials increase the capacitor’s capacitance relative to the type of material
(dielectric constant).
Larger switching distances are possible with conductive objects than with non-conductive materials.

Pneumatic circuit diagram for 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
– Complete the electrical circuit diagram for the filling system.

Logic
1B1 AND 2B1 AND B1 AND B2 AND B3 = advance 1A1
1B2 = retract 1A1
1B1 AND 2B1 AND B1 AND B2 AND (NOT B3) = advance 2A1
2B2 = retract 2A1
Initial position
1B2 are actuated (NO contact 1B1 actuated, relay K1 picked up and NO contact 2B1 actuated, relay
K3 picked up). Changeover contacts K1 and K3 in current path 15 are closed.
Correctly filled jar

If a lid is present (NO contact B1 actuated, relay K5 picked up), and if a jar is present (NO contact B2
actuated, relay K6 picked up) and has been filled (NO contact B3 actuated, relay K7 picked up),
changeover contacts K5, K6 and K7 in current path 16 are closed.
If start button S1 is activated, relay K8 is picked 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 is closed. Relay K9 is picked up.
Changeover contact K9 in current path 16 is closed The electrical circuit of solenoid coil 1M1 is
closed. Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
If cylinder 1A1 leaves its rear end-position, limit switch 1B1 (NO contact) is no longer actuated.
Changeover contact K1 in current path 15 opens, and relay K9 is released. The electrical circuit of
solenoid coil 1M1 is opened. As soon as cylinder 1A1 has reached its front end-position
(changeover contact 1B2 actuated, K2 is picked up), changeover contact K2 in current path 17
closes. The electrical circuit in solenoid coil 1M2 is closed. Double solenoid valve 1V1 is reset.
Cylinder 1A1 is once again retracted.
This sequence is repeated until pushbutton S2 is pressed or the output signal from proximity switch
B1, B2 or B3 is switched.

Unfilled jar
If a lid is present (NO contact B1 actuated, relay K5 picked up), and if a jar is present (NO contact B2
actuated, relay K6 picked up) but has not been filled (NO contact B3 unactuated, relay K7 released),
the changeover contacts at K5 and K6 in current path 18 are closed. The changeover contact at K7
in current path 18 remains open.
If start button S1 is activated, relay K8 is picked 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 is closed. Relay K9 is picked up.
Changeover contact K9 in current path 18 is closed The electrical circuit of solenoid coil 2M1 is
closed. Double solenoid valve 2V1 is reversed. Cylinder 2A1 advances.
If cylinder 2A1 leaves its rear end-position, proximity switch 2B1 (NO contact) is no longer actuated.
Changeover contact K3 in current path 15 opens, and relay K9 is released. The electrical circuit of
solenoid coil 2M1 is opened. As soon as cylinder 2A1 has reached its front end-position
(changeover contact 2B2 actuated, relay K4 picked up), changeover contact K4 in current path 19
closes. The electrical circuit in solenoid coil 2M2 is closed. Double solenoid valve 2V1 is reset.
Cylinder 2A1 is once again retracted.
This sequence is repeated until pushbutton S2 is pressed or the output signal from proximity switch
B1, B2 or B3 is switched.


1 Proximity switch, inductive
1 Proximity switch, capacitive
1 Proximity switch, optical
1 Pushbutton (normally closed)
9 Relay
1 Distributor block
Equipment list


Exercise 7:
Bonding components
Learning objectives
• You’ll be familiar with the setup and function of a pneumatic-electric converter.
• You’ll be familiar with the possible uses of an on-delay timing relay.
• You’ll be familiar with options for querying pressure and time in electro-pneumatic controllers.

Components are bonded together at a processing station in a rotary indexing machine. A specified working
pressure has to be achieved for this process step. The holding time for the locating cylinder has to be
adjustable in order to ensure reliable bonding of the components.
Layout
Processing station in a rotary indexing machine

Exercise 7: Bonding components
Project assignment
2. Draw the pneumatic and electrical circuit diagrams for the bonding device.
Control sequence
1. Locating cylinder 1A1 is retracted and actuates proximity switch 1B1.
2. When start button S1 is activated, locating cylinder 1A1 advances.
3. If locating cylinder 1A1 is in its front end-position and if the specified pressure of 5 bar (500 kPa) has
been reached at pressure sensor 1B3, preset delay time is started at time relay K5.
4. After the delay time has elapsed, locating cylinder 1A1 is retracted again.

Fundamentals: time relays

Basically, time relays can be subdivided into two groups:
• Time relays with switch-off delay
• Time relays with switch-on delay
– Match up the corresponding symbol to the description in the table.
A1 A1
A2 A2
1) 2)
Description Symbol
Time relay with switch-on delay

A1
A2
1)
One or more contacts can be switched by the relay coil in a time relay. Depending on the required function,
relays with normally closed contacts, normally open contacts or changeover contacts are used.
– Describe the layout and contact loadings of the relays depicted below.
Symbol Layout/contact loadings
Time relay with switch-on delay and one changeover contact,

A1
6 8 contacts either as NC (delayed opening) or NO (delayed
closing)
5
A2
Time relay with switch-off delay and one NO contact, delayed

A1 7 opening of normally open contact
8
A2

Fundamentals: switch-on delay
– Depict signal characteristics for switch-on delay in the following diagram and sketch in delay time tv.
Voltage at relay coil
Time t
Contact
Closed
Open
tV Time t
Fundamentals: switch-off delay
– Depict signal characteristics for switch-off delay in the following diagram. Sketch in delay time tv.
Voltage at relay coil
Time t
Contact
Closed
Open
tV Time t

Fundamentals: pressure sensors

The bonding device is operated within a pressure range of 4 to 6 bar (400 to 600 kPa). The selected delay
time should be started when switching pressure SPMAX amounting to 5 bar (500 kPa) is reached.
Switching pressure is adjusted as described in the table.
Adjusting switching pressure
1 Press the EDIT key twice (switching output selection omitted).
2 Press the UP/DOWN key repeatedly until the desired switching function is selected (in this case threshold comparator).
3 Press the EDIT key.
4 Press the UP/DOWN key repeatedly until the desired lower switching pressure [SP] is selected (in this case 4 bar or 400 kPa).
6 Press the UP/DOWN key repeatedly until the desired hysteresis [HY] is selected.
8 Press the UP/DOWN key repeatedly until the desired switching characteristic is selected (in this case [NO]).
9 Press the EDIT key in order to switch to the RUN mode.
Note
Information regarding technical data for the pressure sensor is provided on the CD-ROM included.

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
– Complete the electrical circuit diagram for the bonding device.

Initial position
In its initial position, cylinder 1A1 is in the rear end-position. Proximity switch 1B1 is actuated.
Step 1-2
If cylinder 1A1 is in its rear end-position (1B1 actuated, relay K1 picked up) AND start button S1 is
activated (relay K4 is picked up, changeover contact K4 in current path 9 closes), the electrical
circuit in solenoid coil 1M1 is closed. Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
If cylinder 1A1 leaves its rear end-position, proximity switch 1B1 is no longer actuated. Changeover
contact K1 in current path 9 opens. The electrical circuit of solenoid coil 1M1 is opened.
Step 2-3
When the cylinder reaches its front end-position, proximity switch 1B2 is actuated and relay K2 is
picked up. Changeover contact K2 in current path 8 closes. When the specified pressure is reached
at pressure sensor 1B3, relay K3 is switched. Changeover contact K3 in current path 8 closes. The
electrical circuit in time delay relay K5 is closed. When the specified time has elapsed, changeover
contact K5 in current path 10 closes. The electrical circuit in solenoid coil 1M2 is closed. Double
solenoid valve 1V1 is reset. Cylinder 1A1 returns to its rear end-position.
If cylinder 1A1 leaves its front end-position, proximity switch 1B2 is no longer actuated. Changeover


1 Pressure sensor
4 Relay
1 Relay (with switch-on delay)
1 Distributor block
Equipment list

Exercise 8:
Selecting operating modes
Learning objectives
• You’ll be familiar with operating modes and know how to set up circuits, by means of which single cycle
and continuous cycle operating modes can be implemented.
• You’ll be familiar with the function of an electrical preset counter and learn to use it in circuits.

Bars of chocolate need to be fed via an ejector device to a manual workstation, ten at a time. The ten bars of
chocolate are then placed inside a shipping box. The process is started manually each time.
Layout
Packaging bars of chocolate

Exercise 8: Selecting operating modes
Parameters
• The ejector device must be operated in the automatic mode (single/continuous cycle).
• Operating pressure at the ejector device should be between 4 and 5 bar (400 and 500 kPa). Pressure
should be monitored.
Project assignment
1. Answer the questions and complete the tasks covering the fundamental learning contents.
2. Draw the pneumatic and electrical circuit diagrams for the ejector device.
Control sequence
1. Single cycle or continuous cycle is selected by pressing pushbutton S3 (continuous cycle)
or S4 (single cycle).
2. The sequence is started by pressing start button S1.
3. The sequence is paused by pressing pushbutton S2 (stop at end of cycle).
4. After completing 10 advancing and retracting strokes, ejector cylinder 1A1 remains in the rear end-
position.

Fundamentals: preset counters
– Specify the function of the depicted preset counter with regard to its contact set.
A1 1 R1
A2 R2
4 2
Symbol
Electrical preset counter with one set of changeover contacts
– Describe how the counter’s preselected number is adjusted.
The electrical preset counter is adjusted by pressing the white enabling key, and simultaneously
keying in the preselected number. The preselected number appears at the display window. The
preselected number can be changed at any time, even during operation.
– Describe how the counter is reset.
The preset counter is reset manually by pressing the black reset key, or electrically with a reset
pulse via terminals R1 and R2. The selected preset value is retained when the counter is reset.
Incoming counter pulses are not processed during the resetting procedure.

Fundamentals: pressure sensors
– Name and describe the switching functions of the pressure sensor used.
Threshold comparator switching function:

Monitoring of a selected switching pressure (threshold value). When the specified value is reached,
a contact is opened or closed regardless of the selected switching characteristic.
Window comparator switching function:

Monitoring of a specified pressure range. When the lower switching pressure is reached, a contact
is opened or closed regardless of the selected switching characteristic, and when the upper
switching pressure is reached the contact is correspondingly closed or opened again.
Operating pressure at the ejector device should be reduced from 6 bar (600 kPa) to 4 bar (400 kPa). If
pressure drops below this value, the pressure sensor must generate a signal and stop the system. The
switching pressure setting must be correspondingly changed at the pressure sensor.
– Describe the step by step procedure for changing the switching function.
Changing the switching function
2 Press the UP/DOWN key repeatedly until the desired switching function is selected (in this case threshold comparator).
4 Press the UP/DOWN key repeatedly until the desired switching pressure [SP] is selected (in this case 4 bar or 400 kPa).

The ejector device is operated within a pressure range of 4 to 6 bar (400 to 600 kPa). Upper switching
pressure SPMAX now needs to be reduced to a value of 5 bar (500 kPa). If pressure exceeds this value, the
system must be stopped.
– Describe the step by step procedure for changing the switching function.
Changing the switching function
2 Press the UP/DOWN key repeatedly until the desired switching function is selected (in this case window comparator).
4 Press the UP/DOWN key repeatedly until desired lower switching pressure [SPMIN/SP.L] is selected (in this case 4 bar or 400
kPa).
6 Press the UP/DOWN key repeatedly until desired upper switching pressure [SPMAX/SP.H] is selected (in this case 5 bar or 500
kPa).
The hysteresis range can be adjusted at the utilised sensor.
– Describe what is meant by the term “hysteresis”.
Hysteresis is the largest difference between two output values, for example switch-on and switch-
off points, if the measuring range is run through first of all in the ascending and then in the
descending direction, as is the case in this exercise. And thus, for example, mechanical pressure
switches may demonstrate switching point hysteresis due to internal frictional resistance (spring).
In the case of rising pressure, the electrical output signal is generated when the switch-on point is
reached.
If pressure drops, the sensor is not switched at the same point.
The switch-on and switch-off points are not identical. This characteristic must be taken into
consideration when adjusting the pressure sensor.

Pneumatic circuit diagram for the ejector 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
– Complete the electrical circuit diagram for the ejector device.

– Describe the controller’s working sequence. Take only a single cycle into consideration.
Single cycle sequence

Cylinder 1A1 is in its rear end-position (NO contact 1B1 actuated, relay K3 picked up, changeover
contact K3 in current path 13 closed) AND the start button is activated (relay K2 is picked up,
changeover contact K2 in current path 13 is closed). The current path in solenoid coil 1M1 is closed.
Double solenoid valve 1V1 is reversed. Cylinder 1A1 advances.
If cylinder 1A1 leaves its rear end-position, proximity switch 1B1 is no longer actuated. Changeover
When cylinder 1A1 reaches the front end-position (1B2 actuated, relay K4 picked up, changeover
contact K4 in current path 14 closed), the current path in solenoid coil 1M2 is closed. Double
solenoid valve 1V1 is reset. Cylinder 1A1 is once again retracted.
At the same time, changeover contact K4 in current path 11 closes. The preselected value at preset
counter P6 is reduced by one.
If cylinder 1A1 leaves its front end-position, proximity switch 1B2 is no longer actuated. Changeover
contact K4 in current path 14 opens. The electrical circuit in solenoid coil 1M1 is opened.

Selecting various operating modes
– Explain how the various operating modes are selected.
Pressure sensing
Regardless of the operating mode, a cycle is only started if the specified operating pressure is
detected by pressure sensor 1B3 (relay K5 picked up, changeover contact K5 in current path 3
closed). If pressure drops below the selected value, the current cycle is ended, after which the
system is stopped.
Preset counter
Regardless of the operating mode, only the number of cycles specified at preset counter P6 is
executed. As soon as cylinder 1A1 reaches the front end-position (1B2 actuated, relay K4 picked up,
changeover contact K4 in current path 11 closed), the preset counter is actuated.
The preset counter is reset manually.
Automatic/single cycle operating mode

Relay K1 is released. As a result, self-latching cannot be activated at the start button in current path
4.
Only one cycle is executed when the start button is activated.
Continuous cycles
Relay K1 is picked up. Self-latching is activated by changeover contact K1 in current path 2. At the
same time, activation of self-latching for the start button is initialised by changeover contact K in
current path 4.
Numerous cycles are executed when the start button is activated until continuous cycle is ended by
activating “stop at end of cycle” or “continuous off”, or until all of the cycles specified at preset
counter P6 have been executed.


– Complete the equipment list by entering the quantities of the required components to the table below.
1 Pressure sensor
1 Preset counter, electrical
5 Relay
1 Distributor block
Equipment list


Exercise 9:
Machining key blanks with emergency stop function
Learning objectives
• You’ll be able to develop and set up the emergency stop function for a controller using valves with
spring return.

Key blanks have to be fed to a milling machine. A handling unit is used to this end. First of all, the key blanks
are picked up by a gripper. A lifting cylinder lifts the key blanks up to the milling tool. A feed cylinder moves
the blank into the machining position.
Layout

Exercise 9: Machining key blanks with emergency stop function
Parameters
• The sequence is as follows:
1A1+ 2A1+ 2A1– 1A1–
• Double-acting cylinders and solenoid valves with spring return will be used.
• Emergency stop condition:
• The feed cylinder and the lifting cylinder should both be immediately retracted to their rear end-
positions in the event of an emergency stop.
Project assignment
content.
2. Draw the pneumatic and electrical circuit diagrams for the separating and turning station with
emergency stop function.
Control sequence
1. Lifting cylinder 1A1 is in the rear end-position.
2. After activating pushbutton S1, 5/2-way double solenoid valve 1V1 is reversed and the lifting cylinder
travels to the front end-position.
3. When lifting cylinder 1A1 is advanced, feed cylinder 2A1 advances to its front end-position.
4. After cylinder 2A1 has reached its front end-position, cylinder 2A1 is retracted first. Lifting cylinder 1A1
is then lowered.
Note
The gripper is not taken into consideration in the setup.
The gripper would not open in the event of an emergency stop.
Machining time (cylinder 2A1 in front end-position) is not taken into consideration.

Emergency stop components

An emergency stop device is a combination of components which is designed to avert or diminish arising or
existing personal safety hazards or possible damage to a machine or materials.
The various parts of any given machine are summarised in general in the table below.
– Identify the parts of a machine to which the components of an emergency stop device (ES device) might
belong. Mark the appropriate parts of the machine.
System component Machine component ES device
Control system Signals, displays, warning
Actuation components X
Control devices or command devices X
Data storage and data processing X
Sensors
Non-isolating protective devices
Power control elements X

Operating section
Drive components
Separators, brakes X
Power transmission elements, working elements
Isolating protective devices

Emergency stop requirements

In order to ensure optimised safety, human behaviour must be taken into consideration in the event of an
emergency stop in addition to technical device characteristics (e.g. electrical, mechanical and pneumatic
characteristics).
– Specify general requirements for the emergency stop function.
The emergency stop function must be available and functional at all times regardless of the
operating mode.
The control device and its actuator must function in accordance with the principle of forced
actuation.
The emergency stop function must not be used as a substitute for adequate safety measures or
automatic safety equipment, although it can serve as a supporting measure.
After the actuator has been activated, the emergency stop function must ensure that the respective
hazard is averted or diminished automatically in the best possible way.
The emergency stop function must comply with stop category 0 or stop category 1.
The emergency stop device must be designed so that the decision to activate the emergency stop
actuator does not require any though on the part of the operator about possible consequences
(which system section will be shut down, delay rate etc.). The emergency stop command must have
precedence over all other commands.
The machine’s reaction must not cause any additional hazards.
The emergency stop function must not impair the effectiveness of safety equipment with safety-
related functions.
The emergency stop function must not impair equipment which is intended to extricate persons
from hazardous situations, although it may include the rendering effective of certain devices which
are intended for this purpose.
Any action at the actuator which leads to the generation of an emergency stop command must also
result in detenting of the command device, so that the emergency stop command is retained even
after the actuator is no longer being activated, until the command device is reset (released). The
command device must not become detented without an emergency stop command having been
generated. If a fault should occur in the command device (including the detent mechanism), the
function which generates the emergency stop command must take precedence over the detenting
function.
Resetting of the command device must only be possible as the result of a manually executed action
at the command device. Resetting of the command device alone may not trigger a restart command.
Restarting of the machine or system must not be possible until all activated actuators have been
intentionally reset by hand.
The emergency stop actuators must be designed so that they are easy for operating personnel to
activate. Amongst others, the following types of actuators may be used: mushroom pushbutton,
wires / wire ropes, ropes, bars, handles and in special cases foot switches without protective cover,
safety pressure mats etc.
Emergency stop actuators must be red. Any background behind the actuators must be yellow if at
all possible.
In the event that emergency stop wiring is interrupted, or if actuator wires, wire ropes or ropes
should become disengaged, the emergency stop command must be generated automatically.

Emergency stop conditions for cylinder drive units

In addition to electrical, as well as the associated mechanical components, hardware utilised in the field of
electro-pneumatics also includes pneumatic components.
– List essential emergency stop conditions and functions, which are required of a cylinder drive unit in
actual practice.
The piston rod always returns to its initial position.

The piston rod always returns to its initial position in consideration of a specified sequence.
The cylinder should be exhausted.
The piston rod should be locked.
The piston rod always travels in the reverse direction.

Emergency stop categories

In accordance with EN 418, the emergency stop function must comply with either stop category 0 or stop
category 1.
– Describe the difference between stop categories 0 and 1.
Stop category 0 Stop category 1
The system is stopped by direct interruption of the power supply In this case, controlled stopping takes place with power supply to
to the drive component, or by mechanical interruption the drive component(s) in order to bring motion to a standstill,
(disengagement) of hazardous elements from their drive followed by interruption of power supply after standstill has been
components, and if necessary by means of a brake (uncontrolled achieved.
stopping).
The emergency stop control device and its actuator must function in accordance with the principle of forced
actuation.
– Describe this principle.
When a moving mechanical component forcibly sets another component into motion (by means of
direct contact or via other rigid parts), we say that these parts are positively connected with each
other. This also applies when components, by their mere presence, prevent any motion of another
part.
Note
Wherever a mechanical component is set into motion and thus allows another part to move freely
(e.g. due to gravitational force or spring force), no positive mechanical action is exerted on one part
by another (EN 292-2, section 3.5).
A switch with positive opening operation is an example of a suitable command device. In
accordance with DIN EN 60947-5-1 (section 3, paragraph 2.2), positive opening operation is “the
execution of contact separation as the direct result of specified motion of the switch’s actuator via
parts which are not spring loaded”.

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

Initial position
Step 1-2
button S1 is activated (relay K5 picked up), relay K6 in current path 10 is picked up and the self-
Step 2-3
AND step 1 has been set (relay K6 picked up), relay K7 in current path 12 is picked up and the self-
Step 3-4
AND step 2 has been set (relay K7 picked up), relay K8 in current path 14 is picked up and the self-
is retracted.

Step 4-5
step 3 has been set (relay K8 picked up), relay K9 in current path 16 is picked up and the self-
is retracted.
Also at the same time, changeover contact K9 in current path 10 opens and stops self-latching at
latching at relay K8 (step 3), and changeover contact K8 in current path 16 opens and stops self-
All steps have thus been cleared.
Emergency stop function

The control element (start button) and the sensor signals (1B1, 1B2, 2B1, 2B2) are connected to
permanent positive and are not switched off when the emergency stop mushroom actuator is
activated. The status of the machine can thus be recognised even with activated emergency stop
function.
The emergency stop mushroom actuator is laid out as a normally closed contact. This means that
the circuit functions even in the event of a broken wire.
Changeover contact K10 in current path 9 disconnects electrical power from the entire signal
processing and signal output section.
When the emergency stop function is activated (or in case of power failure), solenoid valves 1V1
and 2V1 are immediately returned to their initial positions by their return springs. At the same time,
cylinders 1A1 and 2A1 travel to their rear end-positions.

Checking the equipment list

– Check the equipment list. Have all of the required components been entered in the table below?
2 5/2-way solenoid valve (slice M in the valve terminal)
1 Mushroom actuator (normally closed)
10 Relay
1 Distributor block
Equipment list

Exercise 10:
Bending mounting brackets with emergency stop function
Learning objectives
• You’ll be able to develop and set up the emergency stop function for a controller using double pilot
valves.
• You’ll be able to develop and set up a specified motion sequence in the event of an emergency stop.

Sheet metal strips are bent to form mounting brackets using a pneumatic bending device. The sheet metal
strips are placed into the bending device manually. The bending cylinders are actuated by means of double
solenoid valves. Operating safety must be ensured for the bending device.
Note
Safety devices which are required in actual practice are not taken into consideration for this
exercise.
Layout
Bending device for sheet metal strips

Exercise 10: Bending mounting brackets with emergency stop function
Parameters
• The sequence is selected as follows:
1A1+ 2A1+ 2A1– 1A1–
• Double-acting cylinders and double solenoid valves will be used.
When the emergency stop function is activated, the actuators must be retracted from the danger zone in
a specified order: cylinder 2A1 should be retracted first. Cylinder 1A1 should not be retracted until
cylinder 2A1 has reached its rear end-position.
Project assignment
1. Complete the additional exercises.
2. Draw the pneumatic and electrical circuit diagrams for the bending device with emergency stop
function.
6. Describe how the circuit responds in the event of an emergency strop.
Control sequence
1. Bending cylinders 1A1 and 2A1 are retracted.
2. When pushbutton S1 is activated, cylinder 1A1 advances.
3. After bending cylinder 1A1 has reached the front end-position, bending cylinder 2A1 advances and
finishes bending the bracket.
4. Bending cylinder 2A1 is subsequently retracted, followed by bending cylinder 1A1.

Emergency stop function for a double solenoid valve

A double-acting cylinder needs to be exhausted in the event of an emergency stop. The circuit is to be
implemented as an indirect actuator using a solenoid valve with spring return and an upstream double
solenoid valve.
In the event of an emergency stop, the supply of air must be blocked and the cylinder’s supply port must be
exhausted. No motion should occur when the emergency stop actuator is released. The upstream valve
should not be switched to the flow position, thus allowing for restart, until a pushbutton has been activated
in order to reset the emergency stop device.
– Complete the electrical circuit diagram for the described emergency stop condition.

Pneumatic circuit diagram for the bending device
1V2 1 1 1V3 2V2 1
2 2 2
-V- 4 2 -V- 4 2 1V1 4 2 2V1 4 2

M M J J
14 14 14 12 14
-M1 -M1 1M1 1M2 2M1
3/5 3/5 3/5 3/5

4 82/84 82/84 82/84 82/84
– Complete the electrical circuit diagram for the bending device.

Sequence
Step 1-2
button S1 is activated (relay K5 picked up), relay K6 is picked up and the self-latching loop
Step 2-3
AND step 1 has been set (relay K6 picked up), relay K7 is picked up and the self-latching loop
Step 3-4
AND step 2 has been set (relay K7 picked up), relay K8 is picked up and the self-latching loop

Step 4-5
step 3 has been set (relay K8 picked up), relay K9 is picked up and the self-latching loop
Step 5-6 (control step)

step 4 has been set (relay K9 picked up), relay K10 is picked up and the self-latching loop
All steps have thus once again been cleared.

Description of the emergency stop function
– Describe the emergency stop function and its sequence.

The control element (start button) and the sensor signals (1B1, 1B2, 2B1, 2B2) are connected to
permanent positive and are not switched off by the emergency stop mushroom actuator. The status
of the machine can thus be recognised even with activated emergency stop function.
The emergency stop mushroom actuator is laid out as a normally closed contact. In this way, the
circuit functions even in the event of a broken wire.
Emergency stop sequence

Relay K11 is released when the emergency stop function is activated. Changeover contact K11 in
current path 9 opens. Electrical power is shut off for the entire signal processing and signal output
section.
At the same time, changeover contact K11 in current path 23 closes. The electrical circuit in
Also at the same time, changeover contact K11 in current path 25 closes. When cylinder 2A1
reaches it rear end-position, changeover contact K3 in current path 25 closes. The electrical circuit
in solenoid coil 1M2 is closed. Double solenoid valve 1V1 is reset. Cylinder 1A1 is retracted.


In addition to the circuit diagram, complete project documentation also includes an equipment list. Have the
correct quantities of all of the required components been entered in the table below?
– Check the equipment list.
The equipment list is correct.
11 Relay
1 Distributor block
Equipment list

Exercise 11:
Transporting chocolate bars with emergency stop function
Learning objectives
• You’ll be able to set up the following emergency stop condition: “cylinder remains in its momentary
position in the event of an emergency stop”.
• You’ll be familiar with the setup and mode of operation of a 5/3-way solenoid valve.
• You’ll be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.
• You’ll be able to integrate the reset operating mode into a controller.

Chocolate bars are transported by means of a handling unit during the production process. An emergency
stop function needs to be developed for the linear drive.
Layout
Handling unit for chocolate bars

Exercise 11: Transporting chocolate bars with emergency stop function
Parameters
• The linear drive should stop at its momentary position when the emergency stop function is activated.
• Reset:
• Resetting should only be possible in the manual operating mode.
Project assignment
1. Complete the additional exercise.
content.
3. Draw the pneumatic and electrical circuit diagrams for the linear drive included in the handling unit with
emergency stop function.
7. Describe how the circuit responds in the event of an emergency strop.
Control sequence
1. The automatic or manual operating mode is selected by pressing the AUTO or the MAN pushbutton.
2. In the manual operating mode, linear drive 1A1 is advanced to the left-hand end-position by pressing
the RESET pushbutton.
3. Single cycle or continuous cycle is selected by pressing pushbutton S3 (continuous cycle) or S4 (single
cycle).
4. The sequence is started by pressing start button S1.
5. The sequence is paused by pressing pushbutton S2 (stop at end of cycle).
Note
The linear drive is replaced by a double-acting cylinder in the test setup.

Mode of operation of flow control and non-return valves

Non-return and flow control valves are used in order to block the flow of air or control its flow rate.
– Describe the design and function of the valves depicted below.
Symbol Design and function
Design:
Adjustable one-way flow control valve (combination flow control/non-return valve)
1
Function:
The one-way flow control valve consists of a combination of a flow control valve and a non-return valve
(shut-off valve). The non-return valve blocks the flow of air in one direction. Air flows through the flow
2
control valve at an infinitely adjustable rate. Flow control takes place in one direction only, and air flows
freely through the non-return valve in the other direction.
Design:
Non-return valve, piloted (shut-off valve)
2
Function:
If input pressure at 1 is greater than output pressure at 2, the non-return valve enables flow, and
1 21
otherwise blocks flow. Furthermore, the non-return valve can be vented via pilot line 12, thus
permitting flow in both directions.
Design:
Shuttle valve (shut-off valve)
2
Function:
1 1 The shuttle valve is equipped with two inlets (1) and one outlet (2). If one of the inlets is pressurised
with compressed air, the sealing element closes off the other inlet and air only flows to 2 (OR function).
If both inlets are pressurised simultaneously, the higher pressure is fed to the outlet.

Function of a 5/3-way solenoid valve

A valve symbol indicates how the respective valve functions, i.e. how many ports it has, its switching
positions and type of actuation, but it says nothing about its engineering design.
– Describe the mode of operation of the depicted directional control valve.
4 2
14 12
(1M1) (1M2)
5 3
1
Description
The symbol represents a normally closed, pilot actuated 5/3-way solenoid valve with spring return
and manual override.
Mode of operation:
The 5/3-way solenoid valve has 5 working ports and 3 switching positions.
In the normal position, the solenoid coils are not energised and the piston is centred at the mid-
position (normal position) by the two springs. All ports are blocked.
If the left-hand solenoid coil is energised, the piston moves to its right-hand limit stop. Port 1
(supply port) and port 4 (consumer port) are connected to each other, as are port 2 (consumer port)
and port 3 (exhaust port). Port 5 (exhaust port) is blocked.
If electrical current flows through the right-hand solenoid coil, the piston moves to its left-hand limit
stop. In this position, ports 1 and 2 are connected to each other, as are ports 4 and 5. Port 3
(exhaust port) is blocked.
Each of the activated switching positions is retained for as long as the respective solenoid coil is
energised. If the flow of current is interrupted, the piston returns to its mid-position (normal
position). This is also the case when both solenoids are energised at the same time, because they
work against each other with identical force.
In the deenergised state, the valve can be switched by means of manual override.
Double-acting cylinders can be brought to a standstill within the stroke range with this valve. The
cylinder piston is briefly held, under pressure, when the valve is in its mid-position (normal
position).

Mid-position of a 5/3-way solenoid valve

Directional control valves with three switching positions provide expanded cylinder actuating options
thanks to their additional mid-position Differentiation is made amongst three types of mid-position: closed,
pressurised and exhausted.
Cylinder performance varies depending on the utilised type of mid-position.
– Describe the effects of the various mid-positions on the performance of a double-acting cylinder, when a
5/3-way solenoid valve is switched to the mid-position.
5/3-way solenoid valve, mid-position closed

All ports are blocked in the mid-position (normal position). In the case of a 5/3-way valve which
blocks all ports in the mid-position, the piston rod comes to a standstill, i.e. is held in position. This
even the case if the piston rod is not at its limit stop.
5/3-way solenoid valve, mid-position pressurised

In the mid-position (normal position), ports 2 and 4 are pressurised via port 1, and ports 3 and 5 are
blocked. In the case of a 5/3-way valve which pressurises in the mid-position, the piston rod
advances with reduced force (because the effective pressurised surface area is smaller on the
piston rod side).
5/3-way solenoid valve, mid-position exhausted

In the mid-position (normal position), ports 2 and 4 are exhausted via ports 3 and 5 respectively,
and port 1 is blocked. In the case of a 5/3-way valve which exhausts the consumer ports in the mid-
position, the piston in the cylinder drive unit does not exert any force on the piston rod. The piston
rod can move freely.

1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
Completing the pneumatic circuit diagram

No 5/3-way solenoid valve has been included in the equipment set.
– How can this solenoid valve be replaced by means of a suitable circuit? Complete the pneumatic 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

Note
A total of 4 pushbuttons and 2 control switches are included in equipment sets TP 201 and TP 202.
You’ll either need a third electrical signal input, or you can proceed as follows:
Omit the “stop at end of cycle” pushbutton.
Use a control switch for the “manual” pushbutton.
Use a control switch for the “reset” pushbutton.

Operating modes
– Describe the controller functions listed below.
Auto/Man
Selection can be made here between the automatic and manual operating modes.
Reset
After an emergency stop, the system may be in an undefined position. The system is returned to its
initial position with the reset function. Resetting is only possible in the manual operating mode.
Single cycle
Only one cycle is executed when the start button is activated.
Continuous cycle
Numerous cycles are executed one after the other when the start button is activated until
continuous cycle is ended by activating “Stop” or “Man”.
Start/Stop
The system is started or stopped in the selected operating mode.

– Describe the controller’s emergency stop and reset functions for the handling unit.

Sensor signals 1B1 and 1B2 are connected to permanent positive and are not switched off by the
emergency stop mushroom actuator. The status of the machine can thus be recognised even with
activated emergency stop function. All operating modes are subordinate to the emergency stop
function. The emergency stop switch is laid out as a normally closed contact. In this way, the circuit
functions even in the event of a broken wire.
Emergency stop sequence

Relay K1 is released when the emergency stop function is activated. Changeover contact K1 in
current path 6 opens. Electrical power is shut off for the entire signal processing and signal output
section.
3/2-way solenoid valves 1V1 and 1V2 (normally closed) are immediately set to the normal position
by their reset springs and block compressed air supply to cylinder 1A1. The two piloted non-return
valves block exhaust air at the cylinder. The cylinder remains in its current position under pressure.
Reset sequence
The reset operating mode (current path 9) is used in order to return cylinder 1A1 to a defined
position after activating the emergency stop mushroom actuator.
If reset is activated in the manual operating mode (changeover contact K4 in current path 9 open),
relay K5 (current path 9) is picked up and self-latching is activated (changeover contact K5 in
current path 10).
At the same time, changeover contact K5 in current path 21 closes. The electrical circuit in solenoid
coil 1M2 is closed. The 3/2-way solenoid valve is switched. Cylinder 1A1 travels to its rear end-
position.
Proximity switch 1B1 is actuated in the rear end-position. Relay K2 is picked up. Changeover
contact K2 in current path 9 closes, and relay K5 is released.


– Check the equipment list. Have all of the required components been entered in the table below?
The equipment list is correct.
2 Non-return valve, piloted
2 5/2-way solenoid valve (slice M on the valve terminal)
9 Relay
1 Distributor block
Equipment list

Exercise 12:
Eliminating a malfunction at a machining station
Learning objectives
• You’ll be able to detect and eliminate errors in complex electro-pneumatic controllers.

The machining station for key blanks comes to a standstill during operation. An error has occurred and must
be eliminated. Afterwards, the system must be restarted.
Layout

Exercise 12: Eliminating a malfunction at a machining station
Project assignment
1. Describe circuit performance and compare this with correct circuit performance. Make use of the
function diagram to this end.
2. Narrow down possible causes of the malfunction. Make use of the pneumatic and electrical circuit
diagrams.
3. Pinpoint the malfunction within the circuit and eliminate it.
4. Place the circuit back into service.
START
1 2 3 4 5=1
(1M1)
1
1B2
1A1
0
(1M1) 1B1
2B2 (2M1)
1
2A1
2B1
0
(2M1)
Notes for the trainer

It’s advisable to carry out this task after completing exercise 4, TP 202, because correct setup of the
circuit has then been carried out and tested.
The error can be directly incorporated into the circuit by the trainer (see error simulation list).
It’s important to make sure that the trainees work systematically during troubleshooting.
Alternative
If a fully set-up circuit for exercise 4 is not available, troubleshooting can also be conducted
theoretically.
The trainer explains the malfunction (“cylinder 1A1 advances and then the circuit jams”).
The trainees narrow down the possible errors based on the GRAFCET chart.
The trainees prepare a list of possible causes of the error and describe how they will proceed during
troubleshooting (where must measurements be performed, what must be tested).

Troubleshooting in complex electro-pneumatic circuits

The following error occurs in the circuit depicted below:
The piston rods in cylinders 1A1 and 2A1 advance and remain in the front end-position.
– Describe the possible causes of this error.
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
– Enter possible causes of error in the list below.

Possible causes of error
Proximity switch 2B2 at cylinder 2A1 incorrectly adjusted or defective (e.g. wire break in current path 5)
Wire break in signal line from proximity switch 2B2 (current path 8)
Wire break in earth wire from relay K4, relay K4 defective (current path 6)
Wire break in the connector cable for changeover contact K4, terminal 14 (current path 12)
Wire break in the connector cable for changeover contact K4, terminal 11, downstream from changeover contact K7, terminal 24
(current path 12)
Wire break in the connector cable for changeover contact K7, terminal 21, downstream from relay K8, terminal A1 (current path 12)
Changeover contact K7 in current path 12 is defective (doesn’t close)
Wire break in earth wire from relay K8, relay K8 defective (current path 12)
Changeover contact K8 in current path 17 is defective (doesn’t open)
Conductors are interrupted at the points identified in the controller shown below.
– Explain which effects a broken wire would have on the circuit’s function at each of the identified points.

Error Effects of the error
Wire break in signal line from limit The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  the piston rod in
switch 2B1 (current path 4) cylinder 2A1 advances to the front end-position, proximity switch 2B2 is actuated  the piston
rod in cylinder 2A1 travels to the rear end-position  relay K3 is not picked up  changeover
contact K3 in current path 14 (connected as an NO contact) doesn’t switch  relay K9 is not
picked up  the changeover contact at K9 in current path 16 (connected as an NC contact)
doesn’t switch  the electrical circuit at solenoid coil 1M1 remains closed, the piston rod at
cylinder 1A1 remains advanced.
Wire break in the connector cable The piston rod in cylinder 1A1 advances  after leaving the rear end-position, limit switch 1B1 is
for changeover contact K6, no longer actuated  changeover contact K1 in current path 8 (connected as an NO contact)
terminal 11 (current path 9) opens  self-latching is not activated at relay K6 due to the wire break  relay K6 is released
and the circuit at solenoid coil 1M1 is open  the piston rod in cylinder 1A1 is advanced and
retracted a short distance without actuating proximity switch 1B2 or triggering subsequent
motion 2A1+  the piston rod in cylinder 2A1 doesn’t advance to the front end-position (remains
retracted).
Broken earth wire at relay K7 The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  current path 10 is
(current path 10) not closed, relay K7 is not picked up  subsequent motion 2A1+ is not triggered  the piston
rod in cylinder 2A1 does not advance to the front end-position (remains actuated), the piston rod
in cylinder 1A1 remains advanced.
Wire break in the connector cable The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  the piston rod in
for changeover contact K8, cylinder 2A1 advances to the front end-position, proximity switch 2B2 is actuated  relay K8 is
terminal 11 (current path 13) picked up, changeover contact K8 in current path 17 (connected as an NC contact) opens, the
electrical circuit at solenoid coil 2M1 is open  the piston rod in cylinder 2A1 is retracted  as
soon as it leaves the front end-position, proximity switch 2B2 is no longer actuated  self-
latching at relay K8 is not activated due to the wire break  relay K8 is only picked up for as long
as proximity switch 2B2 is actuated  when the signal from 2B2 is interrupted, changeover
contact K8 in current path 17 (connected as an NC contact) closes the circuit once again  the
electrical circuit at solenoid coil 2M1 is closed again  the piston rod in cylinder 2A1 is advanced
and retracted in an oscillating fashion without actuating limit switch 2B1 or tripping subsequent
motion 1A1–  the piston rod in cylinder 1A1 is not retracted to the rear end-position (remains
advanced).
Wire break in the connector cable The piston rod in cylinder 1A1 advances  the piston rod in cylinder 2A1 advances  the piston
for changeover contact K8, rod in cylinder 2A1 is retracted  limit switch 2B1 is actuated  relay K3 is picked up 
terminal 21, downstream from changeover contact K3 in current path 14 (connected as an NO contact) closes, as does
relay K9, terminal A1 (current changeover contact K8 (connected as an NO contact)  however, due to the wire break current
path 14) path 14 is not closed and relay K9 is not picked up  changeover contact K9 in current path 16
(connected as an NC contact) remains closed  the electrical circuit in solenoid coil 2M1 remains
closed  subsequent motion 1A1– is not triggered, the piston rod in cylinder 1A1 remains
advanced.

Troubleshooting: determination of the target status
– Create a displacement-step diagram with the help of the handouts.
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal

Troubleshooting: actual versus target status comparison

Determine the actual status of the system on the basis of the following documentation:
• Layout with description of the problem
• Graphic representation
– If correct functioning is not ensured (actual versus target status comparison), clearly mark the point in
the diagram where the error occurs.
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal

Error list for possible error simulation by the trainer

The following is a list of errors which you can incorporate into a controller. The corresponding printed forms
for troubleshooting are in the student workbook.
Error simulation Cause of error Effects of the error
Disconnect the earth Wire break in The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  the piston rod
wire from relay K8 current path 12 in cylinder 2A1 advances to the front end-position, proximity switch 2B2 is actuated 
(current path 12) or broken earth relay K8 is not picked up  changeover contact K8 in current path 17 (connected as an NC
wire from K8 contact) remains unactuated  the electrical circuit in solenoid coil 2M1 remains closed,
the piston rod in cylinder 2A1 remains advanced, subsequent motions 2A1– and 1A1– are
not triggered.
Disconnect the Wire break in The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  the piston rod
connector cable current path 13 in cylinder 2A1 advances to the front end-position, proximity switch 2B2 is actuated 
between changeover relay K8 is picked up, changeover contact K8 in current path 17 (connected as an NC
contact K8 at contact) opens  the electrical circuit at solenoid coil 2M1 is opened  the piston rod in
terminal 11 in cylinder 2A1 is retracted  as soon as it leaves the front end-position, proximity switch
current path 13 and 2B2 is no longer actuated  self-latching at relay K8 is not activated due to the wire break
changeover contact  relay K8 is only picked up for as long as proximity switch 2B2 is actuated  when the
K4 or K7 in current signal from 2B2 is interrupted, changeover contact K8 in current path 17 (connected as an
path 12 NC contact) closes the circuit once again  the electrical circuit at solenoid coil 2M1 is
closed again  the piston rod in cylinder 2A1 is advanced an retracted in an oscillating
fashion without actuating limit switch 2B1 or tripping subsequent motion 1A1–  the
piston rod in cylinder 1A1 is not retracted to the rear end-position (remains advanced).
Disconnect the Wire break in The piston rod in cylinder 1A1 advances  the piston rod in cylinder 2A1 advances  the
connector cable current path 14 piston rod in cylinder 2A1 is retracted  limit switch 2B1 is actuated  relay K3 is picked
between changeover up  changeover contact K3 in current path 14 (connected as an NO contact) closes, as
contact K3, terminal does changeover contact K8 (connected as an NO contact)  due to the wire break,
11, and changeover current path 14 is not closed and relay K9 is not picked up  changeover contact K9 in
contact K8, terminal current path 16 (connected as an NC contact) remains closed  the electrical circuit in
24 solenoid coil 2M1 remains closed  subsequent motion 1A1– is not triggered, the piston
rod in cylinder 1A1 remains advanced.
Disconnect the Wire break in The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  relay K7 is
connector cable current path 17 picked up  current path 17 is not closed due to the wire break between changeover
between changeover contacts K7 and K8  the electrical circuit in solenoid coil 2M1 is not closed, the piston rod
contact K7, terminal in cylinder 2A1 remains retracted, the piston rod in cylinder 1A1 remains advanced.
31, and changeover
contact K8, terminal
32
not triggered.

Error list for possible error simulation by the trainer
Error simulation Cause of error Effects of the error
not triggered.
Disconnect the Wire break in The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  the piston rod
connector cable current path 13 in cylinder 2A1 advances to the front end-position, proximity switch 2B2 is actuated 
between changeover relay K8 is picked up, changeover contact K8 in current path 17 (connected as an NC
contact K8 at contact) opens  the electrical circuit at solenoid coil 2M1 is opened  the piston rod in
terminal 11 in cylinder 2A1 is retracted  as soon as it leaves the front end-position, proximity switch
current path 13 and 2B2 is no longer actuated  self-latching at relay K8 is not activated due to the wire break
changeover contact  relay K8 is only picked up for as long as proximity switch 2B2 is actuated  when the
K4 or K7 in current signal from 2B2 is interrupted, changeover contact K8 in current path 17 (connected as an
path 12 NC contact) closes the circuit once again  the electrical circuit at solenoid coil 2M1 is
closed again  the piston rod in cylinder 2A1 is advanced and retracted in an oscillating
fashion without actuating limit switch 2B1 or tripping subsequent motion 1A1–  the
piston rod in cylinder 1A1 is not retracted to the rear end-position (remains advanced).
Disconnect the Wire break in The piston rod in cylinder 1A1 advances  the piston rod in cylinder 2A1 advances  the
connector cable current path 14 piston rod in cylinder 2A1 is retracted  limit switch 2B1 is actuated  relay K3 is picked
between changeover up  changeover contact K3 in current path 14 (connected as an NO contact) closes, as
contact K3, terminal does changeover contact K8 (connected as an NO contact)  due to the wire break,
11, and changeover current path 14 is not closed and relay K9 is not picked up  changeover contact K9 in
contact K8, terminal current path 16 (connected as an NC contact) remains closed  the electrical circuit in
24 solenoid coil 2M1 remains closed  subsequent motion 1A1– is not triggered, the piston
rod in cylinder 1A1 remains advanced.
Disconnect the Wire break in The piston rod in cylinder 1A1 advances, proximity switch 1B2 is actuated  relay K7 is
connector cable current path 17 picked up  current path 17 is not closed due to the wire break between changeover
between changeover contacts K7 and K8  the electrical circuit in solenoid coil 2M1 is not closed, the piston rod
contact K7, terminal in cylinder 2A1 remains retracted, the piston rod in cylinder 1A1 remains advanced.
31, and changeover
contact K8, terminal
32

Troubleshooting: description of the error

You marked the point at which the error occurs in the diagram in the worksheet for the actual versus target
status comparison.
– Describe the sequence up to the point at which the station or system comes to a standstill in a few
words.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
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_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
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Troubleshooting: pinpointing pneumatic errors

After having determined the system’s actual status, think about what might have caused the error.
In which pneumatic tubing connections might the error be located?
– Enter all possibilities. Specify elements at the beginning and end of the tubing connections in order to
ensure clear identification.
Possible error no. Tubing connection

Beginning End

Troubleshooting: pinpointing electrical errors

After having determined the system’s actual status, think about what might have caused the error.
In which current paths might the error be located?

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

Troubleshooting: narrowing down pneumatic errors

Examine the possible pneumatic causes of error which you have discovered.
Use the same error numbering scheme you used in the worksheet for pinpointing pneumatic errors.
Document the procedure used for inspecting the tubing connections.
– Enter the results of your inspection.
Possible error no. Tubing connection Inspection Results

Beginning End
Measuring and test report:

Troubleshooting: narrowing down electrical errors

Examine the possible electrical causes of error which you have discovered.
Use the same error numbering scheme you used in the worksheet for pinpointing electrical errors.
Document your procedure for inspecting the wiring connections.
– Enter the results of your inspection.
Possible error no. Current path Measuring points Inspection Results
Measuring and test report

Troubleshooting: error elimination

After pinpointing the location of the error, document the procedure used in order to eliminate the error in
this worksheet.
– Fully describe each step.
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_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
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_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
Notes
If the system does not function as required, go back to the first worksheet and repeat the
troubleshooting process.

Troubleshooting: restart
After having detected, localised and eliminated the error or errors, start the system back up again in
accordance with the target status.
– Reset the specified setpoint times.

– Document your procedure in a few words.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Workbook Electropneumatics Advanced Level

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Electropneumatics

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

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

Exercises and solutions

Exercise 1: Implementing a diverting device ____________________________________________________1

© Festo Didactic 541091 III

Exercise 1: Implementing a diverting device ____________________________________________________1

IV © Festo Didactic 541091

The training package for electropneumatics may only be used:

© Festo Didactic 541091 V

VI © Festo Didactic 541091

The structure of the teachware corresponds to that of the hardware. It includes:

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

If so, please send us an e-mail at did@de.festo.com.

© Festo Didactic 541091 VII

VIII © Festo Didactic 541091

© Festo Didactic 541091 IX

X © Festo Didactic 541091

Important elements of the TP 200

Textbook Fundamentals of pneumatics and electropneumatics

Workbooks TP 201 basic level

Optional teachware Set of transparencies and overhead projector

P100 Basic pneumatics knowledge for machine operators

P111 Fundamentals of pneumatics and electro-pneumatics

P121 Maintenance and troubleshooting for pneumatic and electro-pneumatic systems

P-OP Tracking down waste – economic use of pneumatics

P-NEU Pneumatics refresher and update

P-AL Pneumatics for vocational education

P-AZUBI Pneumatics and electro-pneumatics for trainees

© Festo Didactic 541091 XI

• Become familiar with the setup and function of valve terminals.

XII © Festo Didactic 541091

Become familiar with the setup and function of valve • •

Be able to use valve terminals in accordance with • •

Be able to resolve overlapping signals in sequence •

Be able to create a displacement-step diagram for • • •

Be able to convert a function chart into a GRAFCET •

Be able to setup a step sequence using valves with •

Recognise overlapping signals in sequence controls. •

Be able to setup a step sequence using double pilot •

Become familiar with the modes of operation of •

Be able to select proximity switches which are •

Become familiar with logic operations and implement •

Become familiar with options for querying pressure •

Become familiar with the setup and function of a •

Become familiar with the possible uses of an on-delay •

© Festo Didactic 541091 XIII

Become familiar with operating modes and learn to set • •

Become familiar with the function of an electrical •

Be able to develop and set up the emergency stop •

Be able to develop and set up the emergency stop •

Be able to develop and set up a specified motion •

Be able to set up the following emergency stop •

Become familiar with the setup and mode of operation •

Be able to replace a 5/3-way solenoid valve with 3/2- •

Be able to integrate the reset operating mode into a •

Be able to detect and eliminate errors in complex •

XIV © Festo Didactic 541091

Designation Order no. Quantity

Proximity switch, inductive 548643 1