Learning System for Automation

Electrohydraulics
Workbook Advanced Level

094471
Authorised applications and liability
The Learning System for Automation and Communication has been de-
veloped and prepared exclusively for training in the field of automation
and communication. The training organization and / or trainee shall en-
sure that the safety precautions described in the accompanying Techni-
cal documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation, un-
less caused by premeditation or gross negligence on the part of Festo
Didactic.

Order No.: 094471

Description: TEACHW. E-HYDR.
Designation: D.S602-C-SIBU-GB
Edition: 06/1999
Layout: 17.06.1999, OCKER Ingenieurbüro
Grafik: OCKER Ingenieurbüro
Authors: D. Merkle, H. Werner, A. Zimmermann

© Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1999

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for train-
ing purposes, by persons authorised in this sense.

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Preface
Festo Didactic’s Learning System for Automation and Communications
is designed to meet a number of different training and vocational re-
quirements. The Training Packages are structured accordingly:
„ Basic Packages provide fundamental knowledge which is not limited
to a specific technology.
„ Technology Packages deal with the important areas of open-loop and
closed-loop control technology.
„ Function Packages explain the basic functions of automation sys-
tems.
„ Application Packages provide basic and further training closely ori-
ented to everyday industrial practice.
Technology Packages deal with the technologies of pneumatics, elec-
tropneumatics, programmable logic controllers, automation with PCs,
hydraulics, electrohydraulics, proportional hydraulics and application
technology (handling).

Mounting frame Fig. 1:

Example of Hydrau-
lics 2000 –
Mobile laboratory trolley
Festo Didactic
Learning by doing
Return on Qualifikation

U = 230V~
Profile plate

p = 6 MPa

Storage tray

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The modular structure of the Learning System permits applications to be

assembled which go beyond the scope of the individual packages. It is
possible, for example, to use PLCs to control pneumatic, hydraulic and
electrical actuators.
All training packages have an identical structure:
„ Hardware
„ Courseware
„ Software
„ Courses

The hardware consists of industrial components and installations,

adapted for didactic purposes.
The courseware is matched methodologically and didactically to the
training hardware. The courseware comprises:
„ Textbooks (with exercises and example)
„ Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)
„ OHP transparencies and videos (to bring teaching to life)
Teaching and training media are available in several languages. They
have been designed for use in classroom teaching but can also be used
for self-study purposes.
In the software field, CAD programs, computer-based training programs
and programming software for programmable logic controllers are avail-
able.
Festo Didactic’s range of products for basic and further training is com-
pleted by a comprehensive selection of course matched to the contents
of the Technology Packages.

TP602 • Festo Didactic

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Information on the
Technology Package “Electrohydraulics” TP602

New features of Hydraulics 2000

„ Authentic industrial components, nominal size 4 mm, on the profile
plate
„ Development of key qualifications:
Technical competence, methodological competence, social compe-
tence and personal competence
„ Practice in teamwork, cooperation, study technique, independence
and organisational ability

Objective – Competence in action

Contents
Section A Course Exercises and worksheets
Section B Fundamentals Refer to textbook
Section C Solutions Function diagram, circuit diagrams,
solution description and components lists
Section D Appendix Storage tray, mounting systems,
coupling system and data sheets

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TP602 • Festo Didactic

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Table of contents
Introduction 9
Safety recommendations 11
Notes on procedure 12
Technical notes 13
Training contents 19
Training aims / exercise table (Table 1) 20
Equipment set for Basic Level TP 601 21
Equipment set forAdvanced Level TP602 24
List of additional components TP600 27
Component/exercise table (Table 2) 28
Methodological structure of exercises 29

Section A – Course
Exercise 1: Shut-off valve
Rapid-traverse feed circuit, latching A-3
Exercise 2: Clamping unit
Accumulator circuit, pressureless bypass A-5
Exercise 3: Milling machine
Displacement/step control,
standing sequencer with branch A-7
Exercise 4: Veneering press
Accumulator circuit,
sequence control with EMERGENCY STOP A-9
Exercise 5: Bending press
Flow dividing valve, pilot control A-11
Exercise 6: Broaching machine
Differential cylinder,
sequence control with EMERGENCY STOP
and INCHING mode A-13
Exercise 7: Continuous-flow drying oven
Sequence control with timer relay,
motorised return in INCHING mode A-15

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Exercise 8: Polishing machine

Hydraulic differential circuit,
preselect counter A-17
Exercise 9: Plastic injection moulding machine
Pressure sequence control,
single- and continuous-cycle operation A-19
Exercise 10: Embossing press
Accumulator as power supply after
EMERGENCY STOP, two-hand start circuit A-21

Section B – Fundamentals

Section C – Solutions
Solution 1: Shut-off valve C-3
Solution 2: Clamping unit C-11
Solution 3: Milling machine C-17
Solution 4: Veneering press C-25
Solution 5: Bending press C-31
Solution 6: Broaching machine C-35
Solution 7: Continuous-flow drying oven C-41
Solution 8: Polishing machine C-47
Solution 9: Plastic injection moulding machine C-57
Solution 10: Embossing press C-65

Section D – Appendix
Storage tray D-2
Mounting systems D-3
Sub-base D-5
Coupling system D-6
Data sheets ...

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Introduction
This workbook forms part of Festo Didactic’s Learning System for
Automation and Communications. The Training Package TP600 is de-
signed to provide an introduction to the fundamentals of electrohydraulic
control technology. This package comprises a basic level and an ad-
vanced level. The basic level package TP601 teaches basic knowledge
of electrohydraulic control technology. The two equipment sets TP601
and TP602 for the advanced level provide the student with the key
qualification “Technical competence”.

The hydraulic components have been designed to provide the following:

„ Easy handling
„ Secure mounting
„ Environmentally-friendly coupling system
„ Compact component dimensions
„ Authentic measuring methods

We recommend the following for the practical execution of the exer-

cises:
„ A Festo Didactic profile plate or laboratory trolley
„ TP601 and TP602 equipment sets
„ A hydraulic power pack
„ A number of hydraulic hose lines
„ An electrical power supply unit
„ A set of electrical cables

The Training Package TP602 deals with advanced training aims. These
help develop both technical and methodological competence in electro-
hydraulics:
„ Physical interrelationships in electrical engineering and hydraulics.
„ Drafting, assembly and understanding of electrohydraulic circuits.
„ Comparison of the use of various valves and other components.
„ Development of alternative solutions.

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The following technical equipment is required for safe operation of the

components:
„ A hydraulic power pack providing an operating pressure between
5 and 60 bar (0.5 to 6 MPa) and a flow rate of 2 l/min.
„ An electrical power supply for the hydraulic power pack of 230 V AC,
50 Hz, with a 10 A fuse.
„ A short-circuit-proof electrical power supply for the electrical compo-
nents with an output of 24 V DC and a 3 A fuse.
„ A Festo Didactic profile plate for mounting the components.
The profile plate (1100 x 700 mm) has 14 parallel T-grooves equally
spaced and 50 mm apart.

This workbook has been developed for use in the “Dual system” of vo-
cational training. It is, however, equally suitable for use in providing a
practical introduction to electrohydraulics for students at universities and
technical colleges. The modular design of the hardware allows theoreti-
cal questions to be dealt with experimentally in a simple and efficient
form.
The theoretical background to facilitate understanding of this workbook
is provided in the textbook
Learning System for Automation and Communications
„ Electrohydraulics Basic Level

Festo Didactic offers the following further training materials for hydrau-
lics:
„ Sets of OHP transparencies and electronic transparencies for PCs
„ Linear videos and interactive videos (video discs)
„ Autosketch CAD software and hydraulic symbol library
„ Hydraulics simulation program for planning, simulation and visualisa-
tion
„ Sets of magnetic symbols and symbols for OHPs, hydraulic slide cal-
culator
„ Transparent models for OHPs + special hydraulic power pack
„ Equipment sets: BIBB, hand-lever hydraulics, proportional hydraulics,
closed-loop hydraulics, measurement kit in case

Please see our special brochures for a detailed description of further

training materials.

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Safety recommendations
Observe the following in the interests of your own safety:
„ Caution!
Cylinders may advance unexpectedly when the hydraulic power pack
is switched on.
„ Do not exceed the maximum permissible hydraulic operating pres-
sure (see data sheets).
„ Do not operate electrical limit switches directly by hand when carrying
out fault-finding. Use a tool for this.
„ Use only an extra-low voltage of 24 V to operate the components.
„ Observe all general safety instructions.

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Notes on procedure
Always work in the following sequence when assembling or dismantling
an electrohydraulic circuit.

Assembly

1. The hydraulic power pack and electrical power supply must be

switched off during the assembly of the circuit.

2. All components must be securely fitted to the profile plate or mount-

ing frame.

3. Connect up the hydraulic hose lines.

All valves, cylinders and hose lines are fitted with quick-connection
couplings. Do not exceed the maximum permissible pressure of
12 MPa (120 bar). The maximum operating pressure is 6 MPa
(60 bar).

4. Connect up the electrical cables.

Connect test leads to the component sockets by means of 4 mm jack
plugs.

5. Before commissioning a hydraulic control circuit, check that all return

lines are connected and that all connectors are securely fitted.

6. Switch on the electrical power supply first and then the hydraulic
power pack.

7. Commission the control circuit

– Press the START pushbutton
– Adjust components as necessary
– Compare what you have assembled with the description in the book

Dismantling

8. Before dismantling the circuit, ensure that pressure in hydraulic com-

ponents has been released:

Couplings must be disconnected only under zero pressure!

9. Switch off the hydraulic power pack first and then the electrical power
supply.

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Technical notes
Mechanical
„ Mounting the components on the profile plate
The profile plate for the assembly of components is equipped for
mounting variants A to D:
Variant A, Detent system
Light, non load-bearing components (e.g. directional control valves).
Simply clip the components into the groove of the profile plate. The
components can be released by pressing the blue lever.
Variant B, Rotational system
Medium-weight, load-bearing components (e.g. actuators). These com-
ponents are clamped onto the profile plate by means of T-head bolts.
The components are clamped or released by means of the blue triple
grip nut.
Variant C, Screw-in system
For heavy, load-bearing components, i.e. components which are rarely
removed from the profile plate (such as start-up valves with filter regu-
lator). The components are secured by means of cheese head screws
and T-head nuts.
Variant D, Plug-in system
Light, non load-bearing components with locating pins (e.g. signalling
device). These components are secured by means of plug-in adapters.

„ Mounting components in the overhead mounting frame

Introduce the rear of components with black plastic housings and four
locating pins into the mounting frame positioned over the profile plate.
The two spacers at top and bottom will snap into place.
To remove the component, press the spacers inwards and lift out the
component.

Hydraulic
„ The hydraulic power pack incorporates an adjustable pressure relief
valve. In the interests of safety, the pressure is limited to approx.
6 MPa (60 bar). Every time a control circuit is assembled on the pro-
file plate, a second pressure relief valve is used. We recommend that
this should be set to a maximum pressure of 5 MPa (50 bar).

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„ All valves, cylinders and hose lines are fitted with quick-connection
couplings which ensure minimum leakage. The maximum pressure
for all components in the training package is 120 bar (12 MPa).
Thanks to their design, the couplings reduce leakage during connec-
tion and disconnection to a minimum.

The operating pressure should not exceed 60 bar (6 MPa).

„ In the case of double-acting cylinders, the pressure intensification

effect may produce an increased pressure proportional to the area
ratio of the cylinder. With an area ratio of 1:1.7 and an operating
pressure of 60 bar (6 MPa), this increased pressure may be over
100 bar (10 MPa)!

Fig. 2:
Pressure intensification

„ If connections are detached under pressure, the non-return valve in

the coupling may cause pressure to become trapped in the valve or
other component concerned. The pressure relieving device can be
used to release this pressure. Exception: This is not possible in the
case of hose lines and non-return valves. Ensure therefore that con-
trol circuits are depressurised before hose lines are disconnected and
the circuit is dismantled.
„ All valves, other components and hose lines are fitted with self-
closing quick-connection couplings. This prevents the accidental spill-
age of hydraulic fluid. In the interests of simplicity, these couplings
are not shown in circuit diagrams.

Fig. 3:
Detailed and
Simplified representation in
circuit diagrams
Throttle Hose Shut-off valve

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Symbolic representation of directional control valves

Valves are shown symbolically in the “Circuit diagram, hydraulic” (sys-
tem circuit diagram) in the same way as in the textbook TP601. The
crossover position is on the right and the parallel position on the left.
Working port A however is on the right and port B therefore on the left.
This representation of the symbol describes the new hardware of Hy-
draulics 2000.
In the diagram “Practical assembly hydraulic” the valve symbols are
based on the valve designation i.e. hardware orientated. The crossover
position is on the left and the parallel position on the right. Working port
A is once again on the left and port B on the right.
The two different symbolic representations describe all functions of a
given valve. In practice, valves by different manufacturers with identical
functions are sometimes given different symbols. This is permitted by
the applicable standard, “Fluidics: Graphic Symbols and Circuit Dia-
grams”. DIN ISO 121 Part 1, of November 1993.

Valve Circuit diagram, Practical assembly, Representation of

hydraulic hydraulic directional control valves

4/2-way single
solenoid valve

4/3-way double
solenoid valve,
closed in
mid-position

Since hydraulic valves are very expensive, only a small number and
therefore limited types are available for use in the equipment set.

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The 4/2-way valve can be used to produce four further basic functions.

Valve Basic function Connection of 4/2-way double

solenoid valve

2/2-way valve,
normally closed

2/2-way valve,
normally open

3/2-way valve,
normally closed

3/2-way valve,
normally open

Ports on the directional control valve which are not required are sealed
via self-closing coupling nipples. It is not necessary to seal these ports
by means of plugs.

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The 4/3-way valve with closed mid-position fulfils various dif-

ferent functions in the exercises in this book.

Description Function 4/3-way double solenoid valve,

closed in mid-position
in “Circuit diagram, hydraulic” in “Practical assembly, hydraulic”

No electrical connection is
made to solenoid 1Y2.

Solenoid 1Y2 must be acti-

vated via an additional path
in the “Practical assembly,
electrical” drawing.

No electrical connection is
made to solenoid 1Y2.

or

No electrical connection is
made to solenoid 1Y1.

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Electrical
Power supply:
230 V AC, 50 Hz
„ The hydraulic power pack is protected by a 10 A fuse.
„ The short-circuit-proof electrical power supply has a 3 A fuse.
„ The output voltage of this power supply is 24 V DC.
„ The output current is limited to a maximum of 5 A.

Wiring:
Universal cable set: 65 red and 37 blue laboratory cables in 5 lengths.
All electrohydraulic components are equipped with 4 mm sockets. The
electrical connections for these components are made using the labo-
ratory cables with 4 mm jack plugs.

Function wiring:
All electrohydraulic componets are also equipped with sockets to allow
the wiring of functions. This considerably reduces the assembly time
required and the risk of incorrect connections.

A distinction should be made between the two designs of electrical limit

switches:
„ Electrical limit switch, actuated from the left
„ Electrical limit switch, actuated from the right
„ When cylinder piston speeds are high, the limit switches should be
actuated by cylinder cams only in the specified direction.
„ Limit switches must not be actuated from the front.
„ Both types of limit switches are shown by the same symbol in the
hydraulic and electrical circuit diagrams.

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Training contents
„ Basic physical principles of electric engineering and hydraulics. Basic Level
(TP601)
„ Function and use of electrical and electrohydraulic components such
as switches, pushbuttons and solenoid valves.
„ Naming and reading of electrical and hydraulic symbols.
„ Development and reading of standard circuit diagrams.
„ Representation of control exercises as function diagrams.
„ Drafting, assembly and commissioning of basic circuits.
„ Direct and indirect activation of cylinders.
„ Activation of a hydraulic motor.
„ MANUAL and AUTOMATIC modes.
„ Position and pressure-dependent control circuits.
„ Interlock circuit.
„ Rapid-traverse circuit.
„ Fault-finding with simple electrohydraulic control circuits.

„ Function and use of electronic sensors, hydraulic motors and hydrau- Advanced Level
lic accumulators. (TP602)
„ Complex sequence controls.
„ Combination position and pressure-dependent control circuits.
„ Electrical control circuit with several actuators.
„ Sequence controls with MANUAL/AUTOMATIC, EMERGENCY
STOP and SETTING modes.
„ Circuit with hydraulic accumulator.
„ Position- and time-dependent control circuits.
„ Systematic fault-finding in electrohydraulic control circuits.
„ Development of sequence controls from a function diagram.
„ Controls with timer relays with switch-on and switch-off delays.
„ Counter controls with preselect counters.

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Training aims / exercise table (Table 1)

List of training aims Training aim Exercises
1 2 3 4 5 6 7 8 9 10

Use of limit switches • • • • • •

Use of proximity sensors • • • • •
Rapid-traverse feed circuit • • •
Accumulator circuit • •
Existing sequencer with branch •
EMERGENCY STOP circuit • • • • • •
Hydraulic flow divider •
Differential circuit • •
INCHING mode • • •
Use of a timer relay • • •
Use of a counter •
Pressure sequence circuit •
Two-hand start circuit •

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Equipment set for Basic Level TP 601

This equipment set has been compiled for use in basic training in elec-
trohydraulic control technology. The set can be combined in any desired
way with other equipment sets from the Festo Didactic Learning System.

Description Order No. Qty. Equipment set TP 601

Order No.: 184463
Relay, 3-fold* 162241 2
Signal input unit, electrical* 162242 1
Indicator and distributor unit, electrical* 162244 1
Pressure gauge 152841 3
One-way flow control valve 152843 1
Non-return valve, 1 bar 152845 1
Non-return valve, 5 bar 152846 1
Branch tee 152847 8
Pressure relief valve, pressure sequence valve 152848 2
2-way flow control valve 152851 1
Non-return valve, pilot actuated 152852 1
4/2-way single solenoid valve 167082 1
4/3-way double solenoid valve, closed in mid-position 167083 1
Double-acting cylinder, 16/10/200 152857 1
Hydraulic motor, 8 l/min 152858 1
Limit switch, electrical, actuated from left 183322 2
Limit switch, electrical, actuated from right 183345 2
Weight, 9 kg 152972 1

We recommend: Order No. Qty.

Hose lines with quick-connection couplings, 600 mm 152960 10

Hose lines with quick-connection couplings, 1000 mm 152970 8

* These components can be mounted in the overhead mounting frame or, by using the
adapter set (Order No. 35651), on the profile plate.

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Symbols for Pressure gauge One-way flow control valve

equipment set TP601

Non-return valve, 1 bar or 5 bar Pressure relief valve,

Pressure sequence valve

2-way flow control valve Non-return valve, pilot actuated

Cylinder, 16/10/200 Hydraulic motor, 8 l/min

Weight, 9 kg Relay, 3-fold

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Signal input unit, electrical Symbols of

equipment set TP601

Indicator and distributor unit, electrical *Limit switch, electrical,

actuated from left or from right

4/2-way single solenoid valve 4/3-way double solenoid valve,

closed in mid-position

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Equipment set forAdvanced Level TP602

This equipment set has been compiled for advanced-level teaching of
electrohydraulic control technology. The two equipment sets TP601 and
TP602 can be expanded in any desired way with other equipment sets
from Festo Didactic’s Learning System for Automation and Communica-
tions.

Equipment set TP602 Description Order No. Qty.

Order No.: 184464
Branch tee 152847 4
Pressure relief valve, pilot actuated 152849 1
3-way pressure reducing valve 152850 1
Cylinder, 16/10/200 152857 1
Diaphragm accumulator with safety block 152859 1
Flow dividing valve 152967 1
Gradual shut-off valve 152968 1
Relay, 3-fold* 162241 2
Timer relay, 2-fold* 162243 1
Indicator and distributor unit, electrical * 162244 1
Preselect counter, electrical, incremental * 162355 1
Pressure switch 167080 1
4/2-way single solenoid valve 167082 1
Proximity sensor, inductive 178574 1
Proximity sensor, capacitive 178575 1
Proximity sensor, optical 178577 1
EMERGENCY STOP, electrical 183347 1

We recommend: Order No. Qty.

Hose lines with quick-connection couplings, 600 mm 152960 10

Hose lines with quick-connection couplings, 1000 mm 152970 2

*) These components can be mounted in the overhead mounting frame or, by using the
adapter set (Order No. 35651), on the profile plate.

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 25

Relay, 3-fold Preselect counter, electrical, incremental Symbols for

equipment set TP602

Timer relay, 2-fold

switch-on delay switch-off delay

Indicator and distributor unit, electrical Pressure switch

Pressure relief valve, pilot actuated 3-way pressure reducing valve

4/2-way single solenoid valve Diaphragm accumulator with safety block

Cylinder, 16/10/200

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26

Symbols for EMERGENCY STOP, electrical Proximity sensor, inductive

equipment set TP602

Proximity sensor, capacitive Proximity sensor, optical

Flow dividing valve Gradual shut-off valve

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 27

List of additional components TP600

Description Order No.

Mounting kit for hydraulic cylinder 120778

Throttle valve 152842
Shut-off valve 152844
Hose line with quick-connection coupling, 600 mm 152960
Hydraulic power pack, 2 l/min 152962
Hose line with quick-connection coupling, 1000 mm 152970
Pressure relieving device 152971
Cover (for weight, 9 kg) 152973
Hose line with quick-connection coupling, 1500 mm 158352
Hose line with quick-connection coupling, 3000 mm 159386
Power supply unit, attachment fixture, 24V 4,5A 159396
Profile plate, large 159411
Set of hydraulic labels 162383
Power supply unit, table, 24V 4,5A 162417
Flow rate/rotary speed sensor 167081
4/3-way double solenoid valve relieved in mid-position 167084
4/3-way double solenoid valve with recirculating mid-position 167085
Cable set with safety plugs 167091
Coupling nipple 342047
Coupling socket 346491

For further additional components from our “Hydraulics 2000" system,

please see our price lists.

Learning System for Automation and Communications

Technology Packages TP100, TP...

Electrohydraulics TP600

Additional
TP601 TP602 components

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28

Component/exercise table (Table 2)

Description Exercise
1 2 3 4 5 6 7 8 9 10

Relay, 3-fold 3 2 3 3 1 3 3 4 4 3
Signal input unit, electrical 1 1 1 1 1 1 1 1 2 1
Timer relay, 2-off 1 1 1
Preselect counter, electrical, incremental 1
Indicator and distributor unit, electrical 1 1 1 1 1 1 1 1 1 1
Pressure switch 1 1 1 1 1 1
Pressure gauge 2 2 3 2 1 1 1 1 4 2
One-way flow control valve 1 1 1 1 1 2
Non-return valve, 1 bar 1 1 1 2 1 1 1
Non-return valve, 5 bar 1 1 1 1 1 1
Pressure relief valve,
pressure sequence valve 1 1 2 2 2 1 1 2 2 4

Pressure relief valve, pilot actuated 1 1

3-way pressure reducing valve 1 1
2-way flow control valve 1 1 1 1 1
Non-return valve, pilot actuated 1
4/2-way single solenoid valve 2 2 1 2 1 1 2 2 2
4/3-way double solenoid valve,
closed in mid-position 1 1 1 1 1 1 1 1 1 2

Cylinder, 16/10/200 1 1 2 1 2 1 1 2 2 2
Hydraulic motor, 8 l/min 1 1 1
Diaphragm accumulator with safety block 1 1 1
EMERGENCY STOP, electrical 1 1 1 1 1 1
Proximity sensor, inductive 1 1 1 1
Proximity sensor, capacitive 1 1 1 1
Proximity sensor, optical 2 1
Limit switch, electrical, actuated from left 2 1 1 2 2 2
Limit switch, electrical, actuated from right 2 1 1 2 2 2
Flow dividing valve 1

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Methodological structure of exercises

All 10 exercises have the same methodological structure.
„ The exercises in Section A are structured as follows:
– Subject
– Title
– Training aim(s)
– Problem definition
– Exercise
– Positional sketch

„ The solutions in Section C are structured as follows:

– Circuit diagram, hydraulic
– Circuit diagram, electrical
– Solution description
– Practical assembly, hydraulic
– Practical assembly, electrical
– Components list, hydraulic
– Components list, electrical

„ Work through each exercise as follows:

– Read the worksheet.
– Work out your own solution.
– Compare your solution with the one in this book.
– Assemble your control circuit.
– Commission your control circuit.
– Does your control circuit fulfil the requirements specified in the
worksheet?

Practical participation is both an enjoyable and rewarding method of

learning. We wish you success in designing and cunstructing the
circuits.

TP602 • Festo Didactic

30

TP602 • Festo Didactic

 A-1

Section A – Course
Exercise 1: Shut-off valve
Rapid-traverse feed circuit, latching A-3
Exercise 2: Clamping unit
Accumulator circuit, pressureless bypass A-5
Exercise 3: Milling machine
Displacement/step control,
existing sequencer with branch A-7
Exercise 4: Veneering press
Accumulator circuit,
sequence control with EMERGENCY STOP A-9
Exercise 5: Bending press
Flow dividing valve, pilot control A-11
Exercise 6: Broaching machine
Differential cylinder,
sequence control with EMERGENCY STOP
and INCHING mode A-13
Exercise 7: Continuous-flow drying oven
Sequence control with timer relay,
motorised return in INCHING mode A-15
Exercise 8: Polishing machine
Hydraulic differential circuit,
preselect counter A-17
Exercise 9: Plastic injection moulding machine
Pressure sequence control,
single and continuous-cycle operation A-19
Exercise 10: Embossing press
Accumulator as power supply after
EMERGENCY STOP, two-hand start circuit A-21

TP602 • Festo Didactic

A-2

TP602 • Festo Didactic

 A-3
Exercise 1

Electrohydraulics Subject

Shut-off valve Title

„ Drafting and assembly of the electrical and hydraulic circuit Training aims
diagrams for a rapid-traverse feed circuit.
„ Familiarisation with a latching circuit for sensors.

„ Draw the hydraulic and electrical circuit diagrams. Problem definition

„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-4
Exercise 1

Exercise A pipeline valve is being converted from manual operation to remote

control. A double-acting cylinder is being used for this purpose. The
pipeline valve is to be actuated first at high speed until it is approxi-
mately half-closed. The remainder of the motion must be carried out at
an adjustable lower speed.
Since it is not possible to fit limit switches, the instantaneous position of
the closing lever will be interrogated by proximity sensors.
A second pushbutton is used to start motion of the valve in the opposite
direction. Once the motion “OPEN VALVE” or “CLOSE VALVE” has
been started, a motion in the opposite direction may begin only when
the closing lever has reached its end position.

Parameters
The circuit must be switched to pump bypass in both end positions. A
visual indication of each end position must be provided.
A pressure gauge must be fitted in each case upstream of the final con-
trol element and on the piston side of the cylinder.

Fig. 1/1:
Positional sketch

The pipeline valve is shown open.

TP602 • Festo Didactic

 A-5
Exercise 2

Electrohydraulics Subject

Clamping unit Title

„ Familiarisation with an accumulator circuit to maintain Training aims

clamping pressure.
„ Installation of a pressureless tank bypass circuit to save energy.

„ Define the required components. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-6
Exercise 2

Exercise A workpiece must be held in a clamping unit for a lengthy period to allow
machining to be carried out. In order to enable the hydraulic pump to be
switched to pressureless bypass, an accumulator is to be used to com-
pensate for pressure losses.

Fig. 2/1:
Positional sketch

TP602 • Festo Didactic

 A-7
Exercise 3

Electrohydraulics Subject

Milling machine Title

„ Development of electrical and hydraulic circuit diagrams for a dis- Training aims
placement/step control with a cylinder which executes an oscillating
motion.
„ Use of an existing sequencer with branching.

„ Draw the hydraulic and electrical circuit diagrams. Problem definition

„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-8
Exercise 3

Exercise A milling machine is to be used to machine aluminium workpieces. The

workpiece is to be clamped hydraulically. The feed cylinder must not
execute its feed motion until the clamping pressure has been reached
and a limit switch has been actuated. The feed motion must be executed
twice, and the feed speed must be adjustable. An indicating light should
be used to show when the milling-machine motor is switched on after
the workpiece has been clamped. The advancement of the cutting depth
after the first feed motion must also be displayed via an indicating light.

Fig. 3/1:
Positional sketch

TP602 • Festo Didactic

 A-9
Exercise 4

Electrohydraulics Subject

Veneering press Title

„ Drafting and assembly of the electrical and hydraulic circuit diagrams Training aims
for a sequence control with an EMERGENCY STOP parameter.
„ Use of a hydraulic accumulator.

„ Draw the hydraulic and electrical circuit diagrams. Problem definition

„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-10
Exercise 4

Exercise The stroke of a veneering press is executed first at a rapid-traverse

speed, followed by a switchover to a slower speed.
Once the end stop has been reached (limit switch) and the pressure set
on the pressure switch has been exceeded, the circuit switches to pres-
sureless bypass. Pressure is then maintained by the accumulator.
If the pressure falls during the veneering operation, the pump is
switched back in. The return stroke is initiated by means of a pushbut-
ton. The press must open at high speed if the EMERGENCY STOP
button is pressed.

Fig. 4/1:
Positional sketch

TP602 • Festo Didactic

 A-11
Exercise 5

Electrohydraulics Subject

Bending press Title

„ Describing the design and possible uses of a flow dividing valve. Training aims
„ Drafting and assembly of the electrical and hydraulic circuit diagrams
incorporating a flow dividing valve and with electrical activation in the
form of a pilot control.

„ Draw the hydraulic and electrical circuit diagrams. Problem definition

„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-12
Exercise 5

Exercise A 3 m long hydraulic bending press is equipped with 2 cylinders linked

by the press beam. The two cylinders must therefore execute their
working stroke at the same speed. The working pressure must be ad-
justable as appropriate to the workpiece material. The press must be
capable of being operated only in INCHING mode. The press must
come to a standstill if the EMERGENCY STOP button is pressed.

Fig. 5/1:
Positional sketch

TP602 • Festo Didactic

 A-13
Exercise 6

Electrohydraulics Subject

Broaching machine Title

„ Assembly of a sequence control with the parameters of INCHING Training aims

mode, EMERGENCY STOP and rapid traverse in a differential circuit.

„ Draw the function diagram. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Define the required components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Commission the control circuit.
„ Compile the components list.

TP602 • Festo Didactic

A-14
Exercise 6

Exercise A broaching machine is used to cut keyways in gearwheels. The cutting

operation is carried out on the return stroke, and the piston rod must
therefore advance at rapid-traverse speed (differential circuit).
The working operation is started once the magazine has been filled (the
magazine is not monitored). The working speed must be adjustable. For
safety reasons, the machine must switch off on the return stroke when a
preset pressure is reached. Once the preset pressure has been ex-
ceeded, it must be possible to operate the press only in INCHING mode.
It must be possible to initiate a new working cycle only after the limit
switch 1S3 has been actuated.
The installation must stop when the EMERGENCY STOP button is
pressed. After the EMERGENCY STOP button has been unlocked, it
must similarly be possible to restart the machine only after the piston rod
has travelled to the limit switch 1S3.

Fig. 6/1:
Positional sketch

TP602 • Festo Didactic

 A-15
Exercise 7

Electrohydraulics Subject

Continuous-flow drying oven Title

„ Familiarisation with a timer relay with switch-on delay. Training aims

„ Drafting of a motorised return circuit in INCHING mode.

„ Draw the function diagram. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Define the required components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Commission the control circuit.
„ Compile the components list.

TP602 • Festo Didactic

A-16
Exercise 7

Exercise Various painted workpieces are moved on a chain conveyor through an

oven at a slow adjustable speed. An optical sensor is used to detect the
presence of painted workpieces on the belt. If workpieces are present
and the START pushbutton is pressed, the hydraulic belt motor 1M is
switched on. The motor switches off at the end of an adjustable period
(after workpieces have left the oven) and a double-acting cylinder 2A
pushes the workpieces from the oven belt onto a second conveyor belt.
If the EMERGENCY STOP button is pressed, it must then be possible to
operate the oven belt only in INCHING mode. It must be possible to re-
start the installation only after the EMERGENCY STOP button has been
unlocked.

Fig. 7/1:
Positional sketch

TP602 • Festo Didactic

 A-17
Exercise 8

Electrohydraulics Subject

Polishing machine Title

„ Development of a sequence control with a preselect counter. Training aims

„ Assembly of a hydraulic differential circuit.

„ Draw the function diagram. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-18
Exercise 8

Exercise A polishing spindle is used to polish covers. The covers are inserted and
clamped by hand. When the START pushbutton is pressed, the hydrau-
lic motor starts and the lowering cylinder 1A brings the polishing spindle
into its working position. The feed cylinder 3A then executes 15 double
strokes between two sensors. The 15 strokes are recorded by a prese-
lect counter. Once the 15 strokes have been completed, the piston rod
of the feed cylinder “3A” returns to its retracted end position. The motor
is now switched off and the polishing spindle is raised again. The feed
cylinder is activated via a differential circuit.

Fig. 8/1:
Positional sketch

TP602 • Festo Didactic

 A-19
Exercise 9

Electrohydraulics Subject

Plastic injection moulding machine Title

„ Familiarisation with a displacement and time-dependent sequence Training aims

control with two pressure levels.
„ Drafting and assembly of circuit for single and continuous-cycle op-
eration.

„ Draw the function diagram. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-20
Exercise 9

Exercise Plastic granulate is fed by a worm conveyor into a preheated plasticising

cylinder. The worm conveyor is driven by the hydraulic motor 1M.
After the mould has been closed (not represented in this exercise), the
START pushbutton is pressed to switch on the hydraulic motor to drive
the worm conveyor.
At the end of the time t (5 seconds), the motor is switched off and the
injection moulding cylinder 2A is first subjected to a low working pres-
sure. When the limit switch 2S3 is reached, a switchover is made to a
higher pressure. When, with the limit switch 2S3 still actuated, the pres-
sure preset on the pressure switch 1S1 is reached, the piston rod of the
cylinder 2A must execute a return stroke, allowing the mould to be
opened (not represented in the exercise). The workpiece is now ejected
by means of the ejector cylinder 3A.
Circuits must be provided for single and continuous-cycle operation.
When the EMERGENCY STOP button is pressed, the two cylinders
must return to their initial positions and the motor must stop.

Fig. 9/1:
Positional sketch

TP602 • Festo Didactic

 A-21
Exercise 10

Electrohydraulics Subject

Embossing press Title

„ Assembly of an electrical two-hand start circuit. Training aims

„ Familiarisation with an EMERGENCY STOP circuit using an accu-
mulator as an energy source.

„ Draw the function diagram. Problem definition

„ Draw the hydraulic and electrical circuit diagrams.
„ Define the required components.
„ Number the components.
„ Carry out practical assembly of the hydraulic and electrical control
circuits.
„ Compile the components list.

TP602 • Festo Didactic

A-22
Exercise 10

Exercise Workpieces are inserted into an embossing press by hand. When the
hydraulic power pack is switched on, an accumulator must first be filled
at high pressure. When this filling pressure has been reached, a two-
hand start device is used to close the machine guard at a lower pres-
sure. Once the guard is closed, a switchover is made back to the higher
pressure and the embossing operation is initiated.
In cases of emergency or failure of the hydraulic power pack, it must be
possible when the EMERGENCY STOP button is pressed, to open the
guard and the embossing cylinder with the aid of the accumulator. Fur-
thermore, a visual indicator must be provided to show that the
EMERGENCY STOP button has been pressed.

Fig. 10/1:
Positional sketch

TP602 • Festo Didactic

 B-1

Part B – Fundamentals
The theoretical fundamentals for the “Electrohydraulics” training packa-
ge are summarised in the textbook:

Learning System for Automation

Elektrohydraulics
Basic Level

TP602 • Festo Didactic

B-2

TP602 • Festo Didactic

 C-1

Section C – Solutions
Solution 1: Shut-off valve C-3
Solution 2: Clamping unit C-11
Solution 3: Milling machine C-17
Solution 4: Veneering press C-25
Solution 5: Bending press C-31
Solution 6: Broaching machine C-35
Solution 7: Continuous-flow drying oven C-41
Solution 8: Polishing machine C-47
Solution 9: Plastic injection moulding machine C-57
Solution 10: Embossing press C-65

TP602 • Festo Didactic

C-2

TP602 • Festo Didactic

 C-3
Solution 1

Shut-off valve

Fig. 1/2:
Circuit diagram, hydraulic

TP602 • Festo Didactic

C-4
Solution 1

Fig. 1/3:
Circuit diagram,
electrical (1)

S1 = Pushbutton CLOSE VALVE

S2 = Pushbutton OPEN VALVE
1B1 = Proximity sensor capacitive
1B2 = Proximity sensor inductive
H1 = Visual indicator for "Valve open"

Current paths 6+7 = Latching of 1B2

K2´ = Contact duplication of K2

TP602 • Festo Didactic

 C-5
Solution 1

Fig. 1/4:
Circuit diagram,
electrical (2)

1B3 = Proximity sensor, optical

H2 = Visual incicator for "Valve closed"

TP602 • Festo Didactic

C-6
Solution 1

Solution description Switch on the electrical power supply unit and then the hydraulic power
pack. All directional control valves are without power at this stage. The
pump delivery is discharged at virtually zero pressure to the tank via the
4/2-way valve 0V2. When the START pushbutton is pressed, relay K1 is
activated and latches. The contacts of the relay K1 energise the sole-
noid coil 1Y1 of the 4/3-way valve 1V1, and the coils 0Y of the 4/2-way
valve 0V2, and the 4/2-way valve 1V2, causing these valves to reverse.
0V2 shuts off the discharge to the tank, with the result that the pump
delivery flows to the piston chamber of the cylinder via the 4/3-way valve
and the 4/2-way valve 1V2 (a slight quantity of fluid also flows via the
flow control valve 1V3). The piston of the cylinder advances at high
speed to the sensor B 1B2.
Once the piston reaches the sensor 1B2, the relay K5 is activated. The
contact of K5 in current path 6 activates the relay K3, causing the con-
tact of K3 in current path 7 to close and the contact of K3 in current path
3 to open. The effect of the contact in current path 20 is to deactivate
the 4/2-way valve 1V2.
The piston rod now advances further at a slow speed. Once the piston
rod has passed the sensor 1B2, the relay K5 is deenergised and the
contact of K5 in current path 6 opens again. The relay K3 must, how-
ever, not be deenergised at this stage to ensure that the piston rod can
continue to advance at slow speed. This is why the contact current K3 in
current path 7 is essential to maintain the voltage. This type of circuit,
implemented in current paths 6 and 7, produces a latching circuit for the
sensor 1B2.
When the piston rod reaches the sensor 1B3, the latching of K1 is can-
celled. The 4/2-way valve returns to its initial position and the 4/2-way
valve 0V2, switches back to pressureless bypass.The return stroke of
the cylinder is initiated by pressing the pushbutton S2.

The latching circuits can be produced by using a further relay.

Advantages of sensors over limit switches:

„ Sensors are wear-free
„ No direct actuation required
„ Distance to object to be detected can be greater

TP602 • Festo Didactic

 C-7
Solution 1

Area of application:
„ Inductive sensors: For detection of metallic objects
„ Capacitive sensors: Metals, non-metals and liquids
„ Optical sensors: All media with reflective surfaces

Fig. 1/5:
Practical assembly,
hydraulic

* Not connected: 0V2 Ports P, A

1V2 Ports A, T
The self-closing coupling nipples fitted to all components prevent loss of hydraulic
fluid.

TP602 • Festo Didactic

C-8
Solution 1

Fig. 1/6:
Practical assembly
electrical (1)

S1 = Pushbutton CLOSE VALVE

S2 = Pushbutton OPEN VALVE
1B1 = Proximity sensor, capacitive
1B2 = Proximity sensor, inductive
H1 = Visual incicator for "Valve open"

Current paths 6+7 = Latching of 1B2

K2´ = Contact duplication of K2

TP602 • Festo Didactic

 C-9
Solution 1

Fig. 1/7:
Circuit diagram,
electrical (2)

1B3 = Proximity sensor, optical

H2 = Visual incicator for "Valve closed"

TP602 • Festo Didactic

C-10
Solution 1

Components list, hydraulic Item no. Qty. Description

0Z1 1 Hydraulic power pack, 2 l/min

0Z2, 1Z 2 Pressure gauge
0V1 1 Pressure relief valve, pressure sequence valve
0V2, 1V2 2 4/2-way single-solenoid valve
1V1 1 4/3-way double-solenoid valve, closed in mid-position
1V3 1 2-way flow control valve
1A 1 Cylinder, 16/10/200
6 Branch tee
Hose lines with quick-connection couplings,
11 600 and 1000 mm

Components list, electrical Qty. Description

3 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 Proximity sensor, inductive
1 Proximity sensor, capacitive
1 Proximity sensor, optical
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

 C-11
Solution 2

Clamping unit

Fig. 2/2:
Circuit diagram, hydraulic

TP602 • Festo Didactic

C-12
Solution 2

Fig. 2/3:
Circuit diagram,
electrical (1)

S1 = Pushbutton "Clamp"
S2 = Pushbutton "Release"
1B1 = Proximity sensor, inductive
1B2 = Proximity sensor, capacitive
1S = Pressure switch

TP602 • Festo Didactic

 C-13
Solution 2

Fig. 2/4:
Circuit diagram,
electrical (2)

Clamping cylinder Accumulator

advance return

TP602 • Festo Didactic

C-14
Solution 2

Solution description Switch on the electrical power supply unit and then the hydraulic power
pack. The pump delivery is discharged at virtually zero pressure to the
tank via the 4/2-way valve 0Y1.
When the pushbutton S1 "Clamp” is pressed, the 4/2-way valve 0V1, the
4/3-way valve 1V1 and the 4/2-way valve 1V2 are reversed.
The pump delivery now flows to the accumulator 1Z2 and the double-
acting cylinder 1A, whose piston rod advances and clamps the work-
piece. When a pressure of 40 bar has built up and the sensor 1B2 has
been reached, the 4/3-way valve and the 4/2-way valve 0V1 return to
their initial positions, with the result that the pump delivery is once again
discharged to the tank at zero pressure.
The clamping pressure is now maintained by the accumulator. The sen-
sor 1B2 is used to monitor the position of the piston rod, i.e. a switch-
over is made to pressureless bypass only when 1B2 is reached and the
clamping pressure of 40 bar has built up.
When the pushbutton S2 is pressed, the 4/3-way valve 1V1, the 4/2-way
valve 0V1 and the 4/2-way valve 1V2 are reversed, i.e. the 4/2-way
valve 1V2 isolates the accumulator from the hydraulic circuit during the
return stroke of the cylinder. This causes the piston rod of the cylinder to
return to its retracted end position, where it activates the sensor 1B1.
This energises K3. A contact of K3 cancels the latching in current paths
3 and 4, as a result of which the 4/3-way valve 1V1 reverses into its
closed mid-position while the 4/2-way valve 0V1 returns to its initial po-
sition.
This once again produces a virtually pressureless pump bypass. A fur-
ther contact of K3 in current path 1 is closed again to fulfil the condition
for a restart.

TP602 • Festo Didactic

 C-15
Solution 2

Fig. 2/5:
Practical assembly,
hydraulic

TP602 • Festo Didactic

C-16
Solution 2

Components list, hydraulic Item no. Qty. Description

0Z1 1 Hydraulic power pack, 2 l/min

0Z2, 1Z1 2 Pressure gauge
0V2 1 Pressure relief valve, pressure sequence valve
1V1 1 4/3-way double-solenoid valve, closed in mid-position
0V1, 1V2 2 4/2-way single-solenoid valve
1V3 1 One-way flow control valve
1S 1 Pressure switch
1A 1 Cylinder, 16/10/200
1Z2 1 Diaphragm accumulator with safety block
0V3 1 Non-return valve, 1 bar
5 Branch tee
Hose lines with quick-connection couplings,
10 600 and 1000 mm

Components list, electrical Qty. Description

2 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 Proximity sensor, inductive
1 Proximity sensor, capacitive
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

 C-17
Solution 3

Milling machine

Components Time Fig. 3/2:

Function diagram
Desig- Step
Description Status
nation

START button

Clamping cylinder

Milling motor (indicator)

Feed cylinder

Feed indicator

This representation conforms to VDI 3260.

TP602 • Festo Didactic

C-18
Solution 3

Fig. 3/3:
Circuit diagram, hydraulic

TP602 • Festo Didactic

 C-19
Solution 3

Fig. 3/4:
Circuit diagram,
electrical (1)

S = START pushbutton
1S3, 2S1, 2S2 = Limit switches
1S1 = Pressure switch
H1 = Visual indicator "Milling motor on”
st
H2 = Visual indicator "1 feed motion

TP602 • Festo Didactic

C-20
Solution 3

Fig. 3/5:
Circuit diagram,
electrical (2)

1S2 = Limit switch

TP602 • Festo Didactic

 C-21
Solution 3

When the START pushbutton S is pressed, the piston rod of the clamp- Solution description
ing cylinder 1A advances. When this reaches the limit switch 1S3 and
the pressure set on the pressure switch 1S1 has built up, the 4/2-way
valve 2V1 reverses and the piston rod of the feed cylinder advances at
the feed speed set on the flow control valve 2V3.
At the same time, the indicator lamp H1 lights to show that the milling
motor has been switched on.
When the piston rod reaches the limit switch 2S2, it returns to its re-
tracted end position.
When it reaches the limit switch 2S1, the completion of the feed motion
is indicated by H2 and the feed is restarted.
When the limit switch 2S2 is reached, the 4/2-way valve 2V1 reverses
and the piston rod of the feed cylinder returns to its retracted end posi-
tion, where it activates the limit switch 2S1 a second time. This marks
the end of a complete milling operation with 2 passes over the work-
piece. 2S1 now activates the relay K6. The relay K7 is latched via the
contact of K6 in current path 11.
The contacts of K7 release all latchings which are still operative and
cause the 4/3-way valve to reverse, thus in turn causing the clamping
cylinder 1A to return to its retracted end position, at which it activates
the limit switch 1S2, cancelling the latching circuit of K7 and at the same
time closing the normally-open contact of the relay in current path 1 to
fulfil the condition for the start of a new work operation.

TP602 • Festo Didactic

C-22
Solution 3

Fig. 3/6:
Practical assembly,
hydraulic

1S2, 1S3,
2S1, 2S2 = Limit switches
1S1 = Pressure switch

TP602 • Festo Didactic

 C-23
Solution 3

Item no. Qty. Description Components list, hydraulic

0Z 1 Hydraulic power pack, 2 l/min

1Z, 2Z1, 2Z2 3 Pressure gauge
0V2, 2V4 2 Pressure relief valve, pressure sequence valve
1V 1 4/3-way double-solenoid valve, closed in mid-position
1S1 1 Pressure switch
1A, 2A 2 Cylinder, 16/10/200
2V1 1 4/2-way single-solenoid valve
2V3 1 2-way flow control valve
0V1 1 Pressure relief valve, pilot actuated
2V2 1 Non-return valve, 1 bar
2V5 1 Non-return valve, 5 bar
7 Branch tee
Hose lines with quick-connection couplings,
13 600 and 1000 mm

Qty. Description Components list, electrical

3 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
2 Limit switch, electrical, actuated from left
2 Limit switch, elektrisch, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

C-24
Solution 3

TP602 • Festo Didactic

 C-25
Solution 4

Veneering press

Fig. 4/2:
Circuit diagram, hydraulic

TP602 • Festo Didactic

C-26
Solution 4

Fig. 4/3:
Circuit diagram,
electrical (1)

S1 = START pushbutton "Open press"

S2 = START pushbutton "Close press"
1S2 = Limit switch
1B = Proximity sensor, capacitive

TP602 • Festo Didactic

 C-27
Solution 4

Fig. 4/4:
Circuit diagram,
electrical (2)

1S3 = Limit switch

S3 = EMERGENCY STOP
1S1 = Pressure switch

TP602 • Festo Didactic

C-28
Solution 4

Solution description Switch on the electrical power supply unit and then the hydraulic power
pack. The pump delivery is discharged at virtually zero pressure to the
tank via the 4/2-way valve 0V1. When the "Start” pushbutton "Close
press” S1 is pressed, the 4/3-way valve 1V1, the 4/2-way valve 1V2 and
the 4/2-way valve 0V1 are reversed.
As a result, the piston rod advances to the sensor 1B, which deactivates
the 4/2-way valve 1V2. The piston rod now advances at the lower speed
set on the one-way flow control valve 1V3 until it reaches the limit switch
1S3. Once 1S3 has been reached and the pressure set on the pressure
switch 1S1 has built up, the 4/2-way valve 0V1 switches to pressureless
tank bypass. Pressure is now maintained by the accumulator.
If the EMERGENCY STOP button is pressed during the advance or re-
turn stroke of the piston rod, the piston rod travels immediately at high
speed back to its initial position. When the "Start” pushbutton "Open
press” S2 is pressed, the piston rod similarly retracts at high speed.

TP602 • Festo Didactic

 C-29
Solution 4

Fig. 4/5:
Practical assembly,
hydraulic

TP602 • Festo Didactic

C-30
Solution 4

Components list, hydraulic Item no. Qty. Description

0Z1 1 Hydraulic power pack, 2 l/min

0V1, 1V2 2 4/2-way single-solenoid valve
0V2, 1V4 2 Pressure relief valve, pressure sequence valve
0Z2 1 Diaphragm accumulator with safety block
1V1 1 4/3-way double-solenoid valve, closed in mid-position
1V3 1 One-way flow control valve
1Z1, 1Z2 2 Pressure gauge
1S1 1 Pressure switch
1A 1 Cylinder, 16/10/200
0V3 1 Non-return valve, 1 bar
1V5 1 Non-return valve, 5 bar
12 Branch tee
Hose lines with quick-connection couplings,
9 600 and 1000 mm

Components list, electrical Qty. Description

3 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
1 Proximity sensor, capacitive
1 Limit switch, electrical, actuated from left
1 Limit switch, electrical, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

 C-31
Solution 5

Bending press

Fig. 5/2:
Circuit diagram, hydraulic

TP602 • Festo Didactic

C-32
Solution 5

Fig. 5/3:
Circuit diagram, electrical

S1 = INCHING pushbutton "Close"

S2 = INCHING pushbutton "Open"
S3 = EMERGENCY STOP

TP602 • Festo Didactic

 C-33
Solution 5

Fig. 5/4:
Practical assembly,
hydraulic

TP602 • Festo Didactic

C-34
Solution 5

Solution description For safety reasons, the pushbuttons S1 “Close press” and S2 “Open
press” are interlocked mechanically and via relay contacts.
The mechanical interlock ensures that, if the two pushbuttons S1 and
S2 are pressed simultaneously, no current can flow, due to the fact that
the normally-closed contacts always open before the normally-open
contacts close. This means that no motion results if the two pushbuttons
are pressed at the same time.
If the EMERGENCY STOP button is pressed, the entire control system
is deenergised, with the result that the 4/3-way valve assumes its mid-
position and no further motion takes place.
After the EMERGENCY STOP button has been unlocked, the press can
again be operated in the desired direction.
If dissimilar types of non-return valves are used for 1V2 and 1V4, the
cylinders will retract one after the other.

Components list, hydraulic Item no. Qty. Description

0Z 1 Hydraulic power pack, 2 l/min

0V, 1V5 2 Pressure relief valve, pressure sequence valve
1Z 1 Pressure gauge
1V3 1 Flow dividing valve
1V2, 1V4 1 Non-return valve, 1 bar
1V6 1 Non-return valve, 5 bar
1A1, 1A2 2 Cylinder, 16/10/200
1V1 1 4/3-way double-solenoid valve, closed in mid-position
- 9 Branch tee
13 Hose lines with quick-connection couplings,
600 and 1000 mm

If desired, the second non-return valve, 1 bar 1V4 can be replaced by

the pilot-actuated non-return valve.

Components list, electrical Qty. Description

1 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
1 Cable set with safety plugs

TP602 • Festo Didactic

 C-35
Solution 6

Broaching machine

Fig. 6/2:
Circuit diagram, hydraulic

TP602 • Festo Didactic

C-36
Solution 6

Fig. 6/3:
Circuit diagram,
electrical (1)

S1 = START pushbutton S4 =Selector switch for INCHING mode

1S2, 1S3 = Limit switches S5 =INCHING "advance"
S2 = Pushbutton to advance cutter piston S6 =INCHING "return"
S3 = EMERGENCY STOP

TP602 • Festo Didactic

 C-37
Solution 6

Fig. 6/4:
Circuit diagram,
electrical (2)

1S1 = Pressure switch H = "Excess pressure" indicator

TP602 • Festo Didactic

C-38
Solution 6

Solution description After the circuit has been assembled, the cylinder must first be ad-
vanced in INCHING mode. When the magazine has been filled (not rep-
resented in the exercise), the working motion can be started by pressing
the START pushbutton S1. The piston rod will now retract at the speed
preset on the flow control valve. If the pressure preset on the pressure
switch 1S1 is reached or exceeded before the limit switch 1S2 is
reached, the return stroke will be stopped. The working operation is
completed when the limit switch 1S2 is reached.
If the selector switch S4 is pressed, it is then possible to move the cylin-
der forwards or backwards only in INCHING mode. The EMERGENCY
STOP button can be used to switch the installation off. After the
EMERGENCY STOP button has been unlocked after use, the piston rod
must first be advanced in INCHING mode until the limit switch 1S3 is
reached.
If only one cylinder without a brake is available, a one-way flow control
valve can be fitted in the line from port B of the 4/3-way valve.

TP602 • Festo Didactic

 C-39
Solution 6

Fig. 6/5:
Practical assembly,
hydraulic

TP602 • Festo Didactic

C-40
Solution 6

Components list, hydraulic Item no. Qty. Description

0Z 1 Hydraulic power pack, 2 l/min

0V 1 Pressure relief valve, pressure sequence valve
1V1 1 4/3-way double-solenoid valve, closed in mid-position
1V2 1 2-way flow control valve
1S1 1 Pressure switch
1Z 1 Pressure gauge
1V3 1 4/2-way single-solenoid valve
1A 1 Cylinder, 16/10/200
3 Branch tee
9 Hose lines with quick-connection couplings,
600 and 1000 mm

Components list, electrical Qty. Description

3 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
1 Limit switch, electrical, actuated from left
1 Limit switch, electrical, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

 C-41
Solution 7

Continuous-flow drying oven

Components Time Fig. 7/2:

Function diagram
Desig- Step
Description Status
nation

START button

Motor right

left

Time relay

Cylinder

This representation conforms to VDI 3260.

TP602 • Festo Didactic

C-42
Solution 7

Fig. 7/3:
Circuit diagram, hydraulic

TP602 • Festo Didactic

 C-43
Solution 7

Fig. 7/4:
Circuit diagram,
electrical (1)

S = Start pushbutton
2B1 = Proximity sensor, capacitive
2B2 = Proximity sensor, inductive
B1 = Sensor to detect presence of workpieces

TP602 • Festo Didactic

C-44
Solution 7

Fig. 7/5:
Circuit diagram,
electrical (2)

S1 = EMERGENCY STOP button S2 = INCHING mode, motorised return

TP602 • Festo Didactic

 C-45
Solution 7

Fig. 7/6:
Practical assembly
hydraulic

Switch on the electrical power supply and the hydraulic power pack. To Solution description
simulate the detection of the presence of workpieces, cover the optical
sensor with your hand while simultaneously pressing the START push-
button.
The optical sensor B1 should be mounted on the profile plate so that it
does not get in the way of the cylinder stroke.
The motor begins to turn, and simultaneously the time set on the timer
relay with switch-on delay K2 begins to run.
At the end of this time, the contact assembly of the timer relay K2 is
actuated. The normally-open contact of K2 in current path 4 activates
the relay K3. The normally-closed contact of K3 in current path 1

TP602 • Festo Didactic

C-46
Solution 7

switches the motor off and the normally-open contact in current path 17
reverses the 4/2-way valve. This causes the piston rod of the cylinder to
advance to the proximity sensor 2B2, which activates the relay K5. This
in turn cancels the latching of K3 and causes the piston rod to return to
its retracted end position, where it reaches 2B1. The actuation of 2B1 is
the start condition for a further working cycle.
If the EMERGENCY STOP button is pressed, the control circuit is
deenergised and the conveyor motor can run in the reverse direction
only in INCHING mode.

Components list, hydraulic Item no. Qty. Description

0Z1 1 Hydraulic power pack, 2 l/min

0Z2 1 Pressure gauge
0V1 1 Pressure relief valve, pressure sequence valve
1V1 1 4/3-way double-solenoid valve, closed in mid-position
1V2 1 One-way flow control valve
1M 1 Hydraulic motor, 8 l/min
0V2 1 Non-return valve, 1 bar
2V 1 4/2-way single-solenoid valve
2A 1 Cylinder, 16/10/200
- 4 Branch tee
- 10 Hose lines with quick-connection couplings,
600 and 1000 mm

Components list, electrical Qty. Description

3 Relay, 3-fold
1 Signal input unit, electrical
1 Time relay, 2-fold
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
1 Proximity sensor, inductive
1 Proximity sensor, capacitive
1 Proximity sensor, optical
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

 C-47
Solution 8

Polishing machine

Time Fig. 8/2:

Components
Function diagram
Desig- Status Step
Description
nation
START button ON

Motor

Cylinder

Counter coil

Coun-
ter
Reset coil
pre-
select

Working
contact

Feed cylinder

This representation conforms to VDI 3260.

TP602 • Festo Didactic

C-48
Solution 8

Fig. 8/3:
Circuit diagram, hydraulic

TP602 • Festo Didactic

 C-49
Solution 8

Fig. 8/5:
Circuit diagram,
electrical (1)

S = START pushbutton
1S2, 3S1, 3S2 = Limit switches
P1 = Preselect counter

TP602 • Festo Didactic

C-50
Solution 8

Fig. 8/6:
Circuit diagram,
electrical (2)

3B = Proximity sensor
1S1 = Limit switch

TP602 • Festo Didactic

 C-51
Solution 8

When the START pushbutton S is pressed, the 4/3-way double solenoid Solution description
valve is reversed and, at the same time, the hydraulic motor is switched
on. The piston rod of cylinder 1A now travels to the limit switch 1S2. 1S2
activates the relay K3 and latches. The normally-closed contact of K3 in
current path 14 opens, with the result that no signal can be produced as
the piston rod travels over the proximity sensor 3B. The normally-open
contact of K3 energises the solenoid coil 3Y, with the result that the
piston rod of cylinder 3A travels to the limit switch 3S2. 3S2 energises
the relay K4. The normally-open contact of K4 in current path 17 ener-
gises the relay K10, while the normally-closed contact of K10 in current
path 4 cancels the latching of K3. The contacts of K3 are released.
The effect of this is that:
1. The solenoid coil 3Y is deenergised and the piston rod travels back to
the proximity sensor 3B.
2. The normally-closed contact of K3 in current path 14 closes again.
When the piston rod of cylinder 3A reaches the proximity sensor 3B, the
relay K8 is energised. This latches and energises the solenoid coil of the
4/2-way valve 3V. This causes the piston of cylinder 3A to advance up to
3S2. 3S2 once again cancels the latching of K8 and the piston travels
back again to 3B.
The limit switch 3S2 also acts as a counter contact. The piston rod thus
runs between 3S2 and 3B until the number of cycles set on the prese-
lect counter has been reached.
The contact assembly of the preselect counter then reverses and acts
via K6 to interrupt current path 14, i.e. when the piston rod of cylinder 3A
travels over the proximity sensor 3B, this is no longer able to energise
the relay K8 in current path 14. The switching cam of cylinder 3A now
travels to the limit switch 3S1.
The counter is reset and the relay K5 energised. The normally-closed
contact of K5 in current path 2 cancels the latching of K2. The contacts
are released and the hydraulic motor stops. The normally-open contact
of K5 reverses the 4/3-way double solenoid valve, causing the piston of
cylinder 1A to travel towards its retracted end position until it reaches
1S1. 1S1 energises K9. The contacts of K9 cancel any remaining latch-
ings in current paths 10 and 17, and the normally-open contact in cur-
rent path 1 closes again to fulfil the condition for the start of a new
working cycle.
If only 3 relay modules are available, the proximity sensor 3B - K7
should be connected directly into current path 14.

TP602 • Festo Didactic

C-52
Solution 8

Fig. 8/6:
Practical assembly,
hydraulic

TP602 • Festo Didactic

 C-53
Solution 8

Fig. 8/7:
Practical assembly,
electrical (1)

S = START pushbutton In the interest of clarity, the current path numbers

1S2, 3S1, 3S2 = Limit switches from the circuit diagram are shown here.
P1 = Preselect counter
S3 = EMERGENCY-STOP

TP602 • Festo Didactic

C-54
Solution 8

Fig. 8/8:
Practical assembly,
electrical (2)

3B = Proximity sensor
1S1 = Limit switch

TP602 • Festo Didactic

 C-55
Solution 8

Item no. Qty. Description Components list, hydraulic

0Z 1 Hydraulic power pack, 2 l/min

0V1, 1V3 2 Pressure relief valve, pressure sequence valve
0V2 1 3-way pressure reducing valve
0V3 1 Throttle valve
1V1 1 4/3-way double-solenoid valve, closed in mid-position
1V2 1 One-way flow control valve
1V4 1 Non-return valve, 1 bar
1Z 1 Pressure gauge
1A, 3A 2 Cylinder, 16/10/200
2V1, 3V 2 4/2-way single-solenoid valve
2V2 1 2-way flow control valve
2M 1 Hydraulic motor, 8 l/min
2V3 1 Non-return valve, 5 bar
10 Branch tee
17 Hose lines with quick-connection couplings,
600 and 1000 mm

Qty. Description Components list, electrical

4 Relay, 3-fold
1 Signal input unit, electrical
1 Indicator and distributor unit, electrical
1 Preselect counter, electrical, incremental
1 Proximity sensor, inductive
2 Limit switch, electrical, actuated from left
2 Limit switch, electrical, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

C-56
Solution 8

TP602 • Festo Didactic

 C-57
Solution 9

Plastic injection moulding machine

Time Fig. 9/2:

Components
Function diagram
Desig- Step
Description Status
nation

START button

Motor

Cylinder

Cylinder

This representation conforms to VDI 3260.

TP602 • Festo Didactic

C-58
Solution 9

Fig. 9/3:
Circuit diagram, hydraulic

TP602 • Festo Didactic

 C-59
Solution 9

Fig. 9/4:
Circuit diagram,
electrical (1)

S1 = START pushbutton 2S1 = Pressure switch

S2 = EMERGENCY STOP button 2S3 = Limit switch
S3 = Selector switch for single/continuous cycle H = Indicator "Continuous cycle"
S4 = Continuos cycle "OFF"

TP602 • Festo Didactic

C-60
Solution 9

Fig. 9/5:
Circuit diagram,
electrical (2)

Motor

2S2, 3S1 and 3S2 = Limit switches

TP602 • Festo Didactic

 C-61
Solution 9

When the START button S1 is pressed, the hydraulic motor is switched Solution description
on and power is supplied to the timer relay with switch-on delay K4. At
the end of the preset time t = 5 s, the hydraulic motor is switched off and
the 4/3-way valve 2V1 is reversed. The piston rod of cylinder 2A now
advances up to the limit switch 2S3 at the speed preset on the one-way
flow control valve and the maximum achievable pressure as set on the
pressure relief valve 2V3. The effect of the limit switch 2S3 is that the
4/3-way valve with relieved mid-position 2V5 reverses, allowing the
pressure preset on the pressure sequence valve 2V2 to become opera-
tive.
When the pressure preset on the pressure switch 2S1 is reached, this
causes the piston rod of cylinder 2A to return to its retracted end posi-
tion.
Here, it actuates the limit switch 2S2, which acts via the contacts of the
relay K8 to reverse the 4/2-way valve 3V2; the piston rod of cylinder 3A
advances until it reaches the limit switch 3S2. 3S2 acts via the relay K9
to reverse the 4/2-way valve, with the result that the piston rod of cylin-
der 3A returns to its retracted end position. With the switch S3 set to
“Continuous cycle”, the installation continues to run until pushbutton S4
is pressed.

TP602 • Festo Didactic

C-62
Solution 9

Fig. 9/6:
Practical assembly,
hydraulic

There is no electrical connection to solenoid coil 2Y4 of the 4/3-way so-

lenoid valve with relieved mid-position 2V5, since the valve is being used
as a 3/2-way valve, closed in normal-position.

TP602 • Festo Didactic

 C-63
Solution 9

Item no. Qty. Description Components list, hydraulic

0Z 1 Hydraulic power pack, 2 l/min

0V 1 Pressure relief valve, pilot actuated
2Z1, 2Z2,
2Z3, 3Z 1 Pressure gauge

1V1, 3V2 2 4/2-way single-solenoid valve

1V2 1 2-way flow control valve
1M 1 Hydraulic motor, 8 l/min
1V3 1 Non-return valve, 5 bar
2V1 1 4/3-way double-solenoid valve, closed in mid-position
2V2, 2V3 2 Pressure relief valve, pressure sequence valve
2S1 1 Pressure switch
2V5 1 4/3-way double-solenoid valve, relieved in mid-position
2V4 1 One-way flow control valve
2A, 3A 2 Cylinder, 16/10/200
3V1 1 3-way pressure reducing valve
12 Branch tee
22 Hose lines with quick-connection couplings,
600 and 1000 mm

Qty. Description Components list, electrical

4 Relay, 3-fold
2 Signal input unit, electrical
1 Timer relay, 2-fold
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
2 Limit switch, electrical, actuated from left
2 Limit switch, electrical, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

C-64
Solution 9

TP602 • Festo Didactic

 C-65
Solution 10

Embossing press

Time Fig. 10/2:

Components
Function diagram
Desig- Step
Description nation Status

Hydraulic pump ON

Two-hand start button ON

Protective guard

Embossing cylinder

This representation conforms to VDI 3260.

TP602 • Festo Didactic

C-66
Solution 10

Fig. 10/3:
Circuit diagram, hydraulic

TP602 • Festo Didactic

 C-67
Solution 10

Fig. 10/4:
Circuit diagram,
electrical (1)

1S2, 2S1, 2S2 = Limit switches

0S = Pressure switch
S1 and S2 = Pushbutton for two-hand start circuit

TP602 • Festo Didactic

C-68
Solution 10

Fig. 10/5:
Circuit diagram,
electrical (2)

1S1 = Limit switch

S3 = EMERGENCY STOP button
H1 = EMERGENCY STOP indicator

TP602 • Festo Didactic

 C-69
Solution 10

Once the electrical and hydraulic circuits have been assembled and Solution description
checked, switch on the electrical power supply and the hydraulic power
pack. The pump delivery will now fill the diaphragm accumulator. Only
when the accumulator has been filled sufficiently to reach or exceed the
pressure preset on the pressure switch 0S is it possible to start the em-
bossing operation by pressing the pushbuttons S1 and S2 simultane-
ously. The two pushbuttons must be pressed within the time set on K1.
If one pushbutton is jammed, it is not possible to generate a START
signal.
Provided that the start conditions are fulfilled, the contacts of the relay
K2 in current paths 15 and 20 are actuated and the piston rod of cylin-
der 1A advances under the pressure preset on the pressure relief valve
until the limit switch 1S2 is reached.
The piston rod of cylinder 2A now executes its working stroke. When
limit switch 2S1 is reached after the return stroke of cylinder 2A, the
piston rod of cylinder 1A returns to its retracted end position.
If, during the working cycle, the hydraulic power pack is switched off and
the EMERGENCY STOP button is then pressed, the hydraulically-
piloted non-return valve opens to allow the volume of hydraulic fluid
trapped under pressure to flow through the valves, which are also actu-
ated, into the relevant cylinders and drive these back into their retracted
end positions.

In everyday industrial practice, pre-assembled modules are used in Note

place of the discrete two-hand safety start-up circuit assembled here.
The EMERGENCY STOP circuit in the hydraulic section is implemented
in such a way that the 3/2-way valve allows flow when deenergised. This
ensures that the volume of fluid trapped under pressure can be used as
an energy source. The pilot-actuated non-return valve is open for this
purpose.

TP602 • Festo Didactic

C-70
Solution 10

Fig. 10/6:
Practical assembly,
hydraulic

No connection is made to solenoid 0Y2 of the 4/3-way solenoid valve,

closed in mid-position 0V4, since the valve is used here as a 3/2-way
valve.

TP602 • Festo Didactic

 C-71
Solution 10

Item no. Qty. Description Components list, hydraulic

0Z1 1 Hydraulic power pack, 2 l/min

0V1 1 Non-return valve, 1 bar
2V4 1 Non-return valve, 5 bar
0V2, 0V3,
0V7, 2V3 4 Pressure relief valve, pressure sequence valve

0V4, 2V1 2 4/3-way double-solenoid valve, closed in mid-position

0Z2, 2Z 2 Pressure gauge
0V8, 2V2 2 One-way flow control valve
0S 1 Pressure switch
0V6 1 Non-return valve, pilot actuated
0V5, 1V 2 4/2-way single-solenoid valve
1A, 2A 2 Cylinder, 16/10/200
0Z3 1 Diaphragm accumulator with safety block
- 10 Branch tee
- 23 Hose lines with quick-connection couplings,
600 and 1000 mm

Qty. Description Components list, electrical

3 Relay, 3-fold
1 Signal input unit, electrical
1 Timer relay, 2-fold
1 Indicator and distributor unit, electrical
1 EMERGENCY STOP, electrical
2 Limit switch, electrical, actuated from left
2 Limit switch, electrical, actuated from right
1 Cable set with safety plugs
1 Power supply unit, 24 V

TP602 • Festo Didactic

C-72
Solution 10

TP602 • Festo Didactic