Professional Documents
Culture Documents
Advanced Level
Workbook TP 202
CD-ROM included
Festo Didactic
541091 en
Intended use
The Festo Didactic Learning system has been developed and produced solely for
vocational and further training in the field of automation and technology. The
training company and/or instructor need to ensure that trainees observe the safety
precautions specified in this workbook.
Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,
the training company and/or other parties, which may occur during the
use/application of this equipment set other than in a training situation and unless
such damages are caused with intention or through gross negligence on the part of
Festo Didactic.
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005
Internet: www.festo-didactic.com
e-mail: did@festo.com
Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology packages for electropneumatics (TP200) _______________________ 11
Training aims of Advanced Level (TP202) _________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Advanced Level (TP202) _________________________________ 17
Allocation of equipment and exercises ___________________________________ 21
Methodological help for the trainer ______________________________________ 23
Methodological structure of the exercises_________________________________ 25
Designation of equipment _____________________________________________ 26
Contents of the CD-ROM _______________________________________________ 27
Equipment set – Basic Level (TP201) _____________________________________ 29
Training aims – Basic Level (TP201)______________________________________ 30
Part A – Exercises
Part B – Fundamentals
Part C – Solutions
Part D – Appendix
The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.
Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.
This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package TP200 is
comprised exclusively of electropneumatic control systems.
Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-
circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is
used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar
(800 kPa) can be used for compressed air supply.
The equipment set of Basic Level TP201 is used to construct complete control
systems for all of the 12 problem definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook
• Electropneumatics
Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices, etc.).
The following advice should be observed in the interest of your own safety:
• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately.
• Do not switch on compressed air until tubing is securely connected.
• Caution!
Cylinders may advance automatically as soon as the compressed air is switched
on.
• Do not operate an electrical limit switch manually during fault finding (use a
tool).
• Observe general safety regulations. (DIN 58126 and VDE 100).
• With electrical limit switches you need to distinguish between two designs
– Actuation from the left
– Actuation from the right.
• At high piston speeds, limit switches must be approached only in the designated
direction of the trip cam of the cylinder. Limit switches must not be actuated from
the front.
• Do not exceed the permissible working pressure (see data sheets).
• Only use extra-low voltage ≤ 24V.
• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use
cables with jack plugs for the electrical connections.
• Pneumatic circuit assembly:
Connect devices using the silver-metallic plastic tubing of 4 mm outer diameter,
the tubing is plugged into the push-in fitting up to the stop; no need for securing!
• Releasing of push-in fitting:
The tubing can be released by pressing down the releasing ring (disconnection
under pressure is not possible!)
• Switch off compressed air supply and power supply prior to dismantling the
circuit.
• The mounting plates of the devices are equipped with mounting variants A to D:
Variant A, latching system
For lightweight non-loadable devices (e.g. directional control valves). Simply clip
the device into the slot in the profile plate. Devices can be released by pressing
the blue lever.
Variant B, rotary system
Medium weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head bolts. Clamping and releasing is
effected by means of the blue knurled nut.
Variant C, screw system
For heavy loadable devices rarely removed from the profile plate (e.g. On/off
valves with filter regulating valve). These components are mounted by means of
socket head screws and T-head bolts.
Variant D, plug-in system
Lightweight non-loadable devices with locking pins (e.g. indicating devices).
These devices are attached by means of plug-in adapters.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.
Training documentation
Seminars
Details of venues, dates and prices can be found in the current seminar planner.
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aims
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aim
The equipment set for the advanced level has been compiled for further training in
electro-pneumatic control technology. The two equipment sets (TP201 and TP202)
contain all the components required to meet the specified training aims and can be
expanded as desired with other equipment sets of the Learning System for
Automation and Technology.
Relay, 3-off
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
14 24 32 42
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
Description Symbol
17 27 35 45
A1
A2
18 28 36 46
17 27 35 45
A1
A2
18 28 36 46
A2 R2
4 2
EMERGENCY-STOP button 13 21
14 22
1 21
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Equipment
EMERGENCY-STOP button 1 1 1
Relay 2 6 6 6 6 6 4 5 6 6 6 6
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Equipment
Cylinder, double-acting 1 2 2 2 2 2 1 1 2 2 1 2
Pressure sensor 1 1
Relay 3 4 2 4 5 3 3
Manifold 1 1 1 1 1 1 1 1 1 1 1 1
• Training aims
The overall aim of this collection of exercises is the systematic design of circuit
diagrams and practical assembly of a control system on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
The detailed training aims are documented in the table. Actual individual training
aims are allocated to each problem and major training aims are shown in
brackets.
• Time required
The time required to work through a problem depends on the trainee’s prior
knowledge. Skilled workers in the engineering and electrical fields require
approximately 2 weeks. Technicians or engineers require approximately 1 week.
• Components of the equipment set
The book of exercises and equipment set are harmonised. You will require the
components of the equipment set for Basic Level TP 201 and Advanced Level
TP202. Each of the Advanced Level exercises can be assembled on a profile plate.
For exercise 11 you will require an additional electrical input or will need to
assemble the circuit in a different form.
• Representation
Abbreviated notation and motion diagrams are used for the represention of
motion sequences and switching statuses.
The CD-ROM supplied provides you with additional media. The contents of Part A –
Exercises, and Part C – Solutions, are stored in the form of pdf files.
Operating instructions Operating instructions are available for the various pieces of equipment of the
technology package to assist you in the use and commissioning of the equipment.
Data sheets The data sheets for the equipment of the technology package are available in the
form of pdf files.
Demo A demo version of the software package FluidSIM® Pneumatic is stored on the CD-
ROM. This version is suitable for the testing of the control system developed.
Festo catalogue Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of
equipment. The representation and description of equipment in this form is intended
to illustrate how such equipment is represented in an industrial catalogue. You will
also find additional information here regarding the equipment.
FluidSIM® circuit diagrams FluidSIM® circuit diagrams are stored in this directory for all 12 exercises in the
technology package.
For the introduction to logic programming, all FluidSIM® circuit diagrams are also
stored in a variant with logic control in addition to the circuit diagrams with relay
control.
Industrial applications Photos and pictures are provided of industrial applications to enable you to
illustrate your own problem definitions. These can also be added to project
presentations.
Presentations Brief presentations are stored in this directory regarding the equipment for this
technology package. These presentations can for instance be used to create project
presentations.
Product information This directory provides you with the product information and data sheets of Festo
AG & Co. KG regarding the equipment of the technology package and is intended to
explain what information and data are provided for an industrial component.
Videos A number of videos of industrial applications complete the media for the training
package. Short sequences are shown of practice-related applications.
This equipment set has been compiled for basic training in electropneumatic control
technology. It comprises all the components required for the training aims specified
and can be expanded in any way with other equipment sets. In addition you will also
need a profile plate, electrical power supply unit and compressed air supply to
assemble a fully functional control system.
Manifold 152896 1
Part A – Exercises
Training aims • To familiarise yourself with the design and function of valve terminals.
• To be able to use valve terminals in accordance with requirements.
Problem definition Drinks bottles are to be diverted from one conveyor to another using a diverting
device. By pressing a pushbutton the frame of the diverting device is to advance. A
bottle is transferred and conveyed in the opposite direction. By pressing another
pushbutton, the frame is to return into the initial position.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Name: Date:
The following choices are available in respect of configuration, i.e. number of drives
and tubing requirements:
Name: Date:
– Compare the above listed concepts using the example of this control system in
terms of reducing the tubing costs.
Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.
Tubing
Number of compressed
air distribution units
Amount of tubing
between directional
control valves and
cylinders
Silencers
Name: Date:
– Which concept enables you to achieve a reduction in tubing costs? Explain the
reason for your choice.
Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.
Name: Date:
– Compare the above listed concepts using the example of this control system with
regard to reducing wiring costs
Note
Use the individual valves of TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.
Wiring table
Control cabinet 1 1
Solenoids
(2 wires per solenoid)
Name: Date:
– Which concept enables you to achieve a reduction in wiring costs? Explain the
reason for your choice.
Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.
Name: Date:
4 2
5 3
1
Name: Date:
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
Pneumatic circuit diagram with valve terminal (circuit diagram in DIN A3 format in Part D)
Name: Date:
+24 V 1 2 3 4
A1 A1
A2 A2
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list