Neumatica Avanzada

Pneumatics
Advanced Level
Workbook TP 102
CD-ROM included
Festo Didactic
541089 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.
Order No.: 541089

Status: 04/2005
Authors: W. Haring, M. Metzger, R.-C. Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 10/2005
© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2005

Internet: www.festo-didactic.de
e-mail: did@festo.com
The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Parts of this document may be copied by the authorised user exclusively for
training purposes.
2 © Festo Didactic GmbH & Co. KG • 541089

Contents
Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology package for pneumatics (TP100) ______________________________ 11
Training aims – Advanced Level (TP102) __________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Advanced Level (TP102) _________________________________ 17
Allocation of equipment and exercises ___________________________________ 20
Methodological help for the trainer ______________________________________ 22
Methodological structure of the exercises_________________________________ 24
Designation of equipment _____________________________________________ 25
Equipment set – Basic Level (TP101) _____________________________________ 26
Training aims – Basic Level (TP101)______________________________________ 27
Part A – Exercises
Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9
Exercise 3: Drilling of valve manifold blocks ______________________________A-17
Exercise 4: Filling of drinks bottles______________________________________A-25
Exercise 5: Cleaning of workpieces _____________________________________A-35
Exercise 6: Printing of mobile phone housings ____________________________A-43
Exercise 7: Packaging of spark plugs ____________________________________A-49
Exercise 8: Sealing of guide bushes_____________________________________A-55
Exercise 9: Hardening of material test specimens__________________________A-63
Exercise 10: Bending of sheet metal strips _______________________________A-69
© Festo Didactic GmbH & Co. KG • 541089 3

Contents
Part B – Fundamentals
Part C – Solutions
Exercise 1: Opening and closing of an over door____________________________C-3

Exercise 2: Separating of drinks bottles __________________________________C-7
Exercise 3: Drilling of valve manifold blocks ______________________________C-11
Exercise 4: Filling of drinks bottles______________________________________C-17
Exercise 5: Cleaning of workpieces _____________________________________C-27
Exercise 6: Printing of mobile phone housings ____________________________C-35
Exercise 7: Packaging of spark plugs ____________________________________C-41
Exercise 8: Sealing of guide bushes ____________________________________C-47
Exercise 9: Hardening of material test specimens__________________________C-53
Exercise 10: Bending of sheet metal strips _______________________________C-59
Part D – Appendix
Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets
Circuit diagrams

Preface
Festo Didactic’s Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured
into the following training packages:
• Basic packages to provide technology-spanning basic knowledge
• Technology packages to address the major subjects of open and closed-loop
technology
• Function packages to explain the basic functions of automated systems
• Application packages to facilitate vocational and further training based on actual
industrial applications
The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal
computer, hydraulics, electrohydraulics, proportional hydraulics and handling
technology.

Preface
The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.
All the training packages are of identical structure:

• Hardware
• Teachware
• Software
• Seminars
The hardware consists of didactically designed industrial components and systems.

The didactic, methodological design of the teachware is harmonised with the
training hardware and comprises:
• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, additional information, solutions and data
sheets)
• Overhead transparencies and videos (to create an interesting and lively training
environment)
Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.

Introduction
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 TP100 is
comprised exclusively of electropneumatic control systems.
Basic Level TP101 is suitable for basic training in pneumatic control technology and
provides knowledge regarding the physical fundamentals of pneumatics and the
function and use of pneumatic components. The equipment set enables you to
construct simple pneumatic control systems.
Advanced Level TP102 focuses on further training in pneumatic control technology.

The equipment set enables you to construct complex combinatorial circuits with
logic operations of input and output signals as well as control systems with
sequencer modules.
Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T slots spaced 50 mm apart. A mobile,
silenced compressor (230 V, maximum 8 bar = 800 kPa) can be used for compressed
air supply.
Working pressure must not exceed a maximum of p = 6 bar = 600 kPa.
Optimal operational reliability is achieved if the control system is operated on

unlubricated air at a working pressure of p = 5 bar = 500 kPa.
The equipment set of Advanced Level TP102 is used to construct complete control
systems for all of the 10 exercise definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook
• Pneumatics – Basic Level
Also available are data sheets in respect individual devices ( cylinders, valves,
measuring devices, etc.).

Introduction

Notes on safety and operation
The following advice should be observed in the interest of your own safety:
• Pressurised air lines that become detached can cause accidents. Switch off the
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 roller lever valves manually during fault finding (use a tool).
• Observe general safety regulations (DIN 58126).
• Limit switches must always be mounted laterally to the trip cam (not to the
front).
• Do not exceed the permissible operating pressure (see data sheets).
• Pneumatic circuit assembly: Connect the components 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 additional securing required!
• 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 prior to dismantling the circuit.
• The mounting plates of the devices are in the form of mounting variants A, B or C:
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
For 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
achieved 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
valve with filter regulating valve). These components are mounted by means of
socket head screws and T-head bolts.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.

Notes on safety and operation
A stop watch is required for the evaluation of the assembled control systems, i.e.:
• To adjust one-way flow control valves such that the cylinder stroke time complies
with the specified values,
• To adjust time delay valves.

Technology package for pneumatics (TP100)
The technology package TP100 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively pneumatic control
systems. Individual components from the technology package TP100 may also form
a component part of other packages.
Important elements of • Fixed workstation with Festo Didactic profile plate

TP100 • Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa)
• Equipment set or individual components (e.g. cylinders, directional control
valves, predetermining counters, stepper modules, logic elements, pneumatic
proximity sensors)
• Optional training aids (e.g. visual displays, 5/3-way valve, pulling/pushing load)
• Practical training models
• Complete laboratory set-ups
Training documentation
Textbooks Basic Level TP101

Fundamentals of pneumatic control technology
Maintenance of pneumatic devices and systems
Workbooks Basic Level TP101

Advanced Level TP102
Optional teachware Sets of overhead transparencies

Magnetic symbols, drawing template
®
Simulation software FluidSIM Pneumatics
WBT Fluid Studio Pneumatics
Cutaway model sets 1 + 2 with storage case

Technology package for pneumatics (TP100)
Seminars
P111 Fundamentals of pneumatics and electropneumatics
P121 Maintenance of and fault finding on pneumatic and electropneumatic systems
IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic

control systems
P-AL Pneumatics for vocational training
Details of venues, dates and prices can be found in the current seminar planner.
Information regarding further training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually
updated and expanded. The sets of overhead transparencies, films, CD-ROMs and
DVDs as well as technical books are available in several languages.

Training aims of Advanced Level (TP102)
• To familiarise yourself with different types of end position sensing.

• To familiarise yourself with the options of designing control systems with a
memory function.
• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally
open).
• To familiarise yourself with displacement-step diagrams and to be able to design
these for a specified circuit.
• To be able to realise circuits with parallel movements in push-pull mode.
• To be able to use pneumatic decrementing counters.
• To be able to design indirect cylinder actuation.
• To be able to select appropriate sensors for applications and adjust such
sensors.
• To familiarise yourself with the design and function of stepper modules.
• To be able to design the basic „continuous cycle“ stepper control system.
• To be able to install one-way flow control valves dependent on given parameters.
• To be able to realise the OR function of feedback signals.
• To be able to set time delays according to specifications.
• To familiarise yourself with circuits in order to cancel time delays via signal input.
• To be able to realise the following input commands:
EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at
CYCLE END and AUTOMATIC/MANUAL.
• To be able to design a stepper control with idle step.
• To familiarise yourself with the option of facilitating variable step repetitions
within a motion sequence and to assemble this circuit.
• To be able to develop input circuits with self-latching loop
• To familiarise yourself with the option of realising the double stroke of a cylinder
and to be able to assemble this circuit.
• To familiarise yourself with circuits in order to realise the reversal of a cylinder
movement in the partial stroke range.
• To be able to develop an input circuit for a stepper control with protected pilot
air.
• To be able to stop a double-acting cylinder in the partial stroke range.
• To understand how valve output signals can be inverted.
• To be able to realise a control system with control behaviour in combination with
a sequence control in stepper design.

Training aims of Advanced Level (TP102)

Allocation of training aims and exercises
Exercise 1 2 3 4 5 6 7 8 9 10
Training aims
To familiarise yourself with different types of end position •

sensing.
To familiarise yourself with the options of designing •

control systems with a memory function.
To be able to convert 3/2- and/or 5/2-way valves •

(normally closed/normally open).
To familiarise yourself with displacement-step diagrams •

and to be able to design these for a specified circuit.
To be able to realise circuits with parallel movements in •

push-pull mode.
To be able to use pneumatic decrementing counters. •
To be able to design indirect cylinder actuation. • •
To be able to select appropriate sensors for applications • • • •

and adjust such sensors.
To familiarise yourself with the design and function of •

stepper modules.
To be able to design the basic „continuous cycle“ stepper •

control system.
To be able to install one-way flow control valves •

dependent on given parameters.
To be able to realise the OR function of feedback signals. •
To be able to set time delays according to specifications. •
To familiarise yourself with circuits in order to cancel time •

delays via signal input.
To be able to design a stepper control with the input •

commands AUTOMATIC/MANUAL, START and RESET.
To be able to realise the following input commands: •

EMERGENCY-STOP, acknowledge EMERGENCY-STOP,
START, RESET, STOP at CYCLE END and
AUTOMATIC/MANUAL.

Allocation of training aims and exercises
Exercise 1 2 3 4 5 6 7 8 9 10
Training aims
To be able to develop an input circuit with self-latching •

loop, that enables the following inputs:
AUTOMATIC/MANUAL, START, STOP at CYCLE END and
RESET.
To be able to design a stepper control with idle step. •
To familiarise yourself with the option of facilitating a •

variable motion sequence and to be able to design this
circuit.
To familiarise yourself with the option of realising the •

double stroke of a cylinder and to be able to assemble this
circuit.
To familiarise yourself with circuits in order to realise the •

reversal of a cylinder movement in the partial stroke
range.
To be able to develop an input circuit for a stepper control •

with protected pilot air with the inputs START,
AUTOMATIC/MANUAL and RESET.
To be able to stop a double-acting cylinder in the partial •

stroke range.
To be able to adjust proximity sensors in the end positions

and in the partial stroke range.
To understand how valve output signals can be inverted. •
To be able to realise a control system with control •

behaviour in combination with a sequence control in
stepper design.

Equipment set – Advanced Level (TP102)
This equipment set for the advanced level has been compiled for further training in
pneumatic control technology. The two equipment sets (TP101 and TP102) 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.
Equipment set – Advanced Description Order No. Quantity

Level (TP102
3/2-way roller lever valve with idle return, normally closed 152867 1
Order No.: 540711)
3/2-way pneumatic valve, convertible 539768 4
3/2-way valve with pushbutton, normally closed 152860 2
3/2-way valve with mushroom actuator, normally open 152864 1

(EMERGENCY-STOP)
5/2-way pneumatic double pilot valve 539769 2
Back pressure valve 152868 1
Double-acting cylinder 152888 2
Dual pressure valve, 3-fold 152883 1
Non-return valve, piloted 540715 2
One-way flow control valve 539773 2
Plastic tubing 4 x 0.75, 10 m 151496 2
Predetermining counter, pneumatic 152877 1
Push-in sleeve 153251 10
Push-in T-connector 153128 20
Shuttle valve 539771 1
Shuttle valve, 3-fold 152882 1
Stepper module 152886 1
Time delay valve, normally open 539759 1

Equipment set symbols Desccription Symbol
3/2-way valve with pushbutton, 2

normally closed
1 3
3/2-way valve with mushroom 2

actuator,
normally open (EMERGENCY-STOP)
1 3
3/2-way roller lever valve with idle 2

return
1 3
Back pressure valve 2
1 3
3/2-way pneumatic valve, 2

normally closed
12
1 3
5/2-way double pilot valve 4 2
14 12
5 1 3
Predetermining counter, pneumatic 2
12 10
Time delay valve, 2

normally open
10
1 3

Description Symbol
Shuttle valve, 3-fold 2 2 2
1 1/3 1 1/3 1 1/3

Shuttle valve
2
1 1/3
Dual pressure valve, 3-fold 2 2 2
1 1/3 1 1/3 1 1/3

Double-acting cylinder
Non-return valve, piloted 2
1 21
Description Symbol
A1 A2 A3 A4
Stepper module TAA TAA TAA TAB
Yn Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y Yn+1
P P P P P P P P P P P P
Zn Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z Zn+1
L L L L L L L L L L L L
X1 X2 X3 X4

Allocation of equipment and exercises
Equipment set TP102
Exercise 1 2 3 4 5 6 7 8 9 10
Equipment
Cylinder, double-acting 1 2 2 2 2 2 2 1 1 2
One-way flow control valve 2 2 2 2 2 2 2 2 2 2
Non-return valve, piloted 2
3/2-way pneumatic valve, convertible 2 1 1 3 3 4 3 1
5/2-way double pilot valve 2 2 2 2 2 2 2 2 2
3/2-way roller lever valve with idle return, normally closed 1 1 1
Back pressure valve 1 1 1
3/2-way valve with push button, normally closed 1 1 2 2 2 2 1 1
3/2-way valve with mushroom actuator, normally open 1 1

(EMERGENCY-STOP)
Stepper module 1 1 1 1 1 1
Time delay valve, normallyopen 1 1
Predetermining counter, pneumatic 1 1
Shuttle valve 1 1 1
Shuttle valve, 3-fold 3 3 3 3 2
Dual pressure valve, 3-fold 1 2 3 3 1 1 2

Allocation of equipment and exercises
Equipment set TP101
Exercise 1 2 3 4 5 6 7 8 9 10
Equipment
Cylinder, double-acting 1
Cylinder, single-acting 1
One-way flow control valve 2 2 2 2 1 2 1
3/2-way pneumatic valve 1
5/2-way pneumatic valve 1*
5/2-way double pilot valve 1 3 2*
3/2-way roller lever valve with idle return 1 2 2 2 2 2 2 2
Pneumatic proximity sensor 2 1 2 2 2 2 1 1 2
3/2-way valve with pushbutton, normally closed 2 2 1 1
3/2-way valve with selector switch, normally closed 1 1
5/2-way valve with selector switch 1 1 1 1 1
Time delay valve, normally closed 1 1
Shuttle valve 1 1
Dual pressure valve 1
Manifold 1 1 1 1 1 1 1 1 1 1
ON/off valve with filter regulating valve 1 1 1 1 1 1 1 1 1 1
* Convert the available valve into the required valve.

Methodological help for the trainer
• Training
The training aim of this collection of exercises is the systematic design of circuit
diagrams and the practical assembly of control systems on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
Naturally questions and problems arise, which will vary from training group to
training group and these provide a very useful platform for you to discuss the
training aims addressed at the time.
• Variations in training aims
The above training aim can be varied in various different ways. For many
vocational groups, the designing of a control system is only of secondary
importance.
For instance, if the circuit diagram is added to the exercise definition, the
vocational or further training focus can then be shifted to the assembly and
commissioning of the control system.
Other possible main areas of focus in vocational and further training are for
instance fault finding on assembled control systems or the modification of circuit
diagrams, such as circuit documentation due to an altered exercise definition.
Parts of the documentation of a control system can be prepared during the
theoretical part of training.
The preparation of complete solution descriptions or sections thereof based on

the circuit documentation or the assembled control system also facilitates
interdisciplinary tuition.
• Time required
The time required to work through the 10 exercises depends on the prior
knowledge of the trainees:
– Trainees who have undergone vocational training in the engineering and
electrical field:
Just under 160 hours,
– Trainees with technician’s or engineering training:
up to 80 hours.
Whereby the second group is to be involved more in the designing of circuit
diagrams or sections of circuit diagrams.

Methodological help for the trainer
• Components of the equipment set

The collection of exercises in TP102 is didactically and methodologically
harmonised with the training hardware (equipment set of Basic Level TP101 and
Advanced Level TP102).
These two equipment sets are all you require for all the exercises.
• Representation
Abbreviated notation, possibly divided into groups, as well as motion diagrams
are used for the representation of motion sequences and switching statuses.

Methodological structure of exercises
All 10 exercises in Part A are of the same methodological structure.
The exercises are divided into:

• Title
• Training aims
• Problem definition
• Parameters
as well as
• Project task
• Positional sketch
• Worksheets
The proposed solutions in Part C are divided into:

• Circuit diagram
• Solution description
as well as
• Circuit design
• Equipment list
Enlarged circuit diagrams on DIN-A3 sheets are enclosed for exercises 4 to 10.

Designation of equipment
The designation of components in a circuit diagram is effected in accordance with

the DIN-ISO 1219-2 standard. All components of a circuit have the same main code
number. Letters are assigned depending on component. Several components within
a circuit are number consecutively. The designation of multiple pressure ports is P
and these are consecutively numbered separately.
Cylinders: 1A1, 2A1, 2A2, ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...
Sensors: 1B1, 1B2, ...
Signal input: 1S1, 1S2, ...
Accessories: 0Z1, 0Z2, 1Z1, ...

Equipment set – Basic Level (TP101)
This equipment set has been compiled for basic training in pneumatic control
technology. It comprises all the components required for the training aims specified
and can be expanded in any way using other equipment sets. In addition you will
also need a profile plate and compressed air supply to assemble a fully functional
control system.
Equipment set – Basic Level Description Order No. Quantity

(TP101
3/2-way pneumatic valve, convertible 539768 1
Order No.: 540710)
3/2-way roller lever valve with idle return, normally closed 152866 2
3/2-way valve with pushbutton, normally open 152861 1
3/2-way valve with pushbutton, normally closed 152860 2
3/2-way valve with selector switch, normally closed 152863 1
5/2-way double solenoid valve 539769 3
5/2-way pneumatic valve 538694 1
5/2-way valve with selector switch 152862 1
Double-acting cylinder 152888 1
Dual pressure valve 539770 2
Manifold 152896 1
On-off valve with filter regulating valve 540691 1
Plastic tubing 4 x 0.75, 10 m 151496 2
Pneumatic proximity sensor 539775 2
Pressure gauge 152865 2
Pressure regulating valve with pressure gauge 539756 1
Pressure sequence valve 152884 1
Push-in sleeve 153251 10
Push-in T-connector 153128 10
Quick exhaust valve 539772 1
Shuttle valve 539771 1
Single-acting cylinder 152887 1
Time delay valve, normally closed 540694 1

Training aims – Basic Level (TP101)
• To familiarise yourself with the design and function of a single-acting cylinder.

• To familiarise yourself with the design and mode of operation of a 3/2-way valve.
• To be able to identify and draw types of directional control valve actuation.
• To able to explain and design an example of direct actuation.
• To be able to analyse and evaluate circuits.
• To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a 5/2-way valve.
• To be able to explain and design an example of indirect actuation.
• To familiarise yourself with the mode of operation of a 5/2-way valve with
pneumatic actuation.
• To familiarise yourself with the difference between a signalling element and a
control element.
• To be able to measure pressure in pneumatic control circuits.
• To be able to differentiate between and utilise types of flow control according to
specifications.
• To be able to set cylinder advancing and retracting speeds.
• To familiarise yourself with one type of signal storage in pneumatic circuits.
• To be able to explain and realise logic AND/OR/NOT operations.
• To be able to explain and configure latching circuits.
• To familiarise yourself with one option of cylinder end position sensing.
• To be able to combine logic operations.
• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
• To be able to differentiate between and select and use 5/2-way valves according
to specifications.
• To be able to further develop existing circuits.
• To familiarise yourself with the design and mode of operation of a pressure
regulating valve.
• To be able to analyse circuits and optimise these according to specifications.
• To familiarise yourself with the design and mode of operation of a pressure
regulating valve.
• To be able to analyse circuits and optimise these according to specifications.
• To familiarise yourself with the design and mode of operation of a time delay
valve.
• To be able to design circuits with oscillating movements.
• To be able to use time delay valves dependent on parameters.
• To be able to analyse and design circuits using two cylinders.

Contents
Part A – Exercises
Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9
Exercise 3: Drilling of valve manifold blocks ______________________________A-17
Exercise 4: Filling of drinks bottles______________________________________A-25
Exercise 5: Cleaning of workpieces _____________________________________A-35
Exercise 6: Printing of mobile phone housings ____________________________A-43
Exercise 7: Packaging spark plugs ______________________________________A-49
Exercise 8: Sealing of guide bushes_____________________________________A-55
Exercise 9: Hardening of material test specimens__________________________A-63
Exercise 10: Bending of sheet metal strips _______________________________A-69
© Festo Didactic GmbH & Co. KG • 541089 A-1

Contents
A-2 © Festo Didactic GmbH & Co. KG • 541089

Exercise 1: Opening and closing of an oven door
Training aims • To familiarise yourself with different types of end position sensing.
• To familiarise yourself with the options of designing control systems with a
memory function.
• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally
open).
Problem definition The hardening system is designed for the continual hardening of mass produced
metal parts. The workpieces are hardened and subsequently quenched in an oil-
quenching bath. The flaps at the entry and exit of the hardening system are to be
closed and opened using double-acting cylinders.
Parameters • Due to the heat build-up, no limit switches are to be used. The pressure is to be
sensed when the cylinder moves into one of the two end positions.
Project task 1. Complete the pneumatic circuit diagram.

2. Convert the directional control valves contained in the equipment set.
3. Carry out the assembly.
4. Check the assembled circuit.
5. Describe the mode of operation of the circuit.
6. Compile the equipment list.

Positional sketch
Hardening oven
1. The opening and closing function is to be started using a pushbutton 1S1.

2. A 5/2-way double pilot valve controls the double-acting cylinder. The control
pulse for this is to be the pressure that builds up when the cylinder moves into
one of the two end positions.
A pulse occurs either via valves 1V1, 1V3 to1V4: "Retract";
or a pulse occurs via valves 1V2, 1V3 to 1V4: "Advance"
3. The cylinder movement in abbreviated annotation is
1A1+ 1A1–
Additional exercises • What faults may occur when tubing up the circuit?
What are the effects of such faults? Describe these.
• The convertible 3/2-way pneumatic valves are intended for the required
3/2 way valves 1V1 and 1V2. These valves are supplied in normally closed
position. How do they need to be converted in order to fulfil the necessary
function?
• As an alternative, use the 5/2-way pneumatic valves. How do these need to be
converted?
• How does the circuit react after a pressure loss?
• What is a binary reducing stage?

Name: Date:
Completing the pneumatic circuit diagram Sheet 1 of 1
– Complete the pneumatic circuit diagram and enter the port designations.
1A1
1V5 1 1 1V6
2 2
1V4 4 2
14 12
5 3
1
1V3 4 2
14 12
5 3
1 1V2 2
10
1 3
1V1 2 1S1 2
10
1 3 1 3
Pneumatic circuit diagram

Name: Date:
Compiling the equipment list Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list

Name: Date:
Carrying out additional exercises Sheet 1 of 2
– What faults can occur when tubing up the circuit?

What are the effects of such faults? Describe these.
– The convertible 3/2-way pneumatic valves are intended for the required
3/2-way valves 1V1 and 1V2. These valves are supplied in the normally closed
position. How do they need to be converted in order to fulfill the necessary
function?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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Exercise 1: Opening and closing of an over door
Name: Date:
– As an alternative, use the 5/2-way pneumatic valves for this. How do these need
to be converted?
– How does the circuit react after a loss of pressure?
– What is a binary reducing stage?
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Exercise 2: Separating of drinks bottles
Training aims • To familiarise yourself with displacement-step diagrams and to be able to design
these for a specified circuit.
• To be able to realise circuits with parallel movements in push-pull mode.
• To be able to use pneumatic decrementing counters.
Problem definition In a bottling plant, bottles are to be filled with drinks. The bottles are to be
separated immediately after the filling station. Three bottles at a time are to be
pushed on to a conveyor via an ejecting cylinder. In a subsequent station, these
bottles are to be placed into a drinks crate/box?.
Parameters • It is essential to ensure that only one single start signal is emitted even if the
start button is actuated for a longer period.


Positional sketch
Filling system
1. If the 5/2-way pneumatic valve with selector switch 0S1 is actuated, cylinder 1A1
is to advance and cylinder 2A1 to retract.
2. The output signal of the pneumatic proximity sensor 2B1 is to decrement the
numeric value by one at the predetermining counter 0Z1 with each actuation.
3. If the numeric value of the pneumatic predetermining counter 0Z1 is 0, the
compressed air supply of pilot port 14 of the 5/2-way double pilot valve 0V2 is to
be switched off via the 3/2-way pneumatic valve 0V1.
4. Resetting of the 5/2-way pneumatic valve with selector switch 0S1 is to reset the
pneumatic predetermining counter.
5. The cylinder movement in abbreviated notation is
1A+ 1A–
2A– 2A+
3 double strokes

Additional exercise • What happens if both limit switches on the cylinder are moved?
Notes
• You will need to mount one of the two magnetic limit switches of the double-
acting cylinder from TP101 on the double-acting cylinder from TP102.
• The pneumatic predetermining counter 0Z1 is set by pressing the wide key
adjacent to the counter and entering the units (one, ten, .. ) (see data sheet).

Name: Date:
Designing the displacement-step diagram Sheet 1 of 1
– Design the displacement-step diagram for the process described.
1 2 3=1
1
1A1
0
1
2A1
0
Displacement-step diagram

Name: Date:
– Complete the pneumatic circuit diagram.
1A1 2A1
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
0V2 4 2 0Z1 2
14 12 12 10
5 3 1
1
1B1 2 2B1 2
1 3 1 3
0V1 2
10
1 3
2
0S1 4 2
5 3
1

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– What happens if both limit switches on the cylinder are moved?
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Exercise 3: Drilling of valve manifold blocks
Training aims • To be able to design indirect circuit actuation.

• To be able to compare different sensors and select appropriate sensors for an
application.
Problem definition Valve manifold blocks are to be drilled horizontally and vertically by two
pneumatically actuated feed units. The two drilling axes are to intersect.
The start is to be effected via a valve with pushbutton.
Parameters • Since the drilling axes are intersecting, you need to ensure that the first drilling
operation is completed before the second one starts.


Positional sketch
Automatic drilling machine
1. The double-acting cylinders 1A1 and 2A1 are to be monitored in the end position
by a roller lever valve with idle return 1B1, a back pressure valve 1B2, pneumatic
proximity sensor 2B1 and a roller lever valve 2B2.
2. The start is to be effected via a 3/2-way valve with pushbutton 1S1.
3. Cylinder1A1 is to advance and simulate the first drilling operation. In the
forward end position, the cylinder is to actuate a back pressure valve 1B2, which
is to switch the final control element 1V1. Cylinder 1A1 is to retract.
4. If cylinder 1A1 is back in the retracted end position, the roller lever valve with
idle return 1B1 is to switch in the direction of flow and actuate the final control
element 2V1.
5. Cylinder 2A1 is to advance and simulate the second drilling operation. Once it
reaches the forward end position, it is to actuate the roller lever valve 2B2. The
final control element 2V1 is to reverse and cylinder 2A1 is to return into the
retracted end position where it is to actuate the pneumatic proximity sensor 2B1.
1A1+ 1A1– 2A1+ 2A1–

If the cylinder impacts on the back pressure valve, this may be damaged.
Additional exercises • How does the circuit react if a limit switch is moved?
• What must be observed when mounting the back pressure end stop?
• Compare the function and response of the various sensors.

Name: Date:
– Design the displacement-step diagram.
1 2 3 4 5=1
1
1A1
0
1
2A1
0

Name: Date:
2A1
2B1
1A1
1B1 1B2 2B2
2B1 2 1B2 2 1B1 2 2B2 2
1 3 1 3 1 3 1 3
1S1 2
1 3

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– How does the circuit react if a limit switch is moved?

– What needs to be observed when mounting the back pressure end stop?
– Compare the function and response of the various sensors.
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Exercise 4: Filling of drinks bottles
Training aims • To be able to design indirect cylinder actuation.

• To familiarise yourself with the design and function of stepper modules.
• To be able to design the basic „continuous cycle“ stepper control system.
• To be able to install one-way flow control valves dependent on given parameters.
Problem definition A drinks producer requires bottles to be filled automatically. During the filling
operation, the bottles are to be pressed against the extended piston rod of the
separating cylinder by a continuously running conveyor. The storage container is
located above this and is to be opened and closed by a cylinder. The cylinder is to
close the container opening in the retracted state.
Parameters • The flow control of the separating cylinder is to be set such that only the filled
bottle is released and a new, empty drinks bottle is positioned underneath the
filling valve.
Project task 1. First of all, process the introductory exercises for the stepper module.
2. Complete the pneumatic circuit diagram.

Positional sketch
Filling device
1. If a valve is actuated using selector switch 0S1, the closing cylinder 1A1 is to
advance and retract again with restricted exhaust air. Both cylinder end positions
are to be monitored via the roller lever valves 1B1 and 1B2.
2. The separating cylinder 2A1 is then to retract with restricted exhaust air and
immediately advance again with restricted exhaust air. The cylinder end
positions are to be monitored via the pneumatic proximity sensors 2B1 and 2B2.
3. Both proximity sensors and the roller lever valves are to signal the cylinder
positions to the sequencer.
4. The motion sequence is to end if the valve is reset via selector switch 0S1.
1A+ 1A– 2A– 2A+
Additional exercises • How does the circuit react if the roller lever valve 1B2 or the proximity sensor
2B2 are moved?
• Design the displacement-step diagram for this circuit.

Name: Date:
Stepper module Sheet 1 of 3
Introductory exercise using a stepper module

(without drives and sensors)
Connect the correct connections of the stepper so that it runs automatically.
– Which connections do you need to connect together?
Connection Connection
Yn Yn+1
P P
Zn Zn+1
L L
X1 A1
X2 A2
X3 A3
X4 A4
– What are the effects of the interruption in the tubing connections?

Draw up an evaluation table.
Connection Effect
A1 – X1
A2 – X2
A3 – X3
A4 – X4
Zn – Zn+1
Yn – Yn+1

Name: Date:
Mode of operation of a stepper sequencer

A signal is input into the stepper module 1 via input, thereby triggering the output
command, e.g. 1A1+. Step 2 is prepared simultaneously and the last step in the
chain (in this case step 4) is cancelled via the output connection Z.
Step 2 is reset and an output signal, e.g. 2A1, is triggered if step 1 receives the
acknowledgement „step executed" via the limit switch 1B2. Step 3 is prepared
simultaneously and step 1 is cancelled.
The next steps are executed correspondingly.
A1 A2 A3 A4
TAA TAA TAA TAB
X1 X2 X3 X4
Resetting a sequencer
If the sequencer stops in any step, the currently activated step can be cancelled via a
central reset signal at connection "L". The central reset signal is transmitted to one
of the two OR inputs.

Name: Date:
– What are the advantages of the stepper module compared to reversing valve
technology?
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– Which exercises can the individual stepper module undertake?
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Name: Date:
– Design the displacement-step diagram.
1 2 3 4 5=1
1
1A1
0
1
2A1
0

Name: Date:
2A1
2B1 2B2
1A1 1B1 1B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB
Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y

Yn Yn+1
Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B2 2 1B1 2 2B1 2 2B2 2
1 3 1 3 1 3 1 3 1 3

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– How does the circuit react if the roller lever valve 1B2 or the proximity sensor
2B2 are moved?
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Exercise 5: Cleaning of workpieces
Training aims • To be able to design a stepper sequencer control with the input commands
AUTOMATIC/MANUAL, START and RESET.
• To be able to realise an OR function of the feedback signals.
• To be able to set time delays according to specifications.
• To familiarise yourself with circuits in order to cancel time delays via signal input.
Problem definition A cleaning bath is to be fed automatically. A wire cage with material is to be moved
above the bath via a double-acting cylinder. A second double-acting cylinder is to
lower the wire cage into the cleaning bath, where it is to remain for an adjustable
time period, until it is raised again for draining. The draining time must also be
adjustable, after which the first cylinder is to return into the initial position.
Parameters • It must be possible for the drives and sequencer to be reset via a pushbutton
0S3, if a valve with selector switch 0S1 is reset from AUTOMATIC to MANUAL.
• The bath dwell time t1 is to be cancelled if pushbutton 0S4 is pressed and the
dipping cylinder 2A1 is to move into the retracted end position.
• Actuation of a valve with pushbutton 0S5 is to terminate the draining time t2 and
the horizontal cylinder 1A1 is to return into the initial position.
Project task 1. First of all, design a simplified ciruit diagram without taking into account the
parameters and time delay.
2. Assemble this circuit and check its functioning.
3. Expand the pneumatic circuit diagram in accordance with the parameters.
4. Carry out the circuit assembly.
7. Complete the equipment list.

Positional sketch
Cleaning bath
1. A horizontally built-in double-acting cylinder 1A1 is to move the wire cage to the
right underneath the extractor hood, i.e. the cleaning bath, if a valve is actuated
using pushbutton 0S2.
2. The cage is to remain in the bath for t1 = 3 seconds after the double-acting
cylinder 2A1 has advanced.
3. Once the cage is raised again, it is to pause for t2 = 2 seconds to drain before the
horizontal cylinder 1A1 moves into the retracted end position again.
4. The cylinder movements are to be with exhaust air restriction at both ends.
5. The cylinder movements in abbreviated notation are
1A+ 2A+ 2A– 1A–
Additional exercises • Design the displacement-step diagram with signal lines.

Name: Date:
– Design the displacement-step diagram with signal lines.
1 2 3 4 5=1
1
1A1
0
1
2A1
0

Name: Date:
– Complete the pneumatic circuit diagram without realising the parameters.
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S2 2 0S3 2
1 3 1 3
0S1 4 2
5 3
1

Name: Date:
– Complete the pneumatic circuit diagram including the parameters.
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
0V1 2 10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V2 2
2B1 2
5 3 10
1 1 3
1 3
2B2 2
1 3
1 3

Name: Date:
– Modify the circuit diagram such that, during the reset function, cylinder 2A1
advances first and then cylinder 1A1.
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3 2
1 0V7 2 1
1 1/3 0V8
1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V1 2 0V2 2
2B2 2 2B1 2
5 3 10
1
1 3 1 3
1 3
1 3

Name: Date:
Completing the equipment list Sheet 1 of 1
an equipment list.
– Complete the equipment list by entering the required equipment in the table
below.
2 Cylinder, double-acting
4 One-way flow control valve
2 5/2-way pneumatic double pilot valve
5/2-way valve with selector switch
3/2-way valve with pushbutton, normally closed
3/2-way pneumatic valve, normally open
3/2-way roller lever valve, normally closed
Proximity sensor, pneumatic
Shuttle valve (OR)
Dual pressure valve (AND)
Time delay valve, normally closed
Time delay valve, normally open
1 Stepper module Type 3TAA/1TAB
1 Manifold
1 On/off valve with filter regulating valve
1 Compressed air supply
Equipment list


Exercise 6: Printing of mobile phone housings
Training aims • To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at
CYCLE END and AUTOMATIC/MANUAL.
Problem definition Mobile phone faceplates are to be printed using a tampon-printing machine. The
faceplates are to be fed in pairs via a conveyor.
The tampon printing machine sequence is to be realised via a feed unit.
Parameters • Pre-selection between MANUAL and AUTOMATIC mode is to be facilitated via a

valve with selector switch.
• In AUTOMATIC mode, two valves with pushbuttons (START, STOP at CYCLE END),
that influence a memory, are to be pressurised.
• Two further valves with mushroom actuator or pushbutton (EMERGENCY-STOP,
acknowledge EMERGENCY-STOP) also influence a memory.
• In MANUAL mode, the sequencer and the drives must be resettable via a fifth
valve with pushbutton.
Project task 1. Extend the pneumatic circuit diagram in accordance with the parameters.

Positional sketch
Tampon printing machine
1. Continuous operation is to be started by pressing the START button 0S6. The

sequence is to stop at the end of a cycle by pressing the STOP at CYCLE END
button 0S5.
2. In MANUAL mode, the cylinders and sequencer are to be resettable by pressing
the RESET button 0S4.
3. The retracting movements of the cylinders are to be exhaust air restricted.
4. The cylinder movements in abbreviated annotation are:
1A+ 3A+ 1A– 3A–
2A– 2A+

Exercise 6: Printing of mobile phone casings
Name: Date:
1 2 3 4 5=1
1
1A1
0
1
2A1
0
1
3A1
0

Name: Date:
2A1
2B1 2B2
1A1 1B1 1B2 3A1 3B1 3 B2
1V2 1 2V2 1 3V2 1
2 2 2
1V1 4 2 2V1 4 2 3V1 4 2
14 12 14 12 14 12
5 3 0V12 2 5 3 0V13 2 5 3
1 1 1
10 0V11
1 1/3 2
1 3
10
0V9 2 0V10 2 1 3
1 1/3 1 1/3 0V8 2
1 1/3
s1
s2
s3
s4
0V6 4 2
14 12 A1 A2 A3 A4
TAA TAA TAA TAB
Start 5 3
1
0S6 2 0V5 2
1 1/3 Yn Yn+1
1 3
Stop at cycle end P P P P P P P P P P P P
0S5 2 L L L L L L L L L L
Reset L X1 X2 X3 X4 L
0S4 2 Zn Zn+1
1 3
1 3
Manual/Automatic 1B2 2 2B1 2 1B1 2 2B2 2

0S3 4 2
1 3 1 3 1 3 1 3
5 1 3 3B2 2 3B1 2
0V2 4 2
14 12 1 3 1 3
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Name: Date:
an equipment list.
– Complete the equipment list by entering the required equipment in the table
below.
5/2-way pneumatic double pilot valve
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
3/2-way toggle lever valve with idle return, normally closed
3/2-way back pressure valve, normally closed
Shuttle valve (OR)
1 Manifold
Equipment list


Exercise 7: Packaging of spark plugs
Training aims • To be able to design a stepper sequencer control with idle step.
• To familiarise yourself with the option of facilitating variable step repetitions
within a motion sequence and to assemble this circuit.
• To be able to develop an input circuit with self-latching loop, that enables the
following inputs: AUTOMATIC/MANUAL, START, STOP at CYCLE END AND RESET.
• To be able to select suitable sensors for an application and adjust these sensors
(use of a sensor to detect cardboard boxes in a magazine).
Problem definition Two double-acting cylinders 1A1 and 2A1 are to operate two magazines. One flat
magazine is to contain the spark plugs and the other the cardboard boxes for the
packaging. Four spark plugs each are to be fed from the flat magazine to a
cardboard box. The number of spark plugs to be packed is to be adjustable.
A cardboard box is to be pushed out of the gravity feed magazine with the advancing
of cylinder 1A1, to be ready for filling. Then, cylinder 2A1 is to execute four double
strokes, thereby separating the spark plugs from the flat magazine. The cycle is to
be completed with the retraction of cylinder 1A1 (gravity feed magazine).
Parameters • Switching between MANUAL and AUTOMATIC mode is to be possible by actuating

the valve with selector switch 0S1.
• Actuation of the STOP at CYCLE END pushbutton 0S4 is to start the cycle through
to the end and stop the control system.
• In AUTOMATIC mode, the control system is to operate in continuous cycle.
• When switching to MANUAL, both cylinders are to retract if the RESET
pushbutton 0S2 is actuated and the sequencer is to be returned into the initial
position.
• It must not be possible to start unless cardboard boxes are present. A 3/2-way
valve with selector switch 0S5 is to simulate the conditions „magazine empty“
and „magazine loaded“.
Project task 1. Complete the pneumatic circuit diagram and enter the port designations.
3. Check the circuit assembly.

Positional sketch
2A1
0S5
1A1
Packaging device
1. Actuation of the START button 0S3 is to set up a self-holding circuit with the
control system operating in a continuous cycle. Actuation of the STOP at CYCLE
END button 0S4 is to interrupt the self-latching loop and cancel the stored START
signal. The self-latching loop is to be interrupted also, i.e. it cannot be set up, if
the selector switch 0S5 simulates the condition „magazine empty“, i.e. in the
absence of any packaging material in the stacking magazine.
2. In AUTOMATIC mode, the self-holding circuit and sequencer are to be supplied
with compressed air. If operation is switched to MANUAL via a 5/2-way valve
with selector switch 0S1, the RESET button 0S2 is to be supplied with
compressed air. Its actuation is to cause the two cylinders to retract and the
sequencer to assume the initial position.
3. A pneumatic predetermining counter is to count the advance movements of
cylinder 2A1 and emit a signal to the stepper sequencer when reaching a preset
value.
4. The end positions of cylinder 1A1 are to be monitored using pneumatic proximity
sensors. Two roller lever valves are to monitor the end positions of cylinder 2A1.
5. The cylinder movement in abbreviated notation is:
1A1+ 2A1+ 2A1– 1A1–
4x
Additional exercises • Design the displacement-step diagram for this circuit.

Notes
• In practice, a roller lever valve is used to monitor whether the stacking magazine
is full. This is not suitable in this case, since continuous actuation of the valve is
not intended. The use of a 3/2-way valve with selector switch 0S5 is suggested
instead.
• According to the circuit diagram, the stepper sequencer 0Z1 consists of three
modules. The Festo Didactic stepper module is equipped with four modules. You
should therefore bridge the second step by tubing up output A2 and input X2.
The following applies for the bridging of steps:
– The last step must not be an idle step.
– Two idle steps must not be consecutively switched.
• The valves for input are:
STOP at CYCLE END 0S4,
START 0S3,
RESET 0S2,
AUTOMATIC/MANUAL 0S1.
Trial run
Proceed as follows:
1. Reset: "MAN" and "RESET"
2. Start: "AUTO" and "START"
3. Interrupt: "STOP at CYCLE END"

Name: Date:
1 2 3 4 5 6 7 8 9 10 11=1
1
1A1
0
1
2A1
0

Name: Date:
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
0V7
10
1 3
0V4 2 A1 A2 A3 A4
TAA TAA TAA TAB
10
1 3
0S4 0S5 2 Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y
2 Yn Yn+1
1 3 1 3 Z
L
Zn
L
Zn+1 Zn
L L
Zn+1 Zn
L L
Zn+1 Zn
L L
Zn+1
L
Z
L
0V1 1 L L
0V2 2 X1 X2 X3 X4
Zn Zn+1
2 12
1B2 2 1B1 2
1 3
1/3
1 3 1 3
0S3 2
0S2 2 0Z3 2
1 3 12 10
1 3 1
0S1 4 2
2B1 2 2B2 2
5 3
1 1 3 1 3

Name: Date:
an equipment list.
– Complete the equipment list by entering the number of required components in

the table below.
3/2-way valve with selector switch, normally closed
3/2-way pneumatic valve, normally closed
Pneumatic predetermining counter
Shuttle valve (OR)
1 Manifold
Equipment list

Exercise 8: Sealing of guide bushes
Training aims • To familiarise yourself with the option of realising the double stroke of a cylinder
and to be able to assemble this circuit.
• To familiarise yourself with circuits in order to realise the reversal of a cylinder
movement in the partial stroke range.
• To be able to develop an input circuit for a stepper control with protected pilot air
with the inputs START, AUTOMATIC/MANUAL and RESET.
Problem definition Guide bushes with lapped through holes are to be sealed on both sides using a
plastic plug. The guide bushes are to be manually inserted into the device and the
plugs are to be fed via a gravity magazine.
The START signal 0S4 is to first of all trigger the advancing of the piston rod of the
exhaust air restricted double-acting cylinder 1A1. A plug is to be pressed through
the hole and close the rear righthand opening of the bush. Once the piston rod has
retracted a second plug is to follow and the piston then is to advance halfway and
immediately retract again thereby sealing the front lefthand side of the bush. The
bush can then be removed and a new sequence started.
Parameters • Actuation of the EMERGENCY-STOP mushroom actuator 0S1 is to switch off the
compressed air supply. If cylinder 1A1 is in motion, it is to return into the
retracted end position. If cylinder 1A1 is in the forward end position, it is to
remain there.
• If the RESET button 0S5 is actuated, both the cylinder and the stepper sequencer
are to move into the initial position.
Project task 1. Complete the circuit diagram.


Positional sketch
1A1
1B1 1B3 1B2
Sealing device
1. A single cycle is to be introduced by pressing the START button 0S4. The

AUTOMATIC/MANUAL switch 0S3 is switched to AUTOMATIC for this. The pilot air
supply of the stepper sequencer is to be protected by means of a self-latching
loop via valves 0V3, 0V4 and 0V5.
2. The retracted end position of the cylinder is to be monitored via roller lever valve
1B1 and the forward end position via roller lever valve 1B2. The reversal in the
partial stroke range is to be triggered by the pneumatic proximity sensor 1B3.
3. Roller lever valve 1B1 is to transmit its signal to inputs X2 and X4 of the stepper
sequencer, since a second start takes place within a cycle.

Note
• This is a case where a signalling element actuates two stepper modules
simultaneously.
The magnetic limit switch (1S4) simultaneously operates inputs X2 and X4. If the
second step is reset, then this transmits the pulse. If the fourth step is reset, then
the signal is sent to the cylinder via A4 and resets the stepper module. Both step
outputs are connected via the shuttle valve (0V6), i.e. both the second step and
fourth step emit the pulse to the final control element (1V1) via valves (0V7),
(0V10) and (0V11).
Additional exercises • Design the displacement-step diagram with signal lines.

• Convert an available 5/2-way pneumatic valve into the required 3/2-way
pneumatic valve. Check the functioning of the valve prior to installation.

Name: Date:
1 2 3 4 5=1
1A m

Name: Date:
1A1
1B3
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
14 12
5 1 3 0V13 2
1 1/3
0V12 2
0V11 2 1 1/3
10
0V10 2 1 3
10 0V9 2
1 3
10
1 3
0V7 2 0V8 2
1 1/3 1 1/3
s1
s2
0V6 s3
1 1/3 s4
A1 A2 A3 A4
2 TAA TAA TAA TAB

Yn Yn+1
0V5 2 Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z
L L L L L L L L L L
L X1 X2 X3 X4 L
10 Zn Zn+1
1 3
0V4 2 1B2 2 1B3 2 1B1 2
12
0V3 2 1 3
1 3 1 3 1 3
1 1/3
Start Reset
0S4 2 0S5 2
1 3 1 3
Manual/Automatic
0S3 4 2
5 1 3
0V2 4 2
14 12
0V1 2 5 3
EMERGENCY- 1
Acknowledge
STOP 10
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Name: Date:
an equipment list.

the table below.
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
Shuttle valve (OR)
1 Stepper module Type 3TAA/1 TAB
1 Manifold
Equipment list

Name: Date:
Carrying out additional exercises. Sheet 1 of 1
– Convert an available 5/2-way pneumatic valve into the required 3/2-way

pneumatic valve. Check the functioning of the valve prior to installation.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 9: Hardening of material test specimens
Training aims • To be able to stop a double-acting cylinder in the partial stroke range.
• To understand how valve output signals can be inverted.
• To be able to select appropriate sensors for an application and adjust these.
Problem definition Steel tool specimens from various smelters are to undergo reproducible heat
treatment. The alloyed steel tool specimens are to be annealed, quenched and
tempered.
A test specimen is to be placed into a wire cage and the START button actuated.
Cylinder 1A1 is to move from the retracted end position into the mid-position. After
an annealing time of t1 = 3 seconds, the forward end position is to be approached
and the test specimen quenched by a jet of tempered oil or water. Before the
cylinder assumes the initial position again, it is to remain in the mid-position for
tempering for t2 = 2 seconds.

5. Check the equipment list.

t1 = 3 s
Positional sketch
t2 = 2 s
1B1 1B3 1B2
Hardening device
1. If the START button 0S1 is pressed, cylinder 1A1 is to move from the retracted
end position into the mid-position. The retracted end position is to be monitored
via the roller lever valve 1B1 and the mid-position via the pneumatic proximity
sensor 1B3.
2. The cylinder is to remain in the mid-position for a preset time of t1 = 3 seconds
for the annealing of the test specimen. After this, the righthand end position is to
be approached and the roller lever valve 1B2 actuated.
3. The cylinder is to retract into the mid-position again. A further time delay valve
now starts and the cylinder returns into the retracted end position after a time
period of t2 = 2 seconds.
Additional exercise • Design the displacement-step diagram with signal lines.

Name: Date:
1 2 3 4 5=1
1
1A1 m

Name: Date:
1A1
1B3
1B1 1B2
1V5 2 1V6 2
1 21 1 21
1V3 1 1 1V4
2 2
1V1 2 1V2 2
12 12
1 3 1 3
0V5 2 0V6 2
1 1/3 1 1/3
0V4 2
10
0V2 2 0V3 2 1 3
10
1 3
1 3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B3 2 1B2 2 1B1 2
1 3 1 3 1 3 1 3

Name: Date:
Checking the equipment list Sheet 1 of 1
an equipment list.
– Check the equipment list by comparing the number of components listed in the
table below with your circuit design.
Non-return valve, piloted
One-way flow control valve
Time delay valve, normally closed
Shuttle valve (OR)
1 Manifold
Equipment list


Exercise 10: Bending of sheet metal strips
Training aims • To be able to realise a control system with control behaviour in combination with
a sequence control in stepper design.
• To be able to select appropriate sensors for an application and to adjust these.
Problem definition Sheet metal strips are to be bent using a bending tool. A sheet metal strip is to be
manually inserted into the bending device. Once the START button is actuated, a
cylinder is to clamp the workpiece. The first bending cylinder is to pre-bend the
metal strip and immediately retract again. The second bending cylinder is to
complete the bending of the metal strip. Following this, the second bending cylinder
and the clamping cylinder are to retract simultaneously and the newly formed
bracket is to be removed manually.
Parameters • The clamping cylinder is to exhibit monitored behaviour when advancing, i.e. the
sequence control is to be started when the forward end position is reached. If the
START button is released before the cylinder reaches the forward end position, it
is to return into the initial position again.
Project task 1. Complete the circuit diagram.

5. Check the equipment list.

Positional sketch
1A1
2A1
3A1
Bending device
1. The single-acting clamping cylinder 1A1 operates with throttled supply air and is
to be actuated via a spring-returned 3/2-way pneumatic valve. The bending
cylinders 2A1 and 3A1 are to be actuated via 5/2-way double pilot valves and a
stepper module.
2. The end positions of the double-acting bending cylinder 2A1 are to be sensed via
a roller lever valve 2B1 and a roller lever valve with idle return 2B2, and those of
the double-acting bending cylinder 3A1 via a pneumatic proximity sensor 3B1
and 3B2. A back pressure valve 1B2 is to monitor the forward end position of the
single-acting clamping cylinder 1A1 and the retracted end position is to be
monitored via the roller lever valve 1B1.
3. The START button 0S1 must be held down until the clamping cylinder 1A1 is
advanced and the back pressure valve has responded, whereby the stepper
sequencer receives the signal for starting.

4. The bending cylinder 2A1 is to advance and actuate the roller lever valve with
idle return 2B2 in its forward end position. This is to reset the first module and
switch the second step. The bending cylinder 2A1 is to retract immediately again
and actuate the roller lever valve 2B1 in the retracted end position. This is to
reset the second module and switch the third step. Bending cylinder 3A1 is to
advance and actuate pneumatic proximity sensor 3B2 in the forward end
position. This is to reset the third module and switch the fourth step. Clamping
cylinder 1A1 is to be exhausted and return into the retracted end position. At the
same time, the bending cylinder 3A1 is to retract and actuate pneumatic
proximity sensor 3B1 in the retracted end position. This is to reset the fourth
module and consequently the stepper sequencer.
1A1+ 2A1+ 2A1– 3A1+ 3A1–
1A1–
Notes
• The safety guards required in practice are not taken into consideration.
• Reliable clamping is to be ensured before the bending process is started. The
back pressure valve 1B2 ensures that the metal strip is reliably clamped by the
clamping cylinder. The manually operated valve 0S1 must be actuated until the
back pressure valve 1B2 reacts. This latching safeguards the subsequent
bending operations.
• As the circuit requires 3 roller lever valves, but only two are contained in the
TP101 and TP102 construction kits, valve 2B2 has been replaced by a roller lever
valve with idle return.
Additional exercise • Design the displacement-step diagram with signal lines.

• Convert the available 5/2-way double pilot valves into the required 3/2-way
double pilot valves. Check the functioning of the valves prior to installation.

Name: Date:
1 2 3 4 5 6=1
1
1A1
0
1
2A1
0
1
3A1
0

Name: Date:
3A1
3B1 3B2
1A1 2A1
1B1 1B2 2B1 2B2
1V2 2 2V2 1 3V2 1
1 2 2
1V1 2 2V1 4 2 4 2
12 14 12 14 12
1 3 5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB
0V4 2
1 1/3 Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0V3 2
2B2 2 2B1 2
12 10
1 3
1 3 1 3
1B1 2 0V2 2
12 10
1 3 1 3
3B2 2 3B1 2
0S1 2 1B2 2
1 3 1 3
1 3 1 3

Name: Date:
an equipment list.
1 Cylinder, single-acting
3/2-way toggle lever valve with idle return, normally closed
3/2-way back pressure valve, normally closed
Shuttle valve (OR)
1 Manifold
Equipment list

Name: Date:
Carrying out additional exercises. Sheet 1 of 1
– Convert the available 5/2-way double pilot valves into the required 3/2-way
double pilot valves. Check the functioning of the valves prior to installation.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Part B – Fundamentals
The theoretical fundamentals for the pneumatics training package are summarised
in the textbook:
Pneumatics, Basic Level

This book is intended for basic training in pneumatic control technology and teaches
the physical fundamentals of pneumatic control technology as well as the function
and use of pneumatic components. Numerous illustrations and diagrams aid
comprehension. Pneumatic circuits are explained with the help of examples and
sample solutions and detailed explanations improve the students’ knowledge of
circuit design and sequences.
P. Croser, F. Ebel, 2002 edition,

274 pages, bound
Order No.: 093131
© Festo Didactic GmbH & Co. KG • 541089 B-1

B-2 © Festo Didactic GmbH & Co. KG • 541089
Contents
Part C – Solutions
Exercise 1: Opening and closing of an oven door ___________________________C-3

Exercise 2: Separating of drinks bottles __________________________________C-7
Exercise 3: Drilling of valve manifold blocks ______________________________C-11
Exercise 4: Filling of drinks bottles______________________________________C-17
Exercise 5: Cleaning of workpieces _____________________________________C-27
Exercise 6: Printing of mobile phone housings ____________________________C-35
Exercise 7: Packaging of spark plugs ____________________________________C-41
Exercise 8: Sealing of guide bushes_____________________________________C-47
Exercise 9: Hardening of material test specimens__________________________C-53
Exercise 10: Bending of sheet metal strips _______________________________C-59
© Festo Didactic GmbH & Co. KG • 541089 C-1

Contents
C-2 © Festo Didactic GmbH & Co. KG • 541089

Solutions
Name: Date:
1A1
1V5 1 1 1V6
2 2
1V4 4 2
14 12
5 3
1
1V3 4 2
14 12
5 3
1 1V2 2
10
1 3
1V1 2 1S1 2
10
1 3 1 3

Solutions
Name: Date:
Process description Sheet 1 of 1
Initial position
The oven door is closed. The piston rod of cylinder 1A1 is advanced. The 5/2-way
double pilot valve 1V4 (final control element) pressurises the piston chamber and
exhausts the piston rod chamber. The 5/2-way double pilot valve 1V3 (reversing
valve) is switched to flow from 1 to 4.
Steps 1-2 – opening the oven door

The 3/2-way pneumatic valves 1V1 and 1V2 are actuated simultaneously if the
pushbutton on the 3/2-way valve 1S1 is pressed. Pilot ports 12 and 14 of the
reversing valve 1V3 are exhausted. The compressed air then pressurises the pilot
port 12 of the 5/2-way double pilot valve 1V4 via ports 1 and 4 of the 5/2-way
double pilot valve 1V3. Valve 1V4 switches. The piston rod end of cylinder 1A1 is
pressurised and the piston returns into the retracted end position.
At the same time, the pilot port 12 of the reversing valve 1V3 is pressurised via the
3/2-way pneumatic valve 1V2. The reversing valve 1V3 is connected such as to
enable the reversing of the final control element 1V4 via a new start signal.
Steps 2-3 – closing the oven door

The 3/2-way pneumatic valves 1V1 and 1V2 are simultaneously actuated if the
pushbutton at the 3/2-way valve 1S1 is pressed again. The pilot ports 12 and 14 of
the reversing valve 1V3 are exhausted. The compressed air then pressurises pilot
port 14 of the final control element 1V4 via ports 1 and 1 of the reversing valve 1V3.
Cylinder 1A1 is pressurised at the piston end. The piston rod advances.
At the same time pilot port 14 of the reversing valve 1V3 is pressurised again as a
result of the air via the 3/2-way pneumatic valve 1V1. The control system is in the
initial position again and the oven door can be opened again via a new start signal.

Solutions
Name: Date:
Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.
below.
1 3/2-way valve with pushbutton, normally closed
2 3/2-way pneumatic valve, normally open
1 Manifold
Equipment list

Solutions
Name: Date:
What faults can occur during the tubing up of circuits?

What is the effect of such faults? Describe these.
The 3/2-way valves have not been correctly converted. Circuit does not function.
Port 2 has been mixed up with port 4 on valve 1V4. Cylinder does not advance.
How do the 3/2-way valves need to be converted in order to fulfil the necessary
function?
The valves have to be converted to normally open by swapping the blanking plug
and working port.
How do the 5/2-way pneumatic valves need to be converted?

Working port 4 needs to be closed.
Possible solution if a blanking plug is not available: Plug a T-piece (push-in T-
connector) with short tubing onto the valve and connect the remaining two outputs
of the T-piece with a short piece of tubing.
What is the behaviour of the circuit after pressure loss?

The activating circuit stores its status. The result: If the door is moved during
pressure loss, it will return to its previous position if pressure is renewed.
What is a binary reducing stage?

Binary reducing stages are also known as toggle flip flops.
Flip-flops, also referred to as bistable elements, are circuits, that realise basic status
memories.
They assume two statuses: Set and reset. In order to set the flip-flop, a signal needs
to be applied at the input, in this case a pressure signal. The flip-flop then remains in
the set status until a further signal is applied at the input. A binary digit (0 or 1) can
be represented via these statuses.
A binary reducing state changes its status with every active pulse edge, i.e. it acts as
a frequency divider/reducer.

Solutions
Name: Date:
1A1 2A1
1B1 2B1
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
0V2 4 2 0Z1 2
14 12 12 10
5 3 1
1
1B1 2 2B1 2
1 3 1 3
0V1 2
10
1 3
2
0S1 4 2
5 3
1

Solutions
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position. Cylinder 2A1 assumes the forward end
position. The pneumatic proximity sensor 1B1 is actuated. The 5/2-way valve 0S1 is
detented to flow from 1 to 2. The pneumatic predetermining counter 0Z1 is reset and
set to preset value 3.
Separating of drinks bottles

Actuation of the start pushbutton 0S1 causes the pneumatic signal to be switched to
pilot port 14 of the 5/2-way double pilot valve via the 3/2-way valve 0V1 and the
pneumatic proximity sensor 1B1.
Both of the two 5/2-way double pilot valves1V1 and 2V1 are reversed via output 4 of
the 5/2-way double pilot valve 0V2. The piston rod of cylinder 1A1 advances and the
piston rod of cylinder 2A1 retracts.
If cylinder 1A1 moves out of the retracted end position, the pneumatic proximity
sensor 1B1 is no longer actuated and pilot port 14 of the 5/2-way double pilot valve
0V2 is exhausted.
The pneumatic proximity sensor 2B1 is actuated if cylinder 2A1 reaches the
retracted end position. The output signal of the pneumatic proximity sensor 2B1
reverses the 5/2-way double pilot valve 0V2. At the same time, this output signal is
applied to pilot port 12 of the pneumatic predetermining counter and the preset
value is reduced by 1.
Cylinder 1A1 retracts again and cylinder 2A1 advances. This process is repeated
until the pneumatic predetermining counter 0Z1 has counted to 0. Once the value is
0, a pneumatic signal is applied at pilot port 10 of the 3/2-way valve 0V1 by output 2
of the predetermining counter. This causes the air supply to pilot port 14 of the
5/2-way double pilot valve 0V2 to be interrupted.
Cylinder 1A1 is in the retracted end position again and cylinder 2A1 in the forward
end position.

Solutions
Exercise 2:Separating of drinks bottles
Name: Date:

equipment list.
below.
1 5/2-way valve with selector switch
2 Proximity sensor, pneumatic
1 Pneumatic predetermining counter
1 Manifold
Equipment list

Solutions
Name: Date:
– Draw the displacement-step diagram with signal lines.
0S2
1 2 3=1
1
1A1
0
1B1
1
2A1
0
2B1
What happens if both proximity sensors are moved on the cylinder?

If the cylinders move into the end position, the pneumatic proximity sensors are not
actuated and the circuit no longer starts.

Solutions
Name: Date:
2A1
2B1
1A1
1B1 1B2 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
2B1 2 1B2 2 1B1 2 2B2 2
1 3 1 3 1 3 1 3
1S1 2
1 3

Solutions
Name: Date:
In this exercise, the end position of the double-acting cylinder is monitored via four
different sensors.
Double-acting cylinder 1A1
Retracted end position: 3/2-way toggle lever valve with idle return 1B1
Forward end position: Back pressure valve 1B2
Double-acting cylinder 2A1
Retracted end position: Pneumatic proximity sensor 2B1
Forward end position: Roller lever valve 2B2
Initial position
The double-acting cylinders 1A1 and 2A1 are in the retracted end position. The
pneumatic proximity sensor 2B1 is actuated. The roller lever valve with idle return
1B1 is overtravelled by the trip cam of cylinder 1A1 and therefore not actuated. The
final control elements 1V1 and 2V1 each assume the switching position with flow
from 1 to 2.
Drilling using a vertical feed unit

Actuation of the START button 1S1 causes the final control element 1V1 to switch via
the switched-through pneumatic proximity sensor 2B1. The piston rod of cylinder
1A1 advances and back pressure valve 1B2 is actuated in the forward end position.
The final control element 1V1 is reversed again and cylinder 1A1 retracts.
Drilling using a horizontal feed unit

Just before reaching the retracted end position, the trip cam of cylinder 1A1
overtravels the roller lever valve with idle return 1B1. The final control element 2V1
is switched from 1 to 4 via the output signal of valve 1B1. The piston rod of cylinder
2A1 advances. Upon reaching the forward end position, cylinder 2A1 actuates the
roller lever valve 2B2. The output signal of valve 2B2 reverses the final control
element 2V1. The piston rod of cylinder 2A1 retracts and actuates the pneumatic
proximity sensor 2B1.
The interlock of the START button 1S1 is cancelled. A new cycle can be triggered via
a renewed manual start signal. This ensures that the feed units cannot collide.

Solutions
Name: Date:

equipment list.
below.
1 3/2-way toggle lever valve with idle return, normally closed
1 3/2-way back pressure valve, normally closed
1 3/2-way roller lever valve, normally closed
1 Manifold
Equipment list

Solutions
Name: Date:
– Draw the displacement-step diagram with signal lines.
1S1
1 2 3 4 5=1
1B2
1
1A1
0
1B1
2B2
1
2A1
0
2B1

Solutions
Name: Date:
How does the circuit react if the roller lever valve is moved?
The cylinder does not fully advance, but only up to the position of the roller lever
valve.
What needs to be considered when mounting the back pressure valve?

It is important to adjust the back pressure valve correctly. On a permanently
installed valve this is facilitated by releasing the lock nut or by twisting the trip cam
on the piston rod. In the test set-up, the back pressure valve is moved along the
profile slot.
If the cylinder impacts on the valve, this can be damaged.
Use and comparison of different sensors
Sensor Type of actuation Use Observe
Roller lever valve Mechanical Signal overlap Actuation direction, when

with idle return the sensor actuated
Back pressure end Compressed air Monitoring of cylinder Correct adjustment

stop end position
Pneumatic limit Magnetic START interlock Position on cylinder

switch
Roller lever valve Mechanical Monitoring of cylinder Response point

end position

Solutions

Solutions
Name: Date:
Introductory exercise with the stepper module

(without drive or sensors)
Connect the correct step connections so that it runs through automatically.
– Which connections need to be interconnected?
Connection Connection
Yn –––––––––––––––––––––––––––––––––––––––––––– Yn+1
P Compressed air Blanking plug P
Zn –––––––––––––––––––––––––––––––––––––––––––– Zn+1
L Not connected, open L
X1 –––––––––––––––––––––––––––––––––––––––––––– A1
X2 –––––––––––––––––––––––––––––––––––––––––––– A2
X3 –––––––––––––––––––––––––––––––––––––––––––– A3
X4 –––––––––––––––––––––––––––––––––––––––––––– A4
– What are the consequences of the interruption in the tubing connections?

Create an evaluation table.
Connection Effect
A1 – X1 Not running. Stepper module stops.
Zn – Zn+1 Not running. Stepper module stops.
Yn – Yn+1 Not running. Stepper module stops.

Solutions
Name: Date:
Mode of operation of a stepper sequencer

A start signal is input at stepper module 1 via input Yn. This triggers the output
command, e.g. 1A1+. At the same time, step 2 is prepared and the last step in the
sequence (in this case step 4) is cancelled via the output connection Z.
If step 1 receives the "command executed" acknowledgement via limit switch 1B2,
step 2 is set and an output signal, e.g. 2A1+ is triggered. At the same time, step 3 is
prepared and step 1 cancelled.
The next steps are run in parallel.
A1 A2 A3 A4
TAA TAA TAA TAB
X1 X2 X3 X4
Resetting a stepper sequencer

If the sequencer stops at any step, the currently activated step can be cancelled via a
central reset signal at connection "L". The central reset signal is transmitted to one
of the two OR inputs.

Solutions
Name: Date:
What are the advantages of a stepper module compared to reversing valve

technology?
Stepper technology has indisputable advantages compared to reversing valve
technology (cascaded control systems) or the use of roller lever valves with idle
return:
• Minimal design complexity (circuit diagram)
• Simplified reading and understanding of circuit diagram (black box principle)
• Less tubing required (assembly time)
• Parameters can be more easily realised
• Less work required when modifying a control system
• Greater operational reliability
• Simplified monitoring via visual indicator and manual override.
What tasks can the individual stepper module assume?

The individual stepper module completes three tasks:
• Switching through (transmission) of signals from input X to output A
• Preparation of the following step
• Cancelling the previous step

Solutions
Name: Date:
2A1
2B1 2B2
1A1 1B1 1B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B2 2 1B1 2 2B1 2 2B2 2
1 3 1 3 1 3 1 3 1 3

Solutions
Name: Date:
Initial position
Cylinder 1A1 assumes the retracted end position, the piston rod of cylinder 2A1 is
advanced and roller lever valve 1B1 is actuated. The pneumatic proximity sensor
2B2 is switched through via the permanent magnet on the piston and a signal is
therefore applied at input X4 of the stepper sequencer. Output A4 is active. A signal
is applied at the dual pressure valve 0V1 via Yn+1.
Filling bottles, cylinder 1A1

Actuation of the START button 0S1 causes the memory of the first module (Type A)
to be reset via the dual pressure valve 0V1. The output signal A1 reverses the final
control element 1V1 and the cylinder 1A1 advances. Upon reaching the forward end
position, the cylinder actuates the roller lever valve 1B2. This causes the first
module at input X1 to be pressurised. The spring returned 3/2-way valve of the first
module is reversed and the memory is reset at the subsequent second module (Type
A). The output signal A2 of the second module reverses the final control element
1V1. Cylinder 1A1 returns into the retracted end position. Signal A2 also cancels the
memory valve of the first module. It can only be switched via a new start signal and
the output signal Yn+1.
Bottle release, cylinder 2A1

Cylinder 1A1 in the retracted end position actuates the roller lever valve 1B1. Its
signal acknowledges the output signal A2 at X2 and switches through to the third
module (type A). The output signal A3 reverses the final control element 2V1 and
cylinder 2A1 retracts. The pneumatic proximity sensor 2B1 acknowledges the
movement and switches through to the fourth module (type B) via X3. Its signal
reverses the final control element and cylinder 2A1 advances. The pneumatic
proximity sensor 2B2 acknowledges the end position of the cylinder via X4. The
spring returned 3/2-way valve of the fourth module (type B) is switched. The signal
Yn+1 is applied at the dual pressure valve 0V1 again.

Solutions
Name: Date:
Single cycle
If the START button 1S1 is only briefly pressed, i.e. not detented for continuous
cycle, only signal Yn+1 is applied at the dual pressure valve 0V1 at the end of a
cycle. A new cycle cannot be started until the START button is actuated again.
Continuous cycle
If the START button 1S1 is detented, a continuous signal is applied at input 1 of the
dual pressure valve 0V1. A new cycle starts automatically if the initial position of the
cylinder is signalled via connection Yn+1 of the fourth stepper module (type B).
Cycle end
Disengaging the START button 1S1.
Simplified description Filling of bottles, cylinder 1A1

Actuation of the START button 1S1 triggers the output signal A1 via 0V1, which
switches 1V1 via connection 14. Cylinder 1A1 advances and actuates 1B2. 1B2
triggers the output signal A2 via input X1. 1V1 reverses; cylinder 1A1 retracts and
actuates 1B1. Signal is applied at input X2.
Releasing of bottles, cylinder 2A1

Signal at X2 pressurises output A3. 2V1 reverses; cylinder 2A1 retracts and actuates
2B1. 2B1 effects connection X3 and thus pressurises A4. 2V1 reverses; cylinder 2A1
advances and actuates 2B2. 2B2 produces X4 and Yn+1. Dual pressure valve 0V1 is
pressurised on one side.

Solutions
Name: Date:

equipment list.
below.
1 3/2-way valve with selector switch, normally closed
1 Dual pressure valve (AND)
1 Stepper module Type 3TAA/1TAA
1 Manifold
Equipment list

Solutions
Name: Date:
– Design the displacement-step diagram with the signal lines.
0S1
1 2 3 4 5=1
1B2
1
1A1
0
1B1
1
2B2
2A1
0
2B1

Solutions
Name: Date:
How does the circuit react, if sensors 1B2 and 2B2 are displaced?
If the pneumatic proximity sensor 2B2 is displaced when the cylinder is advanced,
the proximity sensor is not attenuated and a start condition is not available. The
system will not start up.
If the roller lever valve 1B2 is displaced such that it is not actuated in the cylinder
end position, the cylinder no longer retracts.

Solutions

Solutions
Name: Date:
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S2 2 0S3 2 1B2 2 2B2 2 2B1 2 1B1 2
1 3 1 3 1 3 1 3 1 3 1 3
0S1 4 2
5 3
1
Pneumatic circuit diagram without parameter conditions

Solutions
Name: Date:
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
0V1 2 10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V2 2
2B1 2
5 3 10
1 1 3
1 3
2B2 2
1 3
1 3
Pneumatic circuit diagram with parameter conditions

Solutions
Name: Date:
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3 2
1 0V7 2 1
1 1/3 0V8
1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V1 2 0V2 2
2B2 2 2B1 2
5 3 10
1
1 3 1 3
1 3
1 3
Pneumatic circuit diagram with latching of the reset function

Solutions
Name: Date:
Components used:
Delays (t1 = 3 sec; t2 = 2 sec) are designated. Component 0V1 is the already familiar
time delay valve with normally closed position. Component 0V2 is a time delay valve
with interchanged positions, i.e. normally open. The output signal of this time delay
valve needs to be inverted. A 3/2-way pneumatic valve with normally open position
0V3 assumes this function.
The 5/2-way pneumatic valve with selector switch 0S1 facilitates the switching of
AUTOMATIC/MANUAL. "MAN" in combination with the actuation of pushbutton 0S2
causes the sequencer and cylinder to be reset, i.e. all valves and cylinders assume
the initial position. "AUTO" in combination with the actuation of the START
button 0S2 initiates the automatic execution of a cycle (single cycle).
The delays can be shortened or cancelled via the pushbuttons 0S4 (immersion time)
and 0S5 (draining time).
Initial position
Cylinder 1A1 is in the retracted end position. The pneumatic proximity sensor 1B1 is
attenuated and switched to flow from 1 to 2. Cylinder 2A1 is in the retracted end
position. The roller lever valve 2B1 is actuated. The 5/2-way pneumatic valve with
selector switch 0S1 is switched to AUTOMATIC, flow from 1 to 2.
Steps 1-2
Cylinder 1A1 moves to the right above the electroplating bath (movement 1A1+).
The START signal is input to the first module of the stepper sequencer, connection
Yn, via the 3/2-way valve 0S2 and via the dual pressure valve 0V6, (module 4 is
deactivated via line Z). The final control element 1V1 is reversed via output A1 and
cylinder 1A1 advances.
Steps 2-3
Cylinder 2A1 immerses the wire cage into the electroplating bath (movement
2A1+).
Cylinder 1A1 switches through the pneumatic proximity sensor 1B2. Its signal is
applied at input X1 of the stepper module 0Z1. The sequencer switches through to
the second module. The final control element is reversed via output A2. Cylinder 2A1
advances and actuates the roller lever valve 2B2 in the forward end position.

Solutions
Name: Date:
Steps 3-4
Cylinder 2A1 raises the wire cage (movement 2A1-).
After the set time t1 = 3 sec, the time delay valve 0V1 switches to flow. Its signal
pressurises input X2 of the second module of the stepper sequencer. The third
module is reset. The final control element 2V1 is reversed via output A3 and the
shuttle valve 0V8. Cylinder 2A1 retracts and actuates the roller lever valve 2B1 in the
retracted end position.
Steps 4-5
Cylinder 1A moves to the left (movement 1A-).
After the set time t2 = 2 sec, the time delay valve 0V2 exhausts the pilot line of the
3/2-way pneumatic valve 0V3. This switches to normally open. Connection X3 of the
stepper sequencer is pressurised via the shuttle valve 0V5 (the signal switch-off of
the time delay valve 0V2 has been inverted). Signal X3 switches through to the
fourth module. The dual pressure valve 0V7 is supplied with compressed air via
output A4. The final control element 1V1 is reversed via the simultaneously applied
output signal of the roller lever valve 2B1. Cylinder 1A1 retracts and actuates the
pneumatic proximity sensor 1B1. Its signal switches through the fourth module of
the stepper sequencer. The signal Yn+1 is applied at the dual pressure valve 0V6. A
new cycle can now commence via a start signal.

Solutions
Name: Date:

equipment list.

the table below.
4 Shuttle valve (OR)
1 Time delay valve, normally closed
1 Time delay valve, normally open
1 Manifold
Equipment list

Solutions
Name: Date:
0S2 0S5
0S4
1 2 3 4 5=1
1
1B2
1A1
0 1B1
0V1 0V2 t2
t1
1
2A1 2B2
0
2B1

Solutions

Solutions
Name: Date:
2A1
2B1 2B2
1A1 1B1 1B2 3A1 3B1 3 B2
1V2 1 2V2 1 3V2 1
2 2 2
1V1 4 2 2V1 4 2 3V1 4 2
14 12 14 12 14 12
5 3 0V12 2 5 3 0V13 2 5 3
1 1 1
10 0V11
1 1/3 2
1 3
10
0V9 2 0V10 2 1 3
1 1/3 1 1/3 0V8 2
1 1/3
s1
s2
s3
s4
0V6 4 2
14 12 A1 A2 A3 A4
TAA TAA TAA TAB
5 3
Start 1
0S6 2 0V5 2
1 1/3 Yn Yn+1
1 3
0S4 2 Zn Zn+1
1 3
1 3

0S3 4 2
1 3 1 3 1 3 1 3
5 1 3 3B2 2 3B1 2
0V2 4 2
14 12 1 3 1 3
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Solutions
Name: Date:
Initial position
The double-acting cylinder 1A1 is in the retracted end position and actuates the
roller lever valve 1B1. The double-acting cylinder 2A1 is advanced and actuates the
pneumatic proximity sensor 2B2. The double-acting cylinder 3A1 is in the retracted
end position and actuates the roller lever valve 3B1. The 5/2-way pneumatic valve
with selector switch 0S3 is detented to flow from 1-2. The 3/2-way pneumatic valve
with the „EMERGENCY-STOP“ mushroom actuator 0S1 is unlatched. The memory
valve 0V2 has flow from 1 to 2. The stepper sequencer is reset.
Continuous cycle
Steps 1-2
Cylinder 1A1 advances, cylinder 2A1 retracts.
The START signal 0S6 switches the memory valve 0V6 from 1 to 4. A continuous
signal is applied at the dual pressure valve 0V7. Combined with signal Yn+1 of the
last module of the sequencer, the dual pressure valve 0V7 is able to input the start
pulse into the stepper sequencer. The output signal A1 simultaneously reverses the
final control elements 1V1 and 2V1 via string s1. Cylinder 1A1 advances and cylinder
2A1 retracts throttled.
Steps 2-3
Feed cylinder 3A1 advances, whereby cylinder 1A1 remains advanced.
As soon as cylinder 1A1 reaches the forward end position and cylinder 2A1 reaches
the retracted end position, the sequencer is advanced via the acknowledgement
signal X1. The dual pressure valve 0V3 ensures that only one signal arrives at X1, if
both the back pressure valve 1B2 and the pneumatic proximity sensor 2B1 are
actuated. Signal A2 reverses the final control element 3V1 via string s2. The double-
acting cylinder 3A1 advances and actuates the roller lever valve with idle return 3B2
in the end position.

Solutions
Name: Date:
Steps 3-4
Cylinder 1A1 retracts, cylinder 2A1 advances.
The acknowledgement signal of the roller lever valve with idle return 3B2 advances
the stepper sequencer by one step via connection X2. The actuating signal A3
reverses the final control elements 1V1 and 2V1 via the pilot line s3. Cylinder 1A1
moves into the retracted end position and actuates the roller lever valve 1B1,
cylinder 2A1 moves into the forward end position and actuates the pneumatic
Steps 4-5
Feed cylinder 3A1 retracts, whereby cylinder 2A1 remains advanced.
Once cylinders 1A1 and 2A1 have acknowledged their end positions (initial position)
(1B1 and 2B2 actuated), the signal of the dual pressure valve 0V4 at input X3
advances the stepper sequencer by one step. The actuating signal reverses the final
control element 3V1 via string s4. Cylinder 3A1 retracts and one cycle is completed.
Two signals are now applied again at the dual pressure valve 0V7, i.e. the
continuous signal from the memory valve 0V6 and the signal Yn+1 from the stepper
sequencer. Consequently all further cycles are executed without a renewed START
signal.

Solutions
Name: Date:
Parameters
• STOP at CYCLE END

The memory valve 0V6, realised via a 5/2-way double solenoid valve in the
exercise, can be converted via the 3/2-way valve with pushbutton 0S5. The line
at the dual pressure valve 0V7 is exhausted. The start signal Yn+1 for the next
cycle is thus blocked via the dual pressure valve 0V7.
• EMERGENCY-STOP
Actuation of the EMERGENCY-STOP valve 0S1 causes the 3/2-way pneumatic
valve 0V1 to be reversed. The memory valve 0V1 is reversed, with flow from
1 to 4. The start processors are exhausted. The final control element 2V1) is
reversed via connection 14. Cylinder 2A1 advances. Port 12 of the final control
element 2V1 is exhausted via the 3/2-way pneumatic valve 0V13. This ensures
that the final control element is able to switch to flow from 1 to 4. The air supply
line to control element 3V1 is exhausted via the 3/2-way pneumatic valve 0V11
and consequently cylinder 3A1 is stationary.
• EMERGENCY-STOP release and RESET

After an EMERGENCY-STOP, the cylinders must be returned to their initial
position. RESET is achieved by actuating the 3/2-way valve via pushbutton 0S4.
The following sequence is to be observed:

1. EMERGENCY-STOP (0S1)
2. Switch from AUTOMATIC to MANUAL (0S3)
3. Release EMERGENCY-STOP (0S2)
4. RESET (0S4)

Solutions
Name: Date:

equipment list.

the table below.
1 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
1 Manifold
Equipment list

Solutions
Name: Date:
0S6
1 2 3 4 5=1
1B2
1
1A1
1B1
0
2B2
1
2A1
0
2B1
3B2
1
3A1
0 3B1

Solutions
Name: Date:
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V9 2 5 3 0V10 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
0V7
10
1 3
0V4 2 A1 A2 A3 A4
TAA TAA TAA TAB
10
1 3
0S4 0S5 2 Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y
2 Yn Yn+1
1 3 1 3 Z
L
Zn
L
Zn+1 Zn
L L
Zn+1 Zn
L L
Zn+1 Zn
L L
Zn+1
L
Z
L
0V1 1 L L
0V2 2 X1 X2 X3 X4
Zn Zn+1
2 12
1B2 2 1B1 2
1 3
1/3
1 3 1 3
0S3 2
0S2 2 0Z3 2
1 3 12 10
1 3 1
0S1 4 2
2B1 2 2B2 2
5 3
1 1 3 1 3

Solutions
Name: Date:
Initial position
The double-acting cylinder 1A1 at the gravity feed magazine is in the retracted end
position and actuates the pneumatic proximity sensor 1B1. The double-acting
cylinder 2A1 at the flat magazine is also in the retracted end position and actuates
the roller lever valve 2B1. The 5/2-way valve with selector switch 0S1 is detented for
flow from 1 to 2 (AUTOMATIC). The 3/2-way valve with selector switch 0S5 is
actuated (a roller lever valve is simulated, which indicates a full cardboard box
magazine).
Continuous cycle
Steps 1-2
Cylinder 1A1 at the gravity feed magazine advances.
The START signal of the 3/2-way valve 0S2 causes the pneumatic valve 0V2 to be
switched to flow from 1 to 2 via the shuttle valve 0V1. The pneumatic valve 0V2
moves into a self-latching loop via valves 0S5, 0V4 (normally open position) and the
shuttle valve (0V1). As a result of this self-latching loop, a continuous signal is
applied at the dual pressure valve 0V5. Combined with the signal Yn+1 of the last
module of the sequencer, the cylinders are actuated. The output signal A1 of the
sequencer switches the final control element 1V1 to flow from 1 to 4. Cylinder 1A1
advances unthrottled and actuates the pneumatic proximity sensor 1B2 in the
forward end position.

Solutions
Name: Date:
Steps 2-3 to 9-10

Cylinder 2A1 at the flat magazine executes four double strokes.
The stepper sequencer receives the acknowledgement signal X1 from the pneumatic
proximity sensor and steps up. The output signal A2 of the sequencer, together with
the signal of the actuated roller lever valve 2B1, is applied at the dual pressure valve
0V8 and switches the final control element to flow from 1 to 4. Cylinder 2A1
advances unthrottled and in the forward end position actuates the roller lever valve
2B2. Its signal is applied at the dual pressure valve 0V6 together with signal A2 and
reverses the final control element 2V1. Cylinder 2A1 retracts again. The roller lever
valve 2B2 also transmits a pulse to the counter of the pneumatic predetermining
counter 0Z3. After the set 4 strokes, the output signal of the counter is applied at the
dual pressure valve 0V3. Together with the signal of the roller lever valve 2B1, the
4 strokes are acknowledged at X2 and the sequencer steps up. The pneumatic valve
0V7 is exhausted via the same output signal of the counter. Only one signal is still
applied at the dual pressure valve 0V8 and cylinder 2A1 is therefore no longer able
to advance.
Steps 10-11
Cylinder 1A1 at the gravity feed magazine retracts.
The output signal A3 reverses the final control element 1V1. Cylinder 1A1 retracts
and actuates the pneumatic proximity sensor 1B1. The 3rd module switches through
and its signal Yn+1 initiates a new cycle.
Please note: This module must be the last module of the stepper sequencer. One
module must be bridged.
STOP at CYCLE END

Actuation of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to exhaust the
self-latching loop. The pneumatic valve 0V2 switches into the normally closed
position and no signal is therefore applied at the dual pressure valve 0V5. The
sequencer can only be activated again via a renewed start signal.
RESET
If the 5/2-way valve with selector switch 0S1 is detented to MANUAL, the cylinders
and sequencer can be moved into the initial position via the actuation of the
3/2-way valve 0S2.

Solutions
Name: Date:

equipment list.

the table below.
1 3/2-way valve with selector switch, normally closed
1 3/2-way pneumatic valve, normally closed
1 Pneumatic predetermining counter
1 Manifold
Equipment list

Solutions
Name: Date:
0S3
1 2 3 4 5 6 7 8 9 10 11=1
1B2
1
1A1
0
1B1
1
2A1 2B2 2B1 2B2 2B1 2B2 2B1 2B2
0
2B1

Solutions

Solutions
Name: Date:
1A1
1B3
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
14 12
5 1 3 0V13 2
1 1/3
0V12 2
0V11 2 1 1/3
10
0V10 2 1 3
10 0V9 2
1 3
10
1 3
0V7 2 0V8 2
1 1/3 1 1/3
s1
s2
0V6 s3
1 1/3 s4
A1 A2 A3 A4
2 TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
10 Zn Zn+1
1 3
0V4 2 1B2 2 1B3 2 1B1 2
12
0V3 2 1 3
1 3 1 3 1 3
1 1/3
Start Reset
0S4 2 0S5 2
1 3 1 3
Manual/Automatic
0S3 4 2
5 1 3
0V2 4 2
14 12
0V1 2 5 3
EMERGENCY- 1
Acknowledge
STOP 10
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Solutions
Name: Date:
Initial position
The piston rod of the double-acting cylinder 1A1 is in the retracted end position and
actuates the roller lever valve 1B1.
The 3/2-way pneumatic valves 0V5, 0V9, 0V10 and 0V11 assume the normally open
position. The 3/2-way pneumatic valve 0V4, required for the latching circuit,
assumes the normally closed position.
The mode selector switch 0S3 is set to AUTOMATIC (flow from 1 to 2)
Steps 1-2
The piston rod moves into the forward end position.
The START signal of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to be
switched to flow via the shuttle valve 0V3. The pilot air can now flow to the
sequencer, port P, via valve 0V5. Via the shuttle valve 0V3, this pilot air
simultaneously transmits a continuous signal to the 3/2-way pneumatic valve 0V4.
This valve switches into a self-latching loop and the compressed air supply for the
sequencer is protected. Pressure is applied at both sides of the dual pressure valve
0V6 via the start signal and signal Yn+1 and this switches through. The sequencer is
able to actuate the final control element. The output signal A1 of the sequencer
reverses the pneumatic valve 0V10 and the final control element 1V1 via the shuttle
valve 0V7. The piston rod advances and actuates the roller lever valve 1B2 in the
forward end position. The over-travelling of the proximity sensor 1B3 does not have
any effect.

Solutions
Name: Date:
Steps 2-3
Piston rod moves into the retracted end position.
The signal of the roller lever valve 1B2 is applied at intput X1 and steps up the
sequencer. The output signal A2 flows via the shuttle valve 0V8, the pneumatic valve
0V9) and shuttle valves 0V12 and 0V13 and resets the final control element 1V1. The
piston rod retracts and actuates the roller lever valve 1B1.
Steps 3-4
Piston rod advances halfway.
The sequencer is stepped up via the acknowledgement signal X2 of the roller lever
valve 1B1. (The AND gate of the 4th module is not yet prepared and the signal at X4
therefore cannot step up the sequencer. Also, the traversing of proximity sensor 1B3
has no effect, since the 3rd module has not yet been prepared). The output signal A3
flows via the shuttle valve 0V7 and the pneumatic valve 0V10 to the pilot port 14 of
the final control element 1V1 and reverses this. The piston rod advances and
actuates the pneumatic proximity sensor 1B3.
Steps 4-5
Piston rod moves into the retracted end position.
The acknowledgement signal of the pneumatic proximity sensor 1B3 can now step
up the sequencer via connection X3. The output signal A4 flows via the shuttle valve
0V8, the pneumatic valve 0V9 and shuttle valves 0V12 and 0V13 to pilot port 12 of
the final control element 1V1 and reverses this. The piston rod retracts. The roller
lever valve 1B1 acknowledges the end position of the piston rod at connection X4.
The signal Yn+1 is applied at the dual pressure valve 0V6 again and the next cycle
can commence via a new start signal.

Solutions
Name: Date:
Behaviour during EMERGENCY-STOP
EMERGENCY-STOP, piston rod in "forward movement"

If the EMERGENCY-STOP mushroom actuator 0S1 is actuated, the self-latching loop
of the compressed air supply for the sequencer is first of all interrupted via valve
0V5. This means that the sequencer cannot emit any output signals. The signal
blocks valves 0V9 and 0V10 and reverses the final control element 1V1 via valves
0V11, 0V12 and 0V13). The piston rod moves into the retracted end position.
EMERGENCY-STOP, piston rod in "retract movement"

The final control element 1V1 is already switched to flow from 1 to 2. The piston rod
consequently moves into the retracted end position.
EMERGENCY-STOP, piston rod in forward end position

The final control element 1V1 is switched to flow from 1 to 4. The roller lever valve
1B2 is actuated and blocks the valve 0V11. Consequently, the line for the signal to
the final control element is interrupted and the piston rod remains in the forward
end position.
EMERGENCY-STOP release and RESET

After an EMERGENCY-STOP, the cylinders must be returned to their initial position.
RESET is achieved by actuating the 3/2-way valve using pushbutton 0S5.
The following sequence is to be observed:

1. EMERGENCY-STOP (0S1)
2. Switch from AUTOMATIC to MANUAL (0S3)
3. Release EMERGENCY-STOP (0S2)
4. RESET (0S5)

Solutions
Name: Date:

equipment list.

the table below.
1 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
1 Manifold
Equipment list

Solutions
Name: Date:
0S1
1 2 3 4 5=1
1B2
1A m
1B3
0 1B1 1B1

Solutions
Name: Date:
1A1
1B3
1B1 1B2
1V5 1 1 1V6
2 2
1V3 2 1V4 2
1 12 1 12
1V1 2 1V2 2
12 12
1 3 1 3
0V5 2 0V6 2
1 1/3 1 1/3
0V4 2
10
0V2 2 0V3 2 1 3
10
1 3
1 3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B3 2 1B2 2 1B1 2
1 3 1 3 1 3 1 3

Solutions
Name: Date:
Initial position
The piston of cylinder 1A1 is in the retracted end position and actuates the roller
lever valve 1B1; the continuous signal Yn+1 is therefore applied at the dual pressure
valve 0V1. The 4th module (type B) of the stepper sequencer is reset and its signal
A4 blocks the time delay valve 0V3. The pneumatic valve 0V4 is not actuated and is
in the normally open position. Consequently, the pilot port 12 of the final control
element 1V2 is pressurised. The piston rod chamber of the cylinder is pressurised at
a pressure of p = 6 bar (600 kPa).
Steps 1-2
Cylinder 1A1 moves into mid position for annealing.
The first module (type A) of the sequencer is reset via the START signal of the
3/2-way valve 0S1. Its signal A1 actuates the final control element 1V1, i.e. a spring
returned 3/2-way pneumatic valve. The time delay valve 0V3 moves into the normal
position (flow). The pneumatic valve 1V2 moves into the normal position. Cylinder
1A1 advances and in the mid-position actuates the pneumatic proximity sensor 1B3.
Steps 2-3
Awaiting the annealing time, cylinder moves into righthand end position for
quenching.
The acknowledgement signal of the pneumatic proximity sensor 1B3 is applied at
connections X1 and X3 of the stepper sequencer, but can only be switched through
via the reset 1st module. Signal A2 actuates the time delay valve 0V2. The cylinder
remains in the mid-position during the set annealing time of t1 = 3 seconds. Valves
1V1 and 1V2 are exhausted. After 3 seconds, the final control element 1V1 is
switched via the time delay valve 0V2. The cylinder moves into the forward end
position and actuates the roller lever valve 1B2.

Solutions
Name: Date:
Steps 3-4
Cylinder moves into mid-position for start-up.
The acknowledgement signal of the roller lever valve 1B2 switches through to the
3rd stepper module. Its signal A3 switches the final control element 1V2 to flow.
Cylinder 1A1 moves to the left into mid-position and re-activates the pneumatic
Steps 4-5
Awaiting the tempering time, cylinder moves into lefthand end.
The acknowledgement signal of the pneumatic proximity sensor 1B3 switches to the
4th module (type B) of the sequencer via connection X3. The signal at X1 has no
effect, since module 1 is not reset. Signal A4 actuates the time delay valve 0V3. After
the tempering time of t2 = 2 seconds, the final control element is switched to flow via
the time delay valve 0V3. The cylinder moves into the initial position.
A new cycle can be started via a renewed START signal.

Solutions
Name: Date:

equipment list.
2 Non-return valve, piloted
1 Time delay valve, normally closed
1 Time delay valve, normally open
1 Manifold
Equipment list

Solutions
Name: Date:
0S1
1 2 3 4 5=1
1
1B2
1B3 1B3
1A1 m
t1 t2
0 0V2 0V3 1B1

Solutions

Solutions
Name: Date:
3A1
3B1 3B2
1A1 2A1
1B1 1B2 2B1 2B2
1V2 2 2V2 1 3V2 1
1 2 2
1V1 2 2V1 4 2 4 2
12 14 12 14 12
1 3 5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB
0V4 2
1 1/3 Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0V3 2
2B2 2 2B1 2
12 10
1 3
1 3 1 3
1B1 2 0V2 2
12 10
1 3 1 3 3B1 2
3B2 2
0S1 2 1B2 2 1 3
1 3
1 3 1 3

Solutions
Name: Date:
Initial position
The three drives are in the retracted end position. Sensors 1B1, 2B1 and 3B1 are
actuated. The memory valve 0V3 is switched to flow from 1 to 2. Memory valve 0V2
is closed.
Steps 1-2
Clamping cylinder 1A1 advances (1A1+).
The final control element 1V1 switches to flow if the START button 0S1 is actuated.
The single-acting clamping cylinder 1A1 advances with throttled supply air and in
the forward end position actuates the back pressure valve 1B2. Two signals (start
signal and acknowledgement signal of movement 1A1+) are applied at the dual
pressure valve 0V1). The final control element 1V1 remains actuated via the memory
valve 0V2 and the shuttle valve 0V4. The clamping cylinder remains in the forward
end position.
Steps 2-3
The first bending cylinder 2A1 advances (2A1+).
A signal is also applied at the dual pressure valve 0V5 via the memory valve 0V2.
Together with signal Yn+1, the first module (type A) of the stepper sequencer is reset
and its signal A1 reverses the final control element 2V1. The bending cylinder 2A1
advances and actuates the roller lever valve with idle return 2B2.
Steps 3-4
The first bending cylinder 2A1 retracts (2A1-).
The second module (type A) is reset via the acknowledgement signal of the roller
lever valve with idle return 2B2 and its signal A2 reverses the final control element
2V1. The bending cylinder 2A1 moves into the retracted end position and actuates
the roller lever valve 2B1.
Steps 4-5
The second bending cylinder 3A1 advances (3A1+).
The acknowledgement signal of the roller lever valve 2B1 causes the third module
(type A) to be reset; its signal A3 reverses the final control element 3V1. The bending
cylinder 3A1 moves into the forward end position and actuates the pneumatic

Solutions
Name: Date:
Steps 5-6
The second bending cylinder 3A1 and the clamping cylinder 1A1 retract
(3A1-), (1A1-).
First of all, the acknowledgement signal of the pneumatic proximity sensor 3B2
switches through to the fourth module (type B), and its signal A4 reverses the final
control element 3V1. Cylinder 3A1 retracts and actuates the pneumatic proximity
sensor 3B1. Secondly, the memory valve 0V2 is reversed, as a result of which there
is no continuous signal at the final control element 1V1. The clamping cylinder 1A1
also retracts and actuates the roller lever valve 1B1, whereby the initial position is
obtained again. The fourth module of the sequencer is switched through and its
signal Yn+1 is applied at the dual pressure valve 0V5. The memory valve 0V3 is back
in the righthand switching position (flow from1 to 2).
A new cycle can be started via a START signal.

Solutions
Name: Date:

equipment list.
1 Cylinder, single-acting
1 Manifold
Equipment list

Solutions
Exercise 10: Bending of strip metal sheets
Name: Date:
0S1
1 2 3 4 5 6=1
1
1A1 1B2
0 1B1
1
2A1 2B2
2B1
0
1
3A1 3B2
0 3B1

Solutions

Part D – Appendix
Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets 3/2-way valve with pushbutton, normally closed _______________________ 152860
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP) 152864
3/2-way roller lever valve with idle return, normally closed_______________ 152867
Back pressure valve ______________________________________________ 152868
Pneumatic predetermining counter __________________________________ 152877
Shuttle valve, 3-fold ______________________________________________ 152882
Dual pressure valve, 3-fold_________________________________________ 152883
Stepper module__________________________________________________ 152886
Double-acting cylinder ____________________________________________ 152888
Time delay valve, normally open ____________________________________ 539759
3/2-way pneumatic valve, convertible________________________________ 539768
5/2-way double pilot valve _________________________________________ 539769
Shuttle valve ____________________________________________________ 539771
One-way flow control valve_________________________________________ 539773
Non-return valve, piloted __________________________________________ 540715
Circuit diagrams Exercise 4: Filling of drinks bottles

© Festo Didactic GmbH & Co. KG • 541089 D-1

Organiser
Equipment set in the organiser
All components of the equipment set for the technology package TP102 are stored in
an organiser within a Systainer. The organiser also serves as a drawer insert for use
in conjunction with our laboratory furniture.
D-2 © Festo Didactic GmbH & Co. KG • 541089

Assembly technology The components of the equipment set are intended for assembly on the Festo
Didactic profile plate, which consists of 14 parallel T-slots, set at 50 mm intervals.
Three variants are available for the assembly of equipment on the profile plate:
Variant A
A latching system, without auxiliary means, clamping mechanism with lever and
spring, adjustable in slot direction, for lightweight non-loadable components.
Variant B
A rotary system, without auxiliary means, knurled nut with locking disc and T-head
bolts, vertical or horizontal alignment, for medium weight loadable components
Variant C
A screwed system, with auxiliary means, socket head screw with T-head bolt, vertical
or horizontal alignment, for heavy loadable components and equipment that is
rarely released from the profile plate.
The proven ER units on a plug-in board can be attached to the profile plate using
adapters.
In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide
is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back
whereby the component can be removed from or attached to the profile plate.
Components are aligned along the slot and can be moved in the direction of the slot.
With variant B, components are attached to the profile plate by means of a T-head
bolt and blue knurled nut. A locking disc serves to fix the device in position, which
can be secured in all four 90° directions. Components can thus be mounted to the
profile plate either lengthwise or perpendicular to the slot.
Once the desired locking disc position is set, the device is mounted on the profile
plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in
the slot by 90° as a result of thread friction. The component is pulled against the
profile plate by further turning the knurled nut.
© Festo Didactic GmbH & Co. KG • 541089 D-3

Variant C is used for heavy or similar devices, screwed on to the profile plate only
once or removed very seldom. Components are attached by means of socket head
screws with internal hex and T-head bolts.
The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be
mounted on the profile plate using adapters. A black adapter is required for each
locating pin. The adapters are plugged into the T-slot, positioned at intervals of
50 mm and secured by means of a 90° turn. The locating pins of the ER unit are
plugged into the adapter holes.
Plastic tubing The polyurethane tubing is particularly flexible and kink resistant.
Technical data
Pneumatics
Colour Silver metallic
Outer diameter 4 mm
Inner diameter 2.6 mm
Minimum bending radius within

temperature range of -35 to +60°C 17 mm
Maximum operating pressure within
Temperature range of -35 to +30°C 10 bar (1000 kPa)

Temperature range of +30 to +40°C 9 bar (900 kPa)
Temperature range of +40 to +60°C 7 bar (700 kPa)
Subject to change
D-4 © Festo Didactic GmbH & Co. KG • 541089

152860
3/2-way valve with pushbutton actuator, normally closed
1 3
Design The 3/2-way valve with pushbutton actuator, normally closed is assembled in a
polymer housing. The unit is mounted on the profile plate via a quick release detent
system with blue lever (mounting alternative "A").
Function The valve is actuated by pressing the pushbutton. Releasing of the pushbutton
returns the valve to the normal position via a return spring.
Technical data Pneumatic
Medium Compressed air, filtered (lubricated or unlubricated)

(or vacuum; port 1)
Design Poppet valve, directly actuated on one side, with return spring
Actuation Pushbutton
Pressure range -95 – 800 kPa (-0.95 – 8 bar)
Standard nominal flow rate 1...2 60 l/min
Actuating force at 600 kPa (6 bar) 6N
Connection QSM-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152864
3/2-way valve with mushroom actuator
1 3
Design The 3/2-way valve with plug-in connections is assembled in a yellow polymer
housing. The unit is mounted on the profile plate via a quick release detent system
with blue lever (mounting alternative „A“).
Function The valve is actuated by pressing the red mushroom actuator. The switching status
is maintained after the actuator has been released. Rotation to the right returns the
mushroom actuator to its normal position and returns the valve to its initial position
via the return spring.
Actuation Mushroom actuator
Pressure range -90 – 800 kPa (-0.90 – 8 bar)
Actuating force at 600 kPa (6 bar) 6N
Connection QSM-4 fittings for plastic tubing PUN 4 x 0.75
152867
3/2-way roller lever valve with idle return, normally closed
1 3
Design The 3/2-way roller lever valve with idle return and push-in elbow fittings is screwed
onto a plastic base. The unit is mounted on the profile plate via the rotary detent
system with blue triple grip nut (mounting alternative "B").
Function The valve is actuated when the trip roller has been traversed by a cylinder trip cam
passing in the positive direction. The valve is returned to the normal position via a
return spring after the trip roller has been released. The trip roller flips down when
traversed in the opposite direction.
Pressure range 0 – 800 kPa (0 – 8 bar)
Actuating force at 600 kPa (6 bar) 12.5 N
Connection QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75
152868
Back pressure valve
1 3
Design The back pressure valve with poppet action and quick push-pull T-connectors is
screwed on to an assembly base. The unit is mounted on the profile plate via a quick
release detent system with blue triple grip nut (mounting alternative „B“).
Function The back pressure valve with poppet action is actuated via the end face of the
cylinder cam. If the stem is actuated, compressed air exhausts to atmosphere until
the nozzle outlet is closed. At this point, a signal is generated at output 2 up to the
level of the supply pressure. There is thus only low air consumption within the stem
actuation range of 1 mm.
Note The connections are identified according to the different tubing lengths:
1 = long tubing
2 = short tubing
The supply pressure can be regulated via a restrictor. Prior to the back pressure
valve being used, a functional check should be carried out. If necessary, the back
pressure valve can be adjusted to the cylinder end position by loosening the lock
nut.
Comment The output signal should be amplified if the supply pressure is very low.
Supply pressure range 0 – 800 kPa (0 – 8 bar)
Closing force at 600 kPa (6 bar) 12.5 N
Connection QS-4 fittings for plastic tubing PUN 4 x 0.75
152877
Pneumatic preselect counter
12 10
Design The pneumatic preselect counter with straight push-in fittings is fitted on a polymer
base. The unit is mounted on the profile plate via a quick release detent system with
blue lever (mounting alternative „A“).
Function The counter counts pneumatic signals downwards from a preselected figure. When
the zero position has been reached, the counter emits a pneumatic output signal.
This output signal is maintained until the counter is reset. The counter is pre-set by
pressing the reset key (alongside the number window) and simultaneously keying-in
(adjustment key on the counter roll) of the preselect value. The figure, once set,
is retained whilst the counter is reset.
Note The valve ports are identified by numbers:

1 = Supply port
2 = Output signal
10 = Reset signal
12 = Counting signal
152877
Pneumatic preselect counter
Medium Compressed air
Design Mechanical counter with pneumatic drive
Display 5-digit, height of figures 4.5 mm
Reset Push button or pneumatic signal
Minimum pulse duration Count: 10 ms, Reset: 180 ms
Counting rate continuous operation 2 Hz
Connection QSMS-4, QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
152882
Shuttle (OR) valve, 3-fold
2 2 2
1 1/3 1 1/3 1 1/3
Design The manifold consisting of three OR gates is screwed on to an assembly base

equipped with the required straight push-in fittings. The unit is mounted on the
profile plate via a quick release detent system with blue lever (mounting
alternative „A“).
Function Each OR gate has two inlets (1, 1/3) and one output (2). The inlet which is not
pressurised is automatically blocked. If different pressures are applied, then the
higher pressure reaches the outlet (2).

2 = Working or outlet port
1, 1/3 = Supply lines
Design OR gate (shuttle valve)
Pressure range 160 – 800 kPa (1.6 – 8 bar)
Standard nominal flow rate 1, 1/3...2 100 l/min
Connection QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
152883
Dual pressure (AND) valve, 3-fold
2 2 2
1 1/3 1 1/3 1 1/3
Design A manifold consisting of three AND gates is screwed on to an assembly base

equipped with the required straight push-in fittings. The unit is mounted on the
profile plate via a quick release detent system with blue lever
(mounting alternative „A“).
Function Each AND gate has two inlets (1, 1/3) and one outlet (2). Outlet (2) is only
pressurised for as long as pressure is applied at both inlets. If different pressures
are applied, then the lower pressure reaches outlet (2).

1, 1/3 = Supply lines
Design AND gate (dual pressure valve)
Pressure range 160 – 800 kPa (1.6 – 8 bar)
152886
Stepper module
A1 A2 A3 A4
TAA TAA TAA TAB
X1 X2 X3 X4
Design This unit consists of three TAA and one TAB stepper module which are screwed on to
an assembly base, which is equipped with the required straight push-in fittings. The
unit is mounted on the profile plate via a quick release detent system with blue lever
(mounting alternative „A“).
152886
Stepper module
Function In the case of module type TAB, an OR gate is positioned upstream of the Yn inlet of
the double pilot valve. If a signal is applied at Yn or L, the valve is reversed and a
signal appears at outlet A. In addition, this signal also resets the preceding stepper
module, the visual indicator and the AND gate is supplied with pressure. When the
acknowledgement signal reaches X, the AND flow is released and the signal Yn+1
appears. This signal is also maintained if the entire sequencer is reset at L and can
thus be used for a renewed start. When the sequencer chain is started, the module
is reset externally at port Z via the reset signal Zn+1 of the first module of the
sequencer. With the TAA modules, an OR gate is connected upstream of port Z in the
double pilot valve. This is why, in this case, the double pilot valve is returned via a
signal at Zn+1 from the following stepper.
Note The valve ports are identified by letters:

P = Supply port
A1, A2, A3, A4 = Outputs
X1, X2, X3, X4 = Acknowledgements
L = Reset (clear)
Yn+1 = Set: Output
Yn = Set: Input
Zn = Reset: Output
Zn+1 = Reset: Input
Design Poppet valve with integrated AND and OR gate
Standard nominal flow rate P…A 60 l/min
152888
Double-acting cylinder
Design The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic
retainer. The unit is mounted on the profile plate via a quick release detent system
with two triple grip nuts (mounting alternative "B").
Function The piston rod of the double-acting cylinder is reversed by means of alternating
supply of compressed air. End position cushioning at both ends prevents a sudden
impact of the piston on the cylinder housing. The end position cushioning can be
adjusted by means of two regulating screws.
The magnetic field of a permanent magnet attached to the cylinder piston actuates
the proximity switches.
Design Piston cylinder
Operating pressure max. 1000 kPa (10 bar)
Piston diameter 20 mm
Max. stroke length 100 mm
Thrust at 600 kPa (6 bar) 189 N
Return force at 600 kPa (6 bar) 158 N
Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
539759
10
1 3
Design The time delay valve is screwed on an assembly base equipped with straight push-in
fittings. The unit is mounted on the profile plate via a quick release detent system
with blue lever (mounting alternative „A“).
Function After the pilot signal is applied at port 10, a preset time elapses before the time
delay valve is actuated. It returns to its initial position via a return spring once the
signal is removed. The time delay is infinitely adjustable by means of a regulatig
screw.

1 = Supply port
3 = Exhaust
10 = Pilot
539759
Design Poppet valve with return spring
Pressure range 200 to 600 kPa (2 to 6 bar)
Pilot pressure >160 kPa (1.6 bar)
Time delay 0.2 to 3 s (adjustable)
Setting accuracy ±0.3 ms
Time delay to reset >200 ms
539768
3/2-way pneumatic valve, pneumatically actuated, one side
12
1 3
or
2
10
1 3
Symbol used in circuit diagrams.
4 2
14
5 1 3
The internal structure of this

valve
Design The 5/2-way pneumatic valve with push-in connectors and a single blanking plug is
screwed on to an assembly base, which is equipped with P-connection and silencers.
The unit is mounted on the profile plate via a quick release detent system with blue
lever (mounting alternative „A“).
Function The pneumatic valve switches at port 14 (Z) (10 (Z)) via a pneumatic signal and is
returned to the initial position via a spring when the signal has been removed.

1 = Supply port
2, 4 = Working or outlet ports
3, 5 = Exhausts (via silencers in function plate)
14, 10 = Pilot port
By blocking a working line (2 or 4), the 5/2-way valve can be converted into a
3/2-way valve:
Blanking plug in outlet 4 = normally open
Blanking plug in outlet 2 = normally closed
539768
3/2-way pneumatic valve, pneumatically actuated, one side
Technical Data Pneumatic
Medium Compressed air, filtered
Design Spool valve, indirectly actuated on one side, with return spring
Operating pressure range -90 to 1000 kPa (-0.9 to 10 bar)
Standard nominal 500 l/min

flow rate 1…2, 1...4
Switching time at 600 kPa (6 bar) On: 8 ms

Off: 18 ms
Connection QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
539769
5/2-way double pilot valve, pneumatically actuated, both sides
4 2
14 12
5 1 3
Symbol used in circuit diagrams
4 2
14 12
5 1 3
The internal structure of this

valve allows flowing of compressed
air in both dir
Design The 5/2-way double pilot valve with push-in fittings is screwed onto the function
plate, which is equipped with P-connection and silencers. The unit is mounted on the
profile plate via a quick release detent system with blue lever (mounting alternative
"A").
Function The double pilot valve is actuated by applying pneumatic signals alternately to ports
14 and 12. It remains in its last switched position until a counter signal is received.
Medium Compressed air, filtered (lubricated or unlubricated) or vacuum
Design Spool valve, directly actuated on both sides
Control pressure range 200 to 1000 kPa (2 to 10 bar)
Operating pressure range -90 to 1000 kPa (-0.9 to 10 bar)
Standard nominal 500 l/min

flow rate 1...2, 1...4
Response time at 600 kPa (6 bar) 6 ms
Connection QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
539771
Shuttle valve (OR)
1 1/3
Design The shuttle valve with push-in elbow fittings is mounted on a function plate. The unit
is mounted on the profile plate via a quick release detent system with blue lever
(mounting alternative "A").
Function The shuttle valve is switched through to output 2 by applying a signal either to input
1 or 1/3 (OR-Function). If both inputs are pressurised simultaneously, then the
higher pressure reaches the output.
Design OR-Gate (Shuttle valve)
Connection QSL-1/8-4 fittings for plastic tubing PUN 4 x 0.75
539773
1 2
Design The adjustable one-way flow control valve is screwed into the function plate,
incorporating a straight push-in fitting. The unit is slotted into the profile plate via a
quick release detent system with a blue lever (mounting alternative “A”).
Function The one-way flow control valve consists of a combination of a flow control valve and
a non-return valve.
The non-return valve blocks the flow of air in one direction, whereby the air flows via
the flow control valve. The throttle cross section is adjustable by means of a knurled
screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the
direction of flow control on the housing. In the opposite direction, the air flow is
unrestricted via the non-return valve.
Medium Compressed air, filtered, (lubricated or unlubricated)
Design One-way flow control valve
Pressure range 20 to 1000 kPa (0.2 to 10 bar)
Standard nominal flow rate in throttled direction: 0 – 110 l/min

free flow direction: 110 l/min (Throttle open)
65 l/min (Throttle closed)
Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75
540715
Non-return valve, piloted
1 21
Design Non-return valve directly connected to the cylinder connection via a push-in sleeve.
Function The non-return valve shuts off flow from port 2 to port 1. The non-return valve can be
released through the application of compressed air at port 21.
Technical data Pneumatics
Medium Compressed air, filtered, lubricated or unlubricated
Design Non-return valve, piloted
Operating pressure 0.5 to 10 bar (50 to 1000 kPa)
Standard nominal flow rate 108 l/min
Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75
2A1
2B1 2B2
1A1 1B1 1B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B2 2 1B1 2 2B1 2 2B2 2
1 3 1 3 1 3 1 3 1 3
© Festo Didactic GmbH & Co. KG • 541089

Solution
2A1
2B1 2B2
1A1 1B1 1B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B2 2 1B1 2 2B1 2 2B2 2
1 3 1 3 1 3 1 3 1 3

Exercise 5: Cleaning of workpieces, without parameter
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S2 2 0S3 2
1 3 1 3
0S1 4 2
5 3
1

Exercise 5: Cleaning of workpieces, complete
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
0V1 2 10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V2 2
2B1 2
5 3 10
1 1 3
1 3
2B2 2
1 3
1 3

Exercise 5: Cleaning of workpieces, with latching of the reset function
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3 2
1 0V7 2 1
1 1/3 0V8
1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V1 2 0V2 2
2B2 2 2B1 2
5 3 10
1
1 3 1 3
1 3
1 3

Exercise 5: Cleaning of workpieces, without parameter
Solution
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S2 2 0S3 2 1B2 2 2B2 2 2B1 2 1B1 2
1 3 1 3 1 3 1 3 1 3 1 3
0S1 4 2
5 3
1

Exercise 5: Cleaning of workpieces, complete
Solution
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V7 2 5 3 0V8 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
0V1 2 10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V2 2
2B1 2
5 3 10
1 1 3
1 3
2B2 2
1 3
1 3

Exercise 5: Cleaning of workpieces, with latching of the reset function
Solution
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3 2
1 0V7 2 1
1 1/3 0V8
1 1/3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
1B2 2 0V4 2 0V5 2 1B1 2
1 1/3 1 1/3
1 3 2 1 3
0S2 2 0S3 2 0S4 2 0V3 0S5 2
10
1 3 1 3 1 3 1 3 1 3
0S1 4 2
0V1 2 0V2 2
2B2 2 2B1 2
5 3 10
1
1 3 1 3
1 3
1 3

2A1
2B1 2B2
1A1 1B1 1B2 3A1 3B1 3 B2
1V2 1 2V2 1 3V2 1
2 2 2
1V1 4 2 2V1 4 2 3V1 4 2
14 12 14 12 14 12
5 3 0V12 2 5 3 0V13 2 5 3
1 1 1
10
1 1/3 0V11 2
1 3
10
0V9 2 0V10 2 1 3
1 1/3 1 1/3 0V8 2
1 1/3
s1
s2
s3
s4
0V6 4 2
14 12 A1 A2 A3 A4
TAA TAA TAA TAB
Start 5 3
1
0S6 2 0V5 2
1 1/3 Yn Yn+1
1 3
0S4 2 Zn Zn+1
1 3
1 3

0S3 4 2
1 3 1 3 1 3 1 3
5 1 3 3B2 2 3B1 2
0V2 4 2
14 12 1 3 1 3
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Solution
2A1
2B1 2B2
1A1 1B1 1B2 3A1 3B1 3 B2
1V2 1 2V2 1 3V2 1
2 2 2
1V1 4 2 2V1 4 2 3V1 4 2
14 12 14 12 14 12
5 3 0V12 2 5 3 0V13 2 5 3
1 1 1
10
1 1/3 0V11 2
1 3
10
0V9 2 0V10 2 1 3
1 1/3 1 1/3 0V8 2
1 1/3
s1
s2
s3
s4
0V6 4 2
14 12 A1 A2 A3 A4
TAA TAA TAA TAB
5 3
Start 1
0S6 2 0V5 2
1 1/3 Yn Yn+1
1 3
0S4 2 Zn Zn+1
1 3
1 3

0S3 4 2
1 3 1 3 1 3 1 3
5 1 3 3B2 2 3B1 2
0V2 4 2
14 12 1 3 1 3
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 5 3
1 1
s1
s2
s3
s4
0V7
10
1 3
0V4 2 A1 A2 A3 A4
TAA TAA TAA TAB
10
1 3
0S4 Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y
2 0S5 2
Yn Yn+1
1 3 1 3 Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z
L L L L L L L L L L
0V1 1 L L
0V2 2 X1 X2 X3 X4
Zn Zn+1
2 12
1B2 2 1B1 2
1 3
1/3
1 3 1 3
0S3 2
0S2 2 0Z3 2
1 3 12 10
1 3 1
0S1 4 2
2B1 2 2B2 2
5 3
1 1 3 1 3

Solution
1A1
1B1 1B2
2A1 2B1 2B2
1V2 1 1 1V3 2V2 1 1 2V3
2 2 2 2
1V1 4 2 2V1 4 2
14 12 14 12
5 3 0V9 2 5 3 0V10 2
1 1
1 1/3 1 1/3
s1
s2
s3
s4
0V7
10
1 3
0V4 2 A1 A2 A3 A4
TAA TAA TAA TAB
10
1 3
0S4 Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y
2 0S5 2
Yn Yn+1
1 3 1 3 Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z
L L L L L L L L L L
0V1 1 L L
0V2 2 X1 X2 X3 X4
Zn Zn+1
2 12
1B2 2 1B1 2
1 3
1/3
1 3 1 3
0S3 2
0S2 2 0Z3 2
1 3 12 10
1 3 1
0S1 4 2
2B1 2 2B2 2
5 3
1 1 3 1 3

1A1
1B3
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
14 12
5 1 3 0V13 2
1 1/3
0V12 2
0V11 2 1 1/3
10
0V10 2 1 3
10 0V9 2
1 3
10
1 3
0V7 2 0V8 2
1 1/3 1 1/3
s1
s2
0V6 s3
1 1/3 s4
A1 A2 A3 A4
2 TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
10 Zn Zn+1
1 3
0V4 2 1B2 2 1B3 2 1B1 2
12
0V3 2 1 3
1 3 1 3 1 3
1 1/3
Start Reset
0S4 2 0S5 2
1 3 1 3
Manual/Automatic
0S3 4 2
5 1 3
0V2 4 2
14 12
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

Solution
1A1
1B3
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
14 12
5 1 3 0V13 2
1 1/3
0V12 2
0V11 2 1 1/3
10
0V10 2 1 3
10 0V9 2
1 3
10
1 3
0V7 2 0V8 2
1 1/3 1 1/3
s1
s2
0V6 s3
1 1/3 s4
A1 A2 A3 A4
2 TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
10 Zn Zn+1
1 3
0V4 2 1B2 2 1B3 2 1B1 2
12
0V3 2 1 3
1 3 1 3 1 3
1 1/3
Start Reset
0S4 2 0S5 2
1 3 1 3
Manual/Automatic
0S3 4 2
5 1 3
0V2 4 2
14 12
0V1 2 5 3
EMERGENCY- 1
10 Acknowledge
STOP
EMERGENCY-STOP
0S1 1 3
2 0S2 2
1 3 1 3

1A1
1B3
1B1 1B2
1V5 2 1V6 2
1 21 1 21
1V3 1 1 1V4
2 2
1V1 2 1V2 2
12 12
1 3 1 3
0V5 2 0V6 2
1 1/3 1 1/3
0V4 2
10
0V2 2 0V3 2 1 3
10
1 3
1 3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B3 2 1B2 2 1B1 2
1 3 1 3 1 3 1 3

Solution
1A1
1B3
1B1 1B2
1V5 2 1V6 2
1 21 1 21
1V3 1 1 1V4
2 2
1V1 2 1V2 2
12 12
1 3 1 3
0V5 2 0V6 2
1 1/3 1 1/3
0V4 2
10
0V2 2 0V3 2 1 3
10
1 3
1 3
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB

Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0S1 2 1B3 2 1B2 2 1B1 2
1 3 1 3 1 3 1 3

3A1
3B1 3B2
1A1 2A1
1B1 1B2 2B1 2B2
1V2 2 2V2 1 3V2 1
1 2 2
1V1 2 2V1 4 2 4 2
12 14 12 14 12
1 3 5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB
0V4 2
1 1/3 Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0V3 2
2B2 2 2B1 2
12 10
1 3
1 3 1 3
1B1 2 0V2 2
12 10
1 3 1 3
3B2 2 3B1 2
0S1 2 1B2 2
1 3 1 3
1 3 1 3

Solution
3A1
3B1 3B2
1A1 2A1
1B1 1B2 2B1 2B2
1V2 2 2V2 1 3V2 1
1 2 2
1V1 2 2V1 4 2 4 2
12 14 12 14 12
1 3 5 3 5 3
1 1
s1
s2
s3
s4
A1 A2 A3 A4
TAA TAA TAA TAB
0V4 2
1 1/3 Yn Yn+1
L L L L L L L L L L
L X1 X2 X3 X4 L
Zn Zn+1
0V3 2
2B2 2 2B1 2
12 10
1 3
1 3 1 3
1B1 2 0V2 2
12 10
1 3 1 3
3B2 2 3B1 2
0S1 2 1B2 2
1 3 1 3
1 3 1 3

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Pneumatics

Order No.: 541089

© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2005

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Exercise 1: Opening and closing of an oven door ___________________________A-3

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Exercise 1: Opening and closing of an over door____________________________C-3

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Festo Didactic’s Learning System for Automation and Technology is orientated

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Advanced Level TP102 focuses on further training in pneumatic control technology.

Working pressure must not exceed a maximum of p = 6 bar = 600 kPa.

Optimal operational reliability is achieved if the control system is operated on

• Pneumatics – Basic Level

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The technology package TP100 consists of numerous individual training media as

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Textbooks Basic Level TP101

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P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

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P-AL Pneumatics for vocational training

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• To familiarise yourself with different types of end position sensing.

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To familiarise yourself with different types of end position •

To familiarise yourself with the options of designing •

To be able to convert 3/2- and/or 5/2-way valves •

To familiarise yourself with displacement-step diagrams •

To be able to realise circuits with parallel movements in •

To be able to use pneumatic decrementing counters. •

To be able to design indirect cylinder actuation. • •

To be able to select appropriate sensors for applications • • • •

To familiarise yourself with the design and function of •

To be able to design the basic „continuous cycle“ stepper •

To be able to install one-way flow control valves •

To be able to realise the OR function of feedback signals. •

To be able to set time delays according to specifications. •

To familiarise yourself with circuits in order to cancel time •

To be able to design a stepper control with the input •

To be able to realise the following input commands: •

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To be able to develop an input circuit with self-latching •

To be able to design a stepper control with idle step. •

To familiarise yourself with the option of facilitating a •

To familiarise yourself with the option of realising the •

To familiarise yourself with circuits in order to realise the •

To be able to develop an input circuit for a stepper control •