WB Electrohidrúalica Basica

Electrohydraulics
Basic Level
Workbook TP 601
Festo Didactic
094470 en
Authorised applications and liability

The Learning System for Automation and Communication has been developed and prepared exclusively for training in the field of automation
and communication. The training organization and / or trainee shall ensure that the safety precautions described in the accompanying Technical documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation,
unless caused by premeditation or gross negligence on the part of Festo
Didactic.
Order no.:
Description:
Designation:
Edition:
Layout:
Graphics:
Author:
094470
TEACHW. E-HYDR.
D.S601-C-SIBU-GB
07/2003
04.07.2003, OCKER Ingenieurbro
OCKER Ingenieurbro
D. Merkle, H. Werner
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2003
The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for training
purposes, by persons authorised in this sense.
TP601 Festo Didactic
Preface
Festo Didactics Learning System for Automation and Communications
is designed to meet a number of different training and vocational requirements. The Training Packages are structured accordingly:
T Basic Packages provide fundamental knowledge which is not limited

to a specific technology.
T Technology Packages deal with the important areas of open-loop and

closed-loop control technology.
T Function Packages explain the basic functions of automation systems.
T Application Packages provide basic and further training closely oriented to everyday industrial practice.
Technology Packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, automation with PCs,
hydraulics, electrohydraulics, proportional hydraulics and application
technology (handling).
Fig. 1
Example of
Hydraulics 2000:
Mobile laboratory trolley
Mounting frame
U = 230V~
Profile plate
p = 6 MPa
Storage tray
The modular structure of the Learning System permits applications to be

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

adapted for didactic purposes.
The courseware is matched methodologically and didactically to the
training hardware. The courseware comprises:
T Textbooks (with exercises and examples)

T Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)
T OHP transparencies, electronic transparencies for PCs and videos

(to bring teaching to life)
Teaching and learning media are available in several languages. They
have been designed for use in classroom teaching but can also be used
for self-study purposes.
In the software field, CAD programs, computer-based training programs
and programming software for programmable logic controllers are available.
Festo Didactics range of products for basic and further training is completed by a comprehensive selection of courses matched to the contents
of the technology packages.
Latest information about the technology package TP601.

New in Hydraulic 2000:
T Industrial components on the profile plate.

T Exercises with exercise sheets and solutions, leading questions.
T Fostering of key qualifications:
Technical competence, personal competence and social competence
form professional competence.
T Training of team skills, willingness to co-operate, willingness to learn,

independence and organisational skills.
Aim Professional competence
Content
Part A
Course
Exercises
Part B
Fundamentals
Reference to the text book
Part C
Solutions
Function diagrams, circuits, descriptions of

solutions and quipment lists
Part D
Appendix
Storage tray, mounting technology

and datasheets
Table of contents
Introduction
11
Notes on safety
13
Notes on operation
14
Technical notes
15
Training contents
21
Training aims/exercise table (Table 1)
22
Equipment set for Basic Level TP 601
23
Equipment set for Advanced Level TP 602
26
List of additional components for TP600
27
Component/exercise table (Table 2)
28
Methodological structure of exercises
29
Part A Course
Simple control circuits without limit switches
Exercise 1: Sorting device
Double-acting cylinder,
directly actuated, manually
A-3
Exercise 2: Component selection on conveyor belt

indirectly actuated, manually
A-13
Exercise 3: Lifting station

Single-acting cylinder,
indirectly actuated, manually
A-23
Exercise 4: Bending device

Double-acting cylinder, latching
A-29
Exercise 5: Press-fitting device

Double-acting cylinder, latching,
return stroke using pressure switch
A-33
Exercise 6: Stamping machine

Double-acting cylinder, differential circuit
A-39
Exercise 7: Door control

Double-acting cylinder, interlock,
INCHING operation
A-43
Control circuits with limit switches

Exercise 8: Machining unit
Differential circuit
return stroke using limit switch
A-49
Exercise 9: Feed for drilling machine

Rapid-traverse feed circuit,
speeds controlled by limit switch
A-53
Exercise 10: Press

Pressure control circuit with limit switch
and pressure switch
A-59
Exercise 11: Feed device

Pressureless pump bypass with limit switch
A-63
Control circuits with two actuators

Exercise 12: Assembly device
Pressure-dependent sequence control with
cylinder and hydraulic motor
A-69
Exercise 13: Lifting device for packages

Position-dependent sequence control
with two cylinders
A-75
Part B Fundamentals
Teil C Solutions
Solution
1: Sorting device
C-3
Solution
2: Component selection on conveyor belt
C-7
Solution
3: Lifting station
C-11
Solution
4: Bending device
C-15
Solution
5: Press-fitting device
C-19
Solution
6: Stamping machine
C-23
Solution
7: Door control
C-27
Solution
8: Machining unit
C-33
Solution
9: Feed for drilling machine
C-39
Solution 10: Press
C-45
Solution 11: Feed device
C-49
Solution 12: Assembly device
C-55
Solution 13: Lifting device for packages
C-61
Part D Appendix
Storage tray
D-2
Mounting systems
D-3
Sub-base
D-5
Coupling system
D-6
Data sheets
...
10
11
Introduction
This workbook forms part of Festo Didactics Learning System for Automation and Communications. The Training Package TP 600 is designed
to provide an introduction to the fundamentals of electrohydraulic control
technology. This package comprises a basic level and an advanced
level. The basic level package TP 601 teaches basic knowledge of
electrohydraulic control technology. The equipment sets TP 601 and TP
602 (for the advanced level) provide the student with the key qualification Technical competence.
The hydraulic components have been designed to provide the following:
T
T
T
T
T
Easy handling
Secure mounting
Environmentally-friendly coupling system
Compact component dimensions
Authentic measuring methods
You will require the following for the practical execution of the exercises:
T
T
T
T
T
T
A Festo Didactic profile plate or a laboratory trolley

An equipment set TP 601 (cylinders, valves, relay plate, ...)
A hydraulic power pack
A number of hydraulic hose lines
An electrical power supply unit
A set of electrical cables
The Training Package TP 601 specifies fundamental training contents.

These help develop both technical and methodological competence in
electrohydraulics:
T Physical interrelationships in electrical engineering and hydraulics

T Drafting, assembly and understanding of basic electrohydraulic circuits
T Comparison of the use of various valves and other components

T Development of alternative solutions
12
The technical requirements for safe operation of the components are as

follows:
T A hydraulic power pack to provide an operating pressure between

0.5 and 6 Mpa (5 to 60 bar) and a flow rate of 2 l/min.
T An electrical power supply for the above of 230 V AC, 50 Hz, with a
10 A fuse.
T A short-circuit-proof electrical power supply for the electrical components with an output of 24 V DC and a 3 A fuse.
T A profile plate to mount the components

The profile plate (1100 x 700 mm) has 14 parallel T-grooves at intervals of 50 mm.
This workbook has been developed for use in the Dual system of vocational training. It is, however, equally suitable for use in providing a
practical introduction to electrohydraulics for students at universities and
technical colleges. The modular design of the hardware allows theoretical questions to be dealt with experimentally in a simple and efficient
form.
The theoretical background to facilitate understanding of this workbook
is provided in the textbook
Learning System for Automation and Communications
T Electrohydraulics Basic Level

Festo Didactic also offers the following further training materials for hydraulics:
T
T
T
T
Sets of OHP transparencies and electronic transparencies for PCs

Linear videos and interactive videos (video discs)
Autosketch CAD software and symbol library
Hydraulics simulation program for planning, simulation and visualisation (in course of preparation)
T Sets of magnetic symbols and symbols for OHPs, hydraulic slide rule
T Transparent models for OHPs, with special hydraulic power pack
T Equipment sets: BIBB, hand-lever hydraulics, proportional hydraulics,
closed-loop hydraulics, measurement kit in case
Please see our special brochures for a detailed description of further
training materials.
13
Notes on safety
Observe the following in the interests of your own safety:
T Caution!
Cylinders may move unexpectedly when the hydraulic power pack is
switched on.
T Do not exceed the maximum permissible hydraulic operating pressure. See the relevant data sheets.
T Do not operate electrical limit switches directly by hand when carrying

out fault-finding. Use a tool for this.
T Use only an extra-low voltage of 24 to operate the components.

T Observe all general safety instructions.
14
Notes on operation
Assembly
Always work in the following sequence when assembling or dismantling
an electrohydraulic circuit.
1. The hydraulic power pack and electrical power supply must be
switched off during the assembly of the circuit.
2. All components must be securely fitted to the profile plate or mounting frame.
3. Connect up the hydraulic hose lines.
All valves, other components and hose lines are fitted with selfclosing quick-acting couplings. Do not exceed the maximum permissible pressure of 12 MPa (120 bar). The maximum operating pressure is 6 MPa (60 bar).
4. Connect up the electrical cables.
Connect test leads to the component sockets by means of 4 mm
plugs.
5. Before commissioning a hydraulic control circuit, check that all return
lines are connected and that all connectors are secure.
6 Switch on the electrical power supply first and then the hydraulic
power pack.
7. Commissioning the control circuit
Press the START pushbutton
Set components, etc.
Compare what you have assembled with the description in thebook.
Dismantling
8. Before dismantling the circuit, ensure that pressure in hydraulic components has been released:
Couplings must be disconnected only under zero pressure!
9. Switch off the hydraulic power pack first and then the electrical power
supply.
15
Technical notes
Observe the following in order to ensure safe operation.
T The hydraulic power pack incorporates an adjustable pressure relief

valve. In the interests of safety, the pressure is limited to approx.
6 MPa (60 bar). Every time a control circuit is assembled on the profile plate, a second pressure relief valve is used. We recommend that
this should be set to a maximum pressure of 5 MPa (50 bar).
T All valves, cylinders and hose lines are fitted with quick-acting couplings which ensure minimum leakage. The maximum pressure for all
components in the training package is 12 MPa (120 bar). Thanks to
their design, the couplings reduce leakage during connection and
disconnection to a minimum.
The operating pressure should not exceed 6 MPa (60 bar)
T In the case of double-acting cylinders, the pressure intensification

effect may produce an increased pressure proportional to the area
ratio of the cylinder. With an area ratio of 1:1.7 and an operating
pressure of 6 MPa (60 bar), this increased pressure may be over
10 MPa (100 bar)!
Fig. 2:
Pressure intensification
T If connections are detached under pressure, the non-return valve in

the coupling may cause pressure to become trapped in the valve or
other component concerned. The pressure relief device can be used
to release this pressure. Exception: This is not possible in the case of
hose lines and non-return valves. Ensure therefore that control circuits are depressurised before hose lines are disconnected and the
circuit is dismantled.
T All valves, other components and hose lines are fitted with selfclosing quick-acting couplings. This prevents the accidental spillage
of hydraulic fluid. In the interests of simplicity, these couplings are not
shown in circuit diagrams.
16
Fig. 3:
Simplified representation
in circuit diagrams
Throttle
Hose
Shut-off valve
17
Symbolic representation of directional control valves

Valves are shown in the Circuit diagram, hydraulic in essentially the
same way as in the textbook. The crossover position is on the right and
the parallel position on the left. Working port A is, however, on the right,
and port B is therefore on the left. This symbolic representation conforms to the new Hydraulics 2000" hardware.
The drawing Practical assembly, hydraulic is based on the symbol on
the valve. The crossover position is on the left and the parallel position
on the right. Working port A is now on the left and port B on the right.
This symbolic representation is hardware-oriented.
The two different symbolic representations describe all functions of a
given valve. In practice, valves by different manufacturers with identical
functions are sometimes given different symbols. This is permitted by
the applicable standard, DIN ISO 1219 Part 1, of November 1993 with
the title Fluidics: Graphic Symbols and Circuit Diagrams.
Circuit diagram, hydraulic
Practical assembly, hydraulic
4/2-way
solenoid valve
4/3-way
solenoid valve in
mid-position
Since hydraulic valves are very expensive, only a small number of these
and only a small number of different types are used in the equipment
set.
Representation of
directional control valves
18
The 4/2-way valve can be used to produce four further basic functions.
Basic function
in Circuit diagram, hydraulic
Connection of 4/2-way solenoid valve

in "Practical assembly, hydraulic"
2/2-way valve with

closed in neutral position
2/2-way valve with

flow in neutral position
3/2-way valve with

closed in neutral position
3/2-way valve with

flow in neutral position
Ports on the directional control valve which are not required are sealed
by the self-closing coupling nipples. It is not necessary to seal these
ports by means of plugs.
19
The 4/3-way valve with closed mid-position fulfils various different functions in the exercises in this book.
Function of solenoid valves
in Circuit diagram, hydraulic
No electrical connection is
made to solenoid 1Y2
Solenoid 1Y2 must be

activated in Practical
assembly, electrical via an
additional path.
made to solenoid 1Y2.
or
made to solenoid 1Y1
Connection of 4/3-way solenoid valve

in "Practical assembly, hydraulic"
20
Electrical
Power supply:
230 VAC, 50 Hz
T
T
T
T
The hydraulic power pack is protected by a 10 A fuse.

The short-circuit proof electrical power supply has a 3 A fuse.
The output voltage of this power supply is 24 V DC.
The output current is limited to a maximum of 4.5 A.
Wiring:
Universal cable set: 61 red and 37 blue laboratory cables in 5 lengths.
All electrohydraulic components are equipped with 4 mm sockets. The
electrical connections for these components are made using the laboratory cables with 4 mm plugs.
A distinction should be made between the two designs of electrical limit
switches:
T Electrical limit switch, actuated from the left.

T Electrical limit switch, actuated from the right.
T When cylinder piston speeds are high, the limit switches should be
actuated by cylinder cams only in the specified direction.
T Limit switches must not be actuated from the front.

T Both types of limit switches are shown by the same symbol in the
hydraulic and electrical circuit diagrams.
21
Training contents
T Basic physical principles of electrical engineering and hydraulics
T Function and use of electrical and electrohydraulic components such
Basic Level
(TP601)
as switches, pushbuttons and solenoid valves
T
T
T
T
T
T
T
T
T
T
T
Naming and identifying electrical and hydraulic symbols

Development and reading of standard circuit diagrams
Representation of control exercises as function diagrams
Drafting, assembly and commissioning of basic circuits
Direct and indirect activation of cylinders
Activation of a hydraulic motor
MANUAL and AUTOMATIC modes
Position and pressure dependent control circuits
Interlock circuit
Rapid-traverse circuit
Fault-finding with simple electrohydraulic control circuits
T Function and use of electronic sensors,

hydraulic motors and hydraulic accumulators
T
T
T
T
Complex sequence controls
T
T
T
T
T
T
Circuit with hydraulic accumulator
Combination position and pressure dependent control circuits

Electrical control circuit with several actuators
Sequence controls with MANUAL/AUTOMATIC,
EMERGENCY STOP and SETTING modes
Position and time dependent control circuits
Systematic fault-finding in electrohydraulic control circuits
Development of sequence controls from a function diagram
Controls with timer relays with pick-up and drop-off delays
Counter controls with predetermining counters
Advanced Level
(TP602)
22
Training aims/exercise table (Table 1)

List of training aims
Training aims
Exercise
1
Actuation of double-acting
cylinders
Actuation of single-acting
cylinders
10 11 12 13
Actuation of a
hydraulic motor
Direct actuation
Indirect actuation
Control circuit operated
manually
Control circuit with latching
Use of a pressure switch
Production of a differential
circuit
Interlock circuit
INCHING operation
Use of limit switches

Rapid-traverse feed circuit
Pressureless pump bypass
23
Equipment set for Basic Level TP 601

This equipment set has been compiled for use in basic training in electrohydraulic control technology. The set can be combined in any desired
way with other equipment sets from the Festo Didactic Learning System.
Description
Order No.
Qty.
Pressure gauge
152841
One-way flow control valve
152843
Non-return valve, 1 bar
152845
152846
Branch tee
152847
Pressure relief valve, pressure sequence valve
152848
2-way flow control valve
152851
Non-return valve, piloted
152852
Double-acting cylinder, 16/10/200
152857
Hydraulic motor, 8 l/min
152858
Loading weight, 9 kg
152972
Relay, 3-fold*
162241
Signal input unit, electrical*
162242
Indicator and distributor unit, electrical *
162244
4/2-way solenoid valve
167082
4/3-way solenoid valve closed in mid-position
167083
Limit switch, electrical, actuated from the right
183322
Limit switch, electrical, actuated from the left
183345
Order No.
Qty.
Hose line with quick-release coupling, 600 mm
152960
10
152970
We recommend
* These components can be mounted in the mounting frame or, by using the adapter
set (Order No. 35651), on the profile plate.
Order No.: 184463 for

equipment set TP 601
24
Symbols for
equipment setTP 601
Pressure gauge
Non-return valve, 1 bar resp. 5bar
Pressure relief valve,

pressure sequence valve
Weight, 9 kg
Relay, 3-fold
25
Signal input unit, electrical
Indicator and distributor unit, electrical
Limit switch, electrical,

actuated from the left or from the right

closed in mid-position
Symbols for
equipment setTP 601
26
Equipment set for Advanced Level TP 602

This equipment set has been compiled for advanced-level teaching of
electrohydraulic control technology. The two equipment sets TP 601 and
TP602 can be expanded in any desired way with other equipment sets
from Festo Didactics Learning System for Automation and Communications.
Order No.: 184464
for equipment set TP 602
Description
Order-No.
Qty.
Relay, 3-fold*
162241
Timer relay, 2-fold*
162243
Predetermining counter, electrical, additive *
162355
Indicator and distributor unit, electrical *
162244
Pressure switch
167080
Branch tee
152847
Pressure relief valve, piloted
152849
3-way pressure reducing valve
152850
167082
152857
Diaphragm accumulator with shut-off block
152859
EMERGENCY STOP, electrical
183347
Proximity switch, inductive
178574
Proximity switch, capacitive
178575
Proximity switch, optical
178577
Order-No.
Qty.
152960
10
152970
We recommend:
* These components can be mounted in the mounting frame or, by using the adapter
set (Order No. 35651), on the profile plate.
27
List of additional components for TP600

Description
Order-No.
Extension kit for hydraulic cylinder
120778
Throttle valve
152842
Shut-off valve
152844
152960
Power pack, hydraulic, 2 l/min
152962
152970
Pressure relief device
152971
Cover (for loading weight, 9 kg)
152973
158352
159386
Power supply unit, attachment fixture, 24V 4.5A, Deutsch
159396
Profile plate, large
159411
Power supply unit, table, 24V 4.5A, Deutsch
162417
Flow rate / rotary speed measuring device
167081
4/3-way solenoid valve with relieving mid-position
167084
4/3-way solenoid valve with recirculating mid-position
167085
Cable set with safety plugs
167091
Coupling nipple
342047
Coupling socket
346491
For further additional components from our Hydraulics 2000" system,

please see our price lists.
Technology Packages TP100, TP...
Electrohydraulics TP600
TP601
TP602
Additional
components
28
Component/exercise table (Table 2)

Description
Exercise
1
10 11 12 13
Indicator and distributor unit,

electrical
Pressure gauge
Relay, 3-fold
Pressure relief valve,

pressure sequence valve

1
1

actuated from the left

actuated from the right

with closed in mid-position
Double-acting cylinder
16/10/200
Loading weight
Branch tee
Hose line with quick-release
coupling, 600 or 1000 mm
11 11
12 12
For exercises 5, 10 and 11 a pressure switch of the equipment set TP 602 is required.
For exercise 13 you will need another double-acting cylinder.
29
Methodological structure of exercises

All 13 exercises have the same methodological structure.
T The exercises in Part A are structured as follows:

Subject
Title
Training aim(s)
Exercise
Problem definition
Positional sketch
A worksheet then follows for use in carrying out the exercise:
T The suggested solutions in Part C are structured as follows:

Circuit diagram, hydraulic Circuit diagram, electrical
Solution description with evaluation and conclusions
Practical assembly, hydraulic
Practical assembly, electrical
Components list, hydraulic
Components list, electrical
T How should I work through an exercise?

Read the worksheet
Complete the worksheet
Assemble and commission the control circuit
Work out your own solution
Compare your solution with the one in this book
Incorporate your solution into the control circuit
Commission this circuit
Does your control circuit fulfil the requirements specified in theworksheet?
30
A-1
Part A Course
Exercise 1: Sorting device
A-3
Exercise 2: Component selection on conveyor belt

A-13
Exercise 3: Lifting station

A-23
Exercise 4: Bending device

A-29
Exercise 5: Press-fitting device

A-33
Exercise 6: Stamping machine

Double-acting cylinder, differential circuit
A-39
Exercise 7: Door control

interlock, INCHING operation
A-43
A-2

Exercise 8: Machining unit
Differential circuit,
return stroke using limit switch
A-49
Exercise 9: Feed for drilling machine

A-53
Exercise 10: Press

and pressure switch
A-59
Exercise 11: Feed device

A-63

Exercise 12: Assembly device
A-69
Exercise 13: Lifting device for packages

with two cylinders
A-75
We hope you enjoy the designing and practical assembly of the circuits.
Understanding hydraulics is fun!
A-3
Exercise 1
Electrohydraulics
Subject
Sorting device
Title
T
T
T
T
T
T
T
T
Understanding an directly actuated, manually operated circuit
Training aims
T
T
T
T
Mounting components in a mounting frame
T
T
T
T
T
T
T
Complete the worksheets
Actuation of a double-acting cylinder using a 4/2-way solenoid valve

Naming the most important components of a double-acting cylinder
Naming the most important components of a 4/2-way solenoid valve
Understanding the use of the electrical signal input unit
Selection of repuired components
Developing and drawing the hydraulic and electrical circuit diagrams
Understanding the variants available for mounting components on the
profile plate
Working with hydraulic hose lines
Connecting up electrical test leads in accordance with a diagram
Commissioning the control circuit
Define the required components

Draw the hydraulic and electrical circuit diagrams
Label the connections
Number the components in the circuit assembly
Familiarise yourself with the hydraulic and electrical power supplies
Carry out practical assembly of the hydraulic and electrical control
circuits
T Commission the control circuit

T Compile the components lists
T Dismantle the control circuit and replace the components in the storage tray
Problem definition
A-4
Exercise 1
Exercise
A sorting device is used to sort heavy steel workpieces.

When a START pushbutton is pressed, the piston rod of a double-acting
cylinder pushes the adjacent workpiece off the conveyor belt.When the
START pushbutton is released, the piston rod returns to ist retracted
end position.
Parameter
Only a small number of hydraulic and electrical components should be
used.
Fig. 1/1:
Positional sketch
A-5
Exercise 1
WORKSHEET
Produce a freehand sketch of the double-acting cylinder.

Fig. 1/2:
Isometric projection of
cylinder, 16/10/200
Name the six most important components of the cylinder.

Number these on your freehand sketch.
1.
2.
3.
4.
5.
6.
A-6
Exercise 1
Produce a freehand sketch of the 4/2-way solenoid valve.

Fig. 1/3:
Isometrische Projektion
4/2-Wege-Magentventil
Name five major components of the 4/2-way solenoid valve.

Number these on your freehand sketch.
1.
2.
3.
4.
5.
A-7
Exercise 1
WORKSHEET
Name five major components of the electrical signal input unit.

Number these on the illustration.
Fig. 1/4:
Signal input unit (photo)
1.
2.
3.
4.
5.
A-8
Exercise 1
Fig. 1/5:
Signal input unit;
front panel
Mark the connection designations on the front panel.

What colour are the 4 mm sockets? Please indicate this.
What is the difference in the function of a pushbutton and a switch?
A-9
Exercise 1
WORKSHEET
Complete the hydraulic circuit diagram.

Fig. 1/6:
Complete the list of hydraulic components.

Qty.
Description
Hydraulic power pack, 2 l/min

Hose line with quick-release coupling, 600 and 1000
List of
hydraulic components
A-10
Exercise 1
Complete the electrical circuit diagram.

Fig. 1/7:
Circuit diagram, electrical
Complete the list of electrical components.

List of
electrical components
Qty.
Description
Cable set, universal with safety plugs
Power supply unit, 24V
A-11
Exercise 1
WORKSHEET
How do you mount the cylinder on the profile plate?

Fig. 1/8:
Variant B
How do you mount the 4/2-way solenoid valve on the profile plate?
Fig. 1/9:
Variant A
A-12
Exercise 1
How do you mount the electrical signal input unit on the profile plate??
Fig. 1/10:
Variant D
Where else could you mount the electrical signal input unit?
A-13
Exercise 2
Electrohydraulics
Subject
Component selection on conveyor belt
Title
T Understanding an indirectly actuated, manually operated circuit

T Understanding the mode of operation of a throttle valve and one-way
Training aims
flow control valve
T
T
T
T
T
T
T
T
T
T
T
Understanding the mode of operation of a pressure relief valve
T
T
T
T
T
T
Understanding the use of the electrical indicator and distributor unit

Understanding the use of the 3-fold relay unit
Understanding the function of a relay
Understanding contact designations
Selection of required components
Development of hydraulic and electrical circuit diagrams
Assembly of control circuit on profile plate
Adjustment of a one-way flow control valve
Adjustment of the motion time of a cylinder

circuits

T Compile the components list
T Dismantle the components and replace in storage trays
Problem definition
A-14
Exercise 2
Exercise
A double-acting cylinder is used to push unsealed cartons from one

conveyor onto another. The advance stroke of the cylinder is manually
controlled. The advance-stroke speed is adjustable, while the returnstroke speed is fixed. The pressure should be measured upstream of
the cylinder and of the directional control valve.
Fig. 2/1:
Positional sketch
A-15
Exercise 2
WORKSHEET
What are the component parts of the one-way flow control valve?
Fig. 2/2:
B
4
6
1.
2.
3.
4.
5.
6.
A
B
A-16
Exercise 2
What is the mode of operation of an adjustable throttle valve?
For what purpose are non-return valves used?
Name three practical examples.
Explain the mode of operation of a one-way flow control valve.
A-17
Exercise 2
WORKSHEET
What are the component parts of the pressure relief valve?

Fig. 2/3:
Pressure relief valve
1.
2.
3.
4.
5.
6.
P
T
A-18
Exercise 2
What function does the 4/2-way solenoid valve have in the activation of
a double-acting cylinder?
For what purpose do you require the electrical indicator and distributor
unit?
Fig. 2/4:
Indicator and
distributor unit, electrical
A-19
Exercise 2
WORKSHEET
What are the major component parts of the 3-fold relay unit?
Fig. 2/5:
Relay, 3-fold
How does the relay in the illustration work?

Return spring
Winding
Armature
Core
Changeover
contact assembly
Terminal lugs for

contact assembly
Terminal lugs for

contact assembly
Fig. 2/6:
Relay
A-20
Exercise 2
T Label the normally-open contacts of relay 1.

T Label the normally-closed contacts of relay 2.
T Label the changeover contacts of relay 3.
Fig. 2/7:
Front panel
A-21
Exercise 2
WORKSHEET

Fig. 2/8:

Qty.
Description
Pressure gauge
Branch tee
List of
hydraulical components
A-22
Exercise 2

Fig. 2/9:
= Normally-closed contact
How is it possible to initiate advance and return strokes of the cylinder

using only one electrical actuating device?
List of
Qty.
Description
Indicator and distributor unit

A-23
Exercise 3
Electrohydraulics
Subject
Lifting station
Title
T Understanding how to use a 4/2-way solenoid valve to actuate a sin-
Training aims
gle-acting cylinder
T Demonstrating that a 4/2-way valve can also be used as a 3/2-way

valve or 2/2-way valve
T
T
T
T
T
T
Understanding the difference between open and closed mid-positions
T
T
T
T
T
T
T
Development and drawing of hydraulic and electrical circuit diagrams

Assembly of control circuit on profile plate
Handling a 9 kg loading weight
Understanding the effect of a compressive load
Problem definition
circuits

Caution!
Risk of serious injury
Oily components may easily slip out of your hands.
This exercise involves the use of a heavy weight.
Clean the weight before handling it
Make sure you have a secure grip on the weight
Use the cover when working with the weight.
This prevents the danger of trapping your fingers
See list of additional components
Problem definition
A-24
Exercise 3
Exercise
Crates arriving on a conveyor belt must be raised to the height of a

packing conveyor by means of a lifting table. The raising and lowering of
the lifting table are to be controlled manually by means of a single-acting
hydraulic cylinder. The advance stroke is adjustable, while the return
stroke cannot be adjusted and is governed by the weight of the lifting
table. The pressure should be measured upstream of the cylinder and of
the directional control valve.
Fig. 3/1:
Positional sketch
A-25
Exercise 3
WORKSHEET
An electrohydraulic 4/2-way valve can be used to produce a number of

different functions. Which ports must be used to produce a given function? (The other ports remain closed.).
4/2-way valve
* Internal leakage-oil connection
Function
Fig. 3/2:
Application of 4/2-way valve
A-26
Exercise 3
How must the 4/2-way solenoid valve be connected up so that the single-acting cylinder is able to advance and also retract again?
Fig. 3/3:
Practical assembly
A-27
Exercise 3
WORKSHEET
F = Force
Fig. 3/4:

Qty.
Description
Pressure gauge
Branch tee
List of
A-28
Exercise 3

Fig. 3/5:

List of
Qty.
Description
Relay, 3-fold
Power supply unit
A-29
Exercise 4
Electrohydraulics
Subject
Bending device
Title
T
T
T
T
T
T
T
T
T
T
Understanding of the mode of operation of a 2-way flow control valve
Training aims
T
T
T
T
T
T
Understanding electrical latching

Correct identification of electrical symbols in a circuit diagram
Assembly of control circuit on a profile plate
Setting pressure values
Compiling a list of electrical components
Compiling a list of hydraulic components

Number the components
circuits

Problem definition
A-30
Exercise 4
Exercise
A bending device with a double-acting cylinder is used to produce Ushaped sheet-metal workpieces. The start signal for this operation is
given by a pushbutton. After the workpiece has been shaped, a second
pushbutton is used to initiate the return stroke of the cylinder. No provision will be made in this exercise for the safety devices required in normal practice. The advance and return strokes must be executed at a
slow adjustable speed. What type of flow control valve should you use to
allow the speed to be adjusted independently of load?
Fig. 4/1:
Positional sketch
A-31
Exercise 4
WORKSHEET

Fig. 4/2:

Qty.
Description
List of
A-32
Exercise 4

Fig. 4/3:
Code
Description
S1
S2
K1
1Y

List of
Qty.
Description
A-33
Exercise 5
Electrohydraulics
Subject
Press-fitting device
Title
T
T
T
T
T
T
T
T
T
T
Understanding the structure of a function diagram
Training aims
T
T
T
T
T
T
Reading and understanding a function diagram

Use of a pressure switch
Understanding electrical latching
Compiling components lists

Draw the function diagram
circuits

Problem definition
A-34
Exercise 5
Exercise
A press-fitting device is to be used to assemble workpieces. If the preset

press pressure is exceeded (for example, because workpieces are incorrectly aligned), the piston rod must be retracted for safety reasons.
After a correct press-fitting operation, the return stroke should be initiated when the value preset on the pressure switch of 3 MPa (30 bar) is
reached. A one-way flow control valve is fitted in the supply line of the
cylinder. Describe the point in time after the circuit is switched on at
which the pressure switch is triggered if the pressure is measured upstream of the throttle valve.
What is the correct point at which to measure the pressure?
Fig. 5/1:
Positional sketch
A-35
Exercise 5
WORKSHEET
Time
Components
Step
Description
Code
Pushbutton
Status
ON
Cylinder
Step 3 is the same as step 1.
T Familiarise yourself with the mode of representation used in function

diagrams by consulting:
T The textbook Electrohydraulics Basic Level TP601"

T VDI1 3260, July 1977
Function Diagrams for Production Machines and Installations
What is the structure of a function diagram?
1 VDI = Verein Deutscher Ingenieure (German Engineering Association)
Fig. 5/2:
Function diagram
A-36
Exercise 5

Fig. 5/3:

List of
Qty.
Description
A-37
Exercise 5
WORKSHEET

Fig. 5/4:
S1 = START pushbutton
1B = Pressure switch

Qty.
Description
List of
A-38
Exercise 5
What procedure do you use for connecting hoses to the components?
What must you bear in mind when disconnecting hose lines fitted with
quick-acting couplings?
Do you have experience of working with the pressure relieving device?
Yes
No
A-39
Exercise 6
Electrohydraulics
Subject
Stamping machine
Title
T Understanding a differential circuit

T Understanding how a 3/2-way valve can be used to activate a double-
Training aims
acting cylinder
T
T
T
T
T
T
T
T
T
T
T
T


circuits

Problem definition
A-40
Exercise 6
Exercise
A hydraulic power pack with a very low pump delivery rate is all that is
available to operate a stamping machine. A suitable circuit must be used
to increase the advance-stroke speed. The power pack output is sufficient to allow this.
A flow control valve is installed at a suitable point in the circuit. This reduces the flow rate to the cylinder.
Fig. 6/1:
Positional sketch
A-41
Exercise 6
WORKSHEET

Fig. 6/2:

Qty.
Description
List of
A-42
Exercise 6

Fig. 6/3:
S2 = RETURN pushbutton

List of
Qty.
Description
A-43
Exercise 7
Electrohydraulics
Subject
Door control
Title
T
T
T
T
T
Training aims
Understanding the mode of operation of a piloted non-return valve

Understanding an electrical interlock
Understanding the positioning of a cylinder in INCHING operation
Classifying hydraulic valves
Understanding how to use a 4/3-way solenoid valve to actuate a
double-acting cylinder
T Demonstrating that a 4/3-way valve can also be used as a 3/2-way

valve
T
T
T
T
T
T
T
Identifying, assembling and assessing an alternative solution
T
T
T
T
T
T


circuits

Problem definition
A-44
Exercise 7
Exercise
A double-acting hydraulic cylinder is used to open and close a furnace

door. INCHING operation allows the door to be driven to any desired
intermediate position. The cylinder is hydraulically clamped in all such
positions.
Fig. 7/1:
Positional sketch
A-45
Exercise 7
WORKSHEET

Fig. 7/2:
A-46
Exercise 7

Classify the components by stating whether they are non-return valves,
pressure valves, flow control valves, directional control valves, actuators, or other hydraulic components.
List of
Qty.
1
Description
Belongs to class of:
Other hydraulic components
A-47
Exercise 7
WORKSHEET

Fig. 7/3:

Qty.
Description
List of
A-48
Exercise 7
A-49
Exercise 8
Electrohydraulics
Subject
Machining unit
Title
T
T
T
T
T
T
T
T
T
Understanding a second variant of a differential circuit
Training aims
T
T
T
T
T
T
Understanding the use of electrical limit switches

Correct use of right-hand and left-hand limit switches

circuits

Problem definition
A-50
Exercise 8
Exercise
The edges of workpieces must be chamfered. It has been possible to

reduce the machining time by using improved tools. The feed speed is
therefore to be increased by using a differential circuit.
The clamping device can accept up to 5 workpieces at the same time. In
order to reduce the working stroke when the number of workpieces is
less than 5, the cylinder return stroke is to be initiated by an adjustable
limit switch.
Install a flow control valve at a suitable point in the circuit so that the
effect of the differential circuit can clearly be seen.
Fig. 8/1:
Positional sketch
A-51
Exercise 8
WORKSHEET

Fig. 8/2:

Qty.
Description
List of
A-52
Exercise 8

Fig. 8/3:
1S1, 1S2 = Limit switches


List of
Qty.
Description
A-53
Exercise 9
Electrohydraulics
Subject
Feed for drilling machine
Title
T
T
T
T
T
T
T
T
Completion and understanding of a function diagram
Training aims
T
T
T
T
T
T
Understanding of a rapid-traverse circuit


circuits

Problem definition
A-54
Exercise 9
Exercise
The feed of a drilling machine is to be automated. When carrying out

drilling with large-diameter drilling bits, it is necessary to achieve constant feed characteristics and a finely-adjustable feed speed. The machine is therefore to be equipped with hydraulic feed, which must
provide a rapid-traverse feed motion and a infinitely-adjustable working
feed motion. The return stroke is to be initiated by pressing a second
pushbutton. During this phase, the flow control valve is to be bypassed
by means of a non-return valve.
Fig. 9/1:
Positional sketch
Rapidtraverse
feed
Return
stroke
Working
feed
A-55
Exercise 9
WORKSHEET
Complete the function diagram.

Fig. 9/2:
Function diagram
START pushbutton
ON
RETURN pushbutton
Cylinder
4/2-way valve
2/2-way valve

A-56
Exercise 9

Fig. 9/3:

List of
Qty.
Description
A-57
Exercise 9
WORKSHEET

Fig. 9/4:


Qty.
Description
List of
A-58
Exercise 9
What is the purpose of the Hydraulics 2000" transparent models?
What do these transparent models illustrate more clearly than the components mounted on the profile plate?
Have you already worked with the Hydraulics electronic transparencies?
Yes
No
A-59
Exercise 10
Electrohydraulics
Subject
Press
Title
T Assembly of a pressure control with a limit switch and pressure
Training aims
switch
T
T
T
T
T

Commissioning of a complex control circuit
Understanding that it is necessary to preset components before the
power supply is switched on
T Understanding that commissioning can be carried out in stages

T Compiling components lists
T
T
T
T
T
T

circuits

Problem definition
A-60
Exercise 10
Exercise
A hydraulic press is used to shape workpieces. An initial pressure of

p1 = 1.5 MPa (= 15 bar) is used to shape the material slowly. After a
press stroke of approx. 100 mm, a switchover must be made as a function of position to a higher pressure of p2 = 4 MPa (= 40 bar). After the
pressing operation is complete, the pressure rises to the maximum
value set on the pressure switch, p3 = 5 MPa (= 50 bar). When this
value is reached, the pressure switch initiates a return stroke of the
press. The flow rate is to be adjustable by means of a flow control valve.
Fig. 10/1:
Positional sketch
A-61
Exercise 10
WORKSHEET

Fig. 10/2:

Qty.
Description
List of
A-62
Exercise 10

Fig. 10/3:
1S = Limit switch

List of
Qty.
Description
A-63
Exercise 11
Electrohydraulics
Subject
Feed device
Title
T
T
T
T
T
T
T
T
Completion and reading of a function diagram
Training aims
T
T
T
T
T
T
Understanding of how pressureless pump bypass can be provided


circuits

Problem definition
A-64
Exercise 11
Exercise
A double-acting hydraulic cylinder is used to eject pressed forgings from

a metal tool.
The cooling time of the forgings has increased considerably due to the
fact that a different material is now being used. To prevent an unnecessary rise in the temperature of the hydraulic fluid, the circuit must be
switched to pressureless pump bypass after the ejection operation.
Fig. 11/1:
Positional sketch
A-65
Exercise 11
WORKSHEET
Complete the function diagram.
Time
Components
Step
Description
Code
Status
ON
1S1, 1S2 = Limit switch
Fig. 11/2:
Function diagram
A-66
Exercise 11

Fig. 11/3:

List of
Qty.
Description
A-67
Exercise 11
WORKSHEET

Fig. 11/4:

Qty.
Description
List of
A-68
Exercise 11
What maintenance do you carry out on your equipment?
How old is the equipment which you are using for training?
A-69
Exercise 12
Electrohydraulics
Subject
Assembly device
Title
T Production of a function diagram by the student working independ-
Training aims
ently
T Use of a 4/2-way solenoid valve to activate a hydraulic motor

T Assembly of a pressure-dependent sequence control with two actuators
T
T
T
T
T
T
T
T
T
T
T
T


circuits

T Compile the components list.
Problem definition
A-70
Exercise 12
Exercise
An assembly device is used to press-fit a plastic bush into a steel workpiece. A screw is then inserted to secure the connection.
When the START pushbutton S1 is pressed, the vertical double-acting
press cylinder 1A presses the plastic bush into the steel workpiece.
When the pressure in the piston chamber of the press cylinder reaches
4.5 MPa (45 bar), the horizontal hydraulic motor 3M screws in the left
hand threaded coarse-pitch screw.
When the RETURN pushbutton S2 is pressed, the press cylinder 1A
retracts and the motor M stops.
Parameters
The cylinder must not slip when the hydraulic power pack is switched
off.
Measures must be taken to ensure that the motor cannot rotate clockwise under any circumstances.
The speed of the press-fitting motion of the cylinder must be adjustable.
A visual indicator must show the position of the detented RETURN
pushbutton S2. The visual indicator must not go out, allowing a re-start,
until the switch has been unlocked.
Fig. 12/1:
Positional sketch
1A
2M
A-71
Exercise 12
WORKSHEET
Plot the function lines in the function diagram.
Time
Components
Step
Description
START pushbutton
Code
Status
ON
RETURN pushbutton
Cylinder
4/3-way valve
Motor
4/2 way valve
1B = Pressure switch, p1 = 2.5 Mpa = 25 bar
Fig. 12/2:
Function diagram
A-72
Exercise 12

Fig. 12/3:

List of
Qty.
Description
A-73
Exercise 12
WORKSHEET

Fig. 12/4:
A-74
Exercise 12
WORKSHEET

List of
Qty.
Description
Compile an electrohydraulics literature list.

Literature list
Author
Title
Publisher
A-75
Exercise 13
Electrohydraulics
Subject
Lifting device for packages
Title
T Assembly of a position-dependent sequence control circuit with two
Training aims
cylinders
T Production of a function diagram by the student working independently
T
T
T
T
T
T
T
T
T
T
T
T


circuits

Problem definition
A-76
Exercise 13
Exercise
Packages are fed in by means of a gravity roller conveyor X and are

lifted by cylinder 1A. Cylinder 2A then ejects the packages onto roller
conveyor Y for further transport. Following this, the two double-acting
cylinders return to their initial positions.
2A
Fig. 13/1:
Positional sketch
1A
A-77
Exercise 13
WORKSHEET
Plot the signal lines in the function diagram.
Time
Components
Step
Description
START pushbutton
Code
Status
ON
Cylinder
4/3-way valve
Cylinder
4/2-way valve
S = START pushbutton
1S1, 1S2, 2S1, 2S2 = Limit switches
Fig. 13/2:
Function diagram
A-78
Exercise 13

Fig. 13/3:

List of
Qty.
Description
A-79
Exercise 13
WORKSHEET

Fig. 13/4:
A-80
Exercise 13
Complete the practical assembly hydraulic

Fig. 13/5:
Practical assembly,
hydraulisch
A-81
Exercise 13
WORKSHEET
Complete the practical assembly electrical

Fig. 13/6:
Practical assembly,
elektrisch
S = STARTpushbutton
A-82
Exercise 13

List of
Qty.
Description
How do you remove the components from the profile plate or mounting
frame?
Where do you store your electrohydraulic components?
B-1
Part B - Fundamentals
The theoretical fundamentals for the Electrohydraulics training package are summarised in the textbook:
Elektrohydraulics
Basic Level
B-2
C-1
Part C Solutions
Solution 1:
Solution 2:
Solution 3:
Solution 4:
Solution 5:
Solution 6:
Solution 7:
Sorting device
C-3

C-7
Lifting station
C-11
Bending device
C-15
C-19
Stamping machine
differential circuit
C-23
Door control
interlock, INCHING operation
C-27
C-2

Solution 8:
Solution 9:
Solution 10:
Machining unit
Differential circuit,
return stroke using limit
C-33

C-39
Press
and pressure switch
C-45

Solution 11:
Solution 12:
Solution 13:
Feed device
C-49
Assembly device
C-55

with two cylinders
C-61
C-3
Solution 1
Sorting device
Fig.1/1:
Circuit diagram,
hydraulic
Fig.1/2:
Circuit diagram,
electrical
S = START-pushbutton
C-4
Solution 1
Solution description
When the START pushbutton S is pressed, the circuit for the solenoid
coil 1Y is closed and the 4/2-way solenoid valve is reversed. The piston
rod of the double-acting cylinder advances to its forward end position.
When the pushbutton S is released, the circuit for solenoid coil 1Y is
interrupted and the 4/2-way solenoid valve returns to its initial position.
The piston rod of the cylinder returns to its retracted end position.
T Note on hydraulic circuit diagram

Components are shown in this diagram by symbols.
The 4/2-way solenoid valve is shown in the circuit diagram with
- the parallel position on the left and
- the crossover position on the right.
This means that there are no intersecting lines in the circuit diagram.
This is the same method of representation as is used in the textbook.
T Note on electrical circuit diagram

In circuits with direct actuation, without relays, the control and power
circuits are not separate.
T Note on Practical assembly, hydraulic drawing

Components are also shown in the Practical assembly, hydraulic
drawing by symbols.
The 4/2-way solenoid valve is shown in the same way as the symbol
on the valve itself.
- Parallel position on the right
- Crossover position on the left
A line intersection thus occurs in the Practical assembly, hydraulic
drawing.
T Electrical components can also be mounted in the mounting frame if

desired.
C-5
Solution 1
Fig.1/3:
Practical assembly,
hydraulic
Item no.
Qty.
Description
0Z
1V
1A
Cylinder, 16/10/200
Hose line with quick-release coupling 600 and 1000
Components list,
hydraulic
C-6
Solution 1
Fig.1/4:
Practical assembly,
electrical
Components list,
electrical
Qty.
Description
C-7
Solution 2
Fig.2/1:
Circuit diagram,
hydraulic
Fig.2/2:
Circuit diagram,
electrical
= Normally-opened contact
C-8
Solution 2
When the START pushbutton S1 is pressed, the relay K1 is energised.

The normally-open contact K1 supplies current to the solenoid coil 1Y
and the 4/2-way solenoid valve is reversed. This causes the piston rod
of the cylinder to advance. As soon as the START pushbutton S1 is released, the piston rod retracts again. The piston rod cannot stop in the
vicinity of the conveyor system if S1 is not pressed. The one-way flow
control valve can be used to adjust the advance-stroke speed.
C-9
Solution 2
Fig.2/3:
Practical assembly,
hydraulic
Item no.
Qty.
0Z1
0Z2, 1Z
Pressure gauge
0V
1V1
1V2
1A
Cylinder, 16/10/200
Branch tee
Description
Components list,
hydraulic
C-10
Solution 2
The following settings must be made:

Pump safety valve
0Z1 to 6 MPa (60 bar)
0V to 5 MPa (50 bar)
Advance-stroke time:
One-way flow control valve 1 division line open
2 division lines open
4 division lines open
Return-stroke time
4.5 s
2.8 s
2.0 s
1.2 s
Fig.2/4:
Practical assembly,
electrical
= Changeover contact connected as
normally-closed contact
= Changeover concact connected as
normally-open contact
Visual actuation indicator is hard-wired
in distributor unit
Components list,
electrical
Qty.
Description
Relay, 3-fold
Indicator and distributor panel, electrical
Electrical power supply unit, 24V
C-11
Solution 3
Lifting station
Fig.3/1:
Circuit diagram,
hydraulic
Fig.3/2:
Circuit diagram,
electrical
C-12
Solution 3
When the START pushbutton S1 is pressed, the relay K1 is energised.

The normally-open contact K1 supplies current to the solenoid coil 1Y of
the 3/2-way solenoid valve. The piston rod now advances. When the
pushbutton S1 is released, the circuit with K1 and 1Y is interrupted, the
valve closes by spring force and the piston rod retracts due to the loading weight. The advance-stroke speed can be adjusted by means of the
one-way flow control valve.
The Practical assembly, hydraulic drawing shows a 4/2-way solenoid

valve instead of the 3/2-way valve.
C-13
Solution 3
Fig.3/3:
Practical assembly,
hydraulic
Item no.
Qty.
0Z1
0Z2, 1Z1
Pressure gauge
0V
1V1
1V2
1A
Cylinder, 16/10/200
1Z2
Branch tee
Description
Components list,
hydraulic
C-14
Solution 3
The following settings must be made::

Pump safety valve
One-way flow control valve 1V2 as desired
Fig.3/4:
Practical assembly,
electrical
= Normally-opened contact
The indicator and distributor unit is
equipped with indicator lamps
Fig.3/5:
Contact allocation
on relay panel
Changeover contact
connected as normallyopen contact
Components list,
electrical
Qty.
Changeover contact
connected as normallyclosed contact
Description
Relay, 3-fold
C-15
Solution 4
Bending device
Fig.4/1:
Circuit diagram,
hydraulic
Fig.4/2:
Circuit diagram,
electrical
C-16
Solution 4
When the START pushbutton S1 is pressed, the relay K1 is energised;

the normally-open contact of K1 latches to maintain the power supply for
the relay K1. Simultaneously, current is fed to the coil 1Y via a further
contact of K1. The solenoid reverses the 4/2-way solenoid valve and the
piston rod advances and remains at its forward end position until the
RETURN pushbutton S2 is pressed, which interrupts the circuit for the
relay K1. This also causes the circuit for the coil 1Y to be interrupted,
and the piston rod returns to its initial position. A flow control valve must
be fitted to ensure that the speed does not vary as a function of load.
This flow control valve should be fitted upstream of the directional control valve and will then control both the advance and return strokes.
C-17
Solution 4
Fig.4/3:
Practical assembly,
hydraulic
Item no.
Qty.
0Z1
0Z2, 1Z
Pressure gauge
0V1
0V2
1V
1A
Cylinder, 16/10/200
Branch tee
Description
Components list,
hydraulic
C-18
Solution 4

Pump safety valve
0V1 to 5 MPa (50 bar)
Flow control valve
approx. 1 1/2 turns open
Fig.4/4
Practical assembly,
hydraulic
Components list,
electrical
Qty.
Description
Relay, 3-fold
Further work
If both pushbuttons, S1 and S2, are pressed simultaneously, the cylinder retracts or remains in its retracted end position. We thus speak of a
latching circuit with dominating off characteristics.
T Modify the electrical circuit in such a way as to obtain dominating on

characteristics.
If both pushbuttons, S1 and S2, are pressed simultaneously in this
case, the cylinder will advance or remain at its forward end position.
C-19
Solution 5
Fig.5/1:
Circuit diagram,
hydraulic
Fig.5/2:
Circuit diagram,
electrical
C-20
Solution 5
When the START pushbutton S1 is pressed, the relay K1 is energised;

the 1st normally-open contact of K1 maintains the power supply for the
relay K1. Simultaneously, the circuit for the coil 1Y is closed via a further
contact of K1. The 4/2-way valve reverses and the piston rod advances
until the pressure preset on the pressure switch 1B is reached. The
pressure switch acts via K2 to cancel the latching of K1. This also interrupts the circuit for the coil 1Y, causing this to become de-energised.
The 4/2-way solenoid is reversed back by spring force and the piston
rod returns to its initial position.
Fit the pressure sensor upstream of the one-way flow control valve:
If the advance-stroke speed is controlled by a throttle valve, the throttle
valve represents such a large resistance that, when the circuit is
switched on, the pressure upstream of this valve rises to over 30 bar.
The result of this is that the pressure switch initiates the return stroke
before the correct press-fitting pressure has been reached. The pressure must therefore be measured directly upstream of the cylinder supply port.
You will require a 2.5 mm Allen key to adjust the pressure switch.
C-21
Solution 5
Fig.5/3:
Practical assembly,
hydraulic
The return lines to the tank are no longer used in exercise 5 and subsequent exercises. Symbolic representation.
Item no.
Qty.
0Z1
0Z2, 1Z
Pressure gauge
0V
1V1
1V2
1A
Cylinder, 16/10/200
1B
Pressure switch
Branch tee
Description
Components list,
hydraulic
C-22
Solution 5

Pump safety valve
Pressure relief valve 0V to 5 MPa (50 bar)
Fig.5/4
Practical assembly,
hydraulic
Components list,
electrical
Qty.
Description
Relay, 3-fold
C-23
Solution 6
Stamping machine
Fig.6/1:
Circuit diagram,
hydraulic
Fig.6/2:
Circuit diagram,
electrical
C-24
Solution 6
A differential circuit is only possible using cylinders with a single-ended

piston rod and is intended to increase speed in the forward stroke, whilst
pressure is applied to both piston surfaces. Due to the difference in
surface areas, a differential force is created, which causes the piston
rod to advance. The oil displaced on the piston rod side is fed to the
large piston side. The active surface area for the pressing force corresponds to the piston rod surface area. This is why the pressing force is
less in the case of increased advancing speed than if pressure is
applied to a single-sided piston surface.
The solenoid coil 1Y of the 3/2-way valve is actuated via the START
button S1. The piston rod advances using the recirculated oil. If the
RETURN STROKE button S2 is pressed, 1Y is de-energised, the 3/2way valve reverses by means of spring force and the piston rod retracts.
The flow control valve is used to represent a hydraulic power unit with
reduced pump delivery. The effect of the differential circuit is thus more
clearly identifiable.
The "Practical assembly, hydraulic" drawing shows a 4/2-way solenoid

valve instead of the 3/2-way valve.
C-25
Solution 6
Fig.6/3:
Practical assembly,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2
Pressure gauge
0V1
0V2
1V
1A
Cylinder, 16/10/200
Branch tee
Components list,
hydraulic
C-26
Solution 6

Pump safety valve
Pressure relief valve 0V1 to 5 MPa (50 bar)
Fig.6/4
Practical assembly,
hydraulic
Components list,
electrical
Qty.
Description
Relay, 3-fold
C-27
Solution 7
Door control
Fig.7/1:
Circuit diagram,
hydraulic
Fig.7/2:
Circuit diagram,
electrical
S1 = Close door pushbutton

S2 = Open door pushbutton
C-28
Solution 7
The hydraulically-piloted non-return valve prevents the piston rod from

being pulled out by the tractive load. The piloted non-return valve opens
and allows the piston rod to advance only when the Close door pushbutton S1 is pressed, causing the 3/2-way valve to reverse. When the
pushbutton S1 is released, the 3/2-way valve returns to its initial position
and the piloted non-return valve closes immediately. The piston rod is
hydraulically clamped and remains where it is. The hydraulic clamping
ensures that the piston rod cannot be pulled out by a tractive load.
When S1 is pressed again, the piston rod moves forward until the desired end position is reached.
When the Open door pushbutton S2 is pressed, the piston rod moves
back. When S2 is released, the 4/3-way valve reverses, while the piston
rod stays where it is and is hydraulically clamped. The two pushbuttons
S1 and S2 are mechanically interlocked. If both of these are pressed at
the same time or if one is held down and the other pressed, the piston
rod stops.
The one-way flow control valve is installed on the piston-rod side in order to ensure that a back-pressure develops as the door closes. This
pressure is used firstly to provide counter-holding and secondly to ensure reliable opening of the pilot-operated non-return valve.
If AC solenoid valves are used, the pushbuttons S1 and S2 must be

interlocked to prevent damage to the solenoid coils if both of these are
energised at the same time.
In the case of DC solenoids, an interlock should be provided for safety
reasons.
C-29
Solution 7
Fig.7/3:
Practical assembly,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2
Pressure gauge
0V
1V1
1V2
1V3
1V4
1A
Cylinder, 16/10/200
Branch tee
Components list,
hydraulic
C-30
Solution 7

Pump safety valve
Fig.7/4
Practical assembly,
hydraulic
S1 = Close door pushbutton

Components list,
electrical
Qty.
Description
Relay, 3-fold
C-31
Solution 7
Alternative solution
Fig.7/5:
Practical assembly,
hydraulic
The supply line for 1Y3 is not connected up.
C-32
Solution 7
Fig.7/6
Practical assembly,
hydraulic
S1 = Closed door pushbutton

C-33
Solution 8
Machining unit
Time
Components
Step
Description
Pushbutton
Code
Status
ON
Cylinder
4/2-way valve
3/2-way valve
Fig.8/1:
Function diagram
C-34
Solution 8
Fig.8/2:
Circuit diagram,
hydraulic
Fig.8/3:
Circuit diagram,
electrical

C-35
Solution 8
The circuit is started by pressing S1. The 4/3-way valve then reverses,
and the fluid from the piston-rod side is used together with the pump
delivery to power the advance stroke of the cylinder. When the limit
switch 1S2 is reached, the 4/3-way valve and 4/2-way valve are reversed and the piston rod retracts again. When the piston rod reaches
the limit switch 1S1 at its retracted end position, the 4/2-way valve
switches back to its initial position. A new processing cycle can now be
started. In this circuit, the flow control valve is used only to restrict the
pump delivery to allow a clearer demonstration of the effects of a differential circuit.
The limit switch 1S1 could also be installed directly in current path 4 in
place of the normally-closed contact K2. In complex electrical circuits,
the limit switch always operates as shown, via a relay.
C-36
Solution 8
Fig.8/4:
Practical assembly,
hydraulic
Components list,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2
Pressure gauge
0V1
0V2
1V1
1V2
1A
Cylinder, 16/10/200
Branch tee
C-37
Solution 8
1Y3
41
44
1Y2
21
1Y1
21
11
1 5
7
8
A2
4 1
2
6
K3
A2
K2
A2
A1
K2
22
14
14
11
0V
K1
32
K3
K2
11
14
14
12
S1
13
34
31
A1
K1
12
14
1S1
13
1S2
13
24
21
A1
42
K3
24
22
K3
24
22
12
14
K1
7
6
5
4
3
2
1
+24 V-
Fig.8/5
Practical assembly,
hydraulic
K3

Pump safety valve
Flow control valve
0V2 in such a way that no oil emerges from
the outlet T of 0V1 during the rapid advance stroke (approx. 1/2 to 1 turn open).

C-38
Solution 8
Components list,
electrical
Further work
Qty.
Description
Relay, 3-fold
T Assemble an alternative solution.

T Swap over the directional control valves:
4/2-way solenoid valve (1V1)

4/3-way solenoid valve, closed in mid-position (1V2)
T Complete the drawing Practical assembly, hydraulic.

T Complete the drawing Practical assembly, electrical.
T Assemble the control circuit on the profile plate.
Commission the control circuit.
T What are the advantages and disadvantages of the alternative solution?
C-39
Solution 9
Time
Components
Step
Description
ADVANCE pushbutton
Code
Status
ON
RETURN pushbutton
Cylinder
4/2-way valve
2/2-way valve

Fig.9/1:
Function diagram
C-40
Solution 9
Fig.9/2:
Circuit diagram,
hydraulic
Fig.9/3:
Circuit diagram,
electrical

C-41
Solution 9
During the rapid traverse motion, the 2-way flow control valve is bypassed via the 2/2-way directional control valve. Switchover from rapid
to feed speed is position-dependent and is initiated by the limit switch
1S2, which feeds an electrical signal via the relay K2 to the solenoid coil
1Y2.
The return stroke is initiated by the pushbutton S2. In the retracted end
position of the piston rod, the limit switch 1S1 switches the 2/2-way
valve back to rapid traverse, thus fulfilling the condition for a re-start.
During the return stroke, the flow control valve is bypassed by the nonreturn valve, 1V4.
C-42
Solution 9
Fig.9/4:
Practical assembly,
hydraulic
Components list,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2, 1Z
Pressure gauge
0V
1V1
1V2
1V3
1V4
1A
Cylinder, 16/10/200
Branch tee
11
C-43
Solution 9

Pump safety valve
1
+24 V-
13
S1
2
12
14
K1
14
14
12
3
13
22
24
K2
1S1
11
14
5
22
24
K1
21
6
32
7
34
K1
21
32
34
K2
31
Fig.9/5
Practical assembly,
hydraulic
31
K2
11
31
21
S2
1S2
32
A1
22
A1
K1
K2
A2
0V
1Y1
1Y2
1Y3
A2
6 2
5
7 4
1

Qty.
Description
Relay, 3-fold
Components list,
electrical
C-44
Solution 9
C-45
Solution 10
Press
Fig.10/1:
Circuit diagram,
hydraulic
Fig.10/2:
Circuit diagram,
electrical
1S = Limit switches
C-46
Solution 10
Pre-settings:
Set the components before switching on the electrical and hydraulic
power supplies.
1.
1V2
Close one-way flow control valve fully, then open 1/4 turn
2.
0V4
Bring 2-way flow control valve to mid-position
3.
0V2
Close pressure relief valve 2/3
4.
0V1
Close pressure relief valve 1/3
5.
1B
Open pressure switch fully
Commissioning:
After switching on the electrical and hydraulic power supplies, press the
START pushbutton repeatedly to restore the circuit to its initial setting.
1.
0Z1
Pump safety valve to 6 MPa (60 bar)
2.
0V4
2-way flow control valve to mid-position
3.
0V2
Pressure relief valve to 1.5 MPa (15 bar)
4.
0V1
Pressure relief valve to 4 MPa (40 bar)
5.
1B
Pressure switch to approx. 3.6 MPa (36 bar)
When the START pushbutton S1 is pressed, the relay K1 is energised

and latches via its normally-open contact in current path 2. A further
normally-open contact of K1 energises the solenoid coil 1Y1 of the 4/2way valve and the piston rod advances. The 2/2-way valve is still open,
with the result that the pressure relief valve, with its lower pressure setting, becomes operative. When the piston rod reaches the limit switch
1S, the 2/2-way valve is deactivated, producing a switchover to the
pressure set on the 2nd pressure relief valve. When the piston rod
reaches its forward end position, the pressure continues to rise until the
preset pressure is reached. The pressure switch cancels the latching of
K1 and K2. K1 reverses the 4/2-way valve to initiate the piston return
stroke. The relay K2, which has also been de-energised, acts via the
normally-closed contact in current path 7 to switch the system back to
low pressure. A re-start can now be carried out.
C-47
Solution 10
Fig.10/3:
Practical assembly,
hydraulic
The supply line for 0Y2 is not connected up.
C-48
Solution 10
Components list,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2, 1Z
Pressure gauge
0V1, 0V2
0V3
0V4
1V1
1V2
1B
Pressure switch
1A
Cylinder, 16/10/200
Branch tee
Fig.10/4
Practical assembly,
hydraulic
1S = Limit switches
Components list,
electrical
Qty.
Description
Relay, 3-fold
C-49
Solution 11
Feed device
Components
Time
Step
Description
Pushbutton
Code
Status
ON
Cylinder
4/2-way valve
2/2-way valve
Fig.11/1:
Function diagram
C-50
Solution 11
Fig.11/2:
Circuit diagram,
hydraulic
Fig.11/3:
Circuit diagram,
electrical
C-51
Solution 11
When the START pushbutton S1 is pressed, the coil of relay K1 is energised. Relay K1 latches via its 1st normally-open contact. The normally-closed contact of K1 de-energises relay K3, causing the normallyopen contact of K3 to open and de-energise the solenoid valve 0Y2.
As a result, the 2/2-way valve reverses, shutting off the pressureless
pump bypass, The pump delivers directly into the system.
Since the normally-open contact of K1 which supplies the solenoid coil
1Y1 is also closed, the 4/2-way valve reverses and the piston rod advances to the limit switch 1S1. 1S1 acts via K2 to cancel the latching of
K1, thus de-energising the solenoid coil 1Y1 and switching the 4/2-way
valve over for the return stroke.
When the piston rod reaches the limit switch 1S2 at the retracted end
position, the 2/2-way valve is once again switched to pressureless bypass. The result of this is that the pump delivery is discharged to the
tank not at the system pressure of 50 bar but only against the resistance
of the 2/2-way valve.
C-52
Solution 11
Fig.11/4:
Practical assembly,
hydraulic
The supply line for 0Y2

is not connected up.
Components list,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2
Pressure gauge
0V1
0V2
0V3
1V
1A
Cylinder, 16/10/200
Branch tee
C-53
Solution 11

Pump safety valve
Flow control valve
0V3 2 turns open
Fig.11/5
Practical assembly,
hydraulic
Qty.
Description
Relay, 3-fold
Components list,
electrical
C-54
Solution 11
C-55
Solution 12
Assembly device
Time
Components
Step
Description
Pushbutton
Code
Status
ON
RETURN-pushbutton
Cylinder
4/3-way valve
Motor
4/2-way valve
1B = Pressure switch, p1 = 2.5 MPa = 25 bar
Fig.12/1:
Function diagram
C-56
Solution 12
Fig.12/2:
Circuit diagram,
hydraulic
Fig.12/3:
Circuit diagram,
electrical
C-57
Solution 12
When the START pushbutton S1 is pressed, the relay K1 is energised

and latches. The normally-open contact of K1 in current path 7 energises the solenoid coil 1Y1 of the 4/3-way valve. This causes the piston
rod of cylinder 1A to advance.
When the pressure set on 1B is reached, the relay K3 is energised. As a
result, the normally-open contact of K3 in current path 9 closes and the
hydraulic motor rotates counterclockwise. The piston rod remains advanced until the switch S2 is actuated.
When the switch S2 is actuated, its detented position is shown by a visual indicator. S2 cancels the latching of K1 and K3, causing the 4/3-way
valve to switch over and initiate the return stroke of the cylinder. Simultaneously, the pressure falls. The pressure switch causes the relay K3
to become de-energised, which results in the opening of the normallyopen contact of K3 in current path 9. 2Y accordingly becomes deenergised and the 4/2-way valve is reversed by spring force. The motor
stops.
Only after the switch S2 is released (indicator lamp goes out) does the
4/3-way valve switch to its mid-position, allowing a new working cycle to
be started.
In practice, a pressure sensor would not be used alone to determine

whether cylinder 1A has reached its end position. An additional limit
switch would also be used to provide reliable detection of the end position.
C-58
Solution 12
Fig.12/4:
Practical assembly,
hydraulic
Components list,
hydraulic
Item no.
Qty.
Description
0Z1
0Z2, 1Z
Pressure gauge
0V
1V1
1V2
1V3
1B
Pressure switch
1A
Cylinder, 16/10/200
2V1
2V2
2M
Branch tee
12
C-59
Solution 12

Pump safety valve
Pressure switch
1B to 2.5 MPa (25 bar)
Fig.12/5
Practical assembly,
hydraulic
B1 = Pressure switch
Qty.
Description
Relay, 3-fold
Components list,
electrical
C-60
Solution 12
C-61
Solution 13
Time
Components
Step
Description
START pushbutton
Code
Status
ON
Cylinder
4/3-way valve
Cylinder
4/2-way valve
1S1, 1S2, 2S1, 2S2 = Limit switches
Fig.13/1:
Function diagram
C-62
Solution 13
Fig.13/2:
Circuit diagram,
hydraulic
C-63
Solution 13
Fig.13/3:
Circuit diagram,
electrical
C-64
Solution 13
When the START pushbutton S is pressed, the relay K1 is energised

and latches. The normally-open contact of K1 in current path 9 energises the solenoid coil 1Y1 of the 4/3-way valve. This causes the piston
rod of cylinder 1A to advance until it reaches the limit switch 1S2.
1S2 energises the relay K2 as long as cylinder 1A is advanced. The
normally-open contact of K2 in current path 10 energises the solenoid
coil 2Y of the 4/2-way valve and the piston rod of cylinder 2A advances
until it reaches the limit switch 2S2 at its end position.
2S2 energises K3, whose normally-closed contacts in current paths 1
and 3 de-energise the relays K1 and K2. 2S2 thus cancels the latching
contacts K1 for 1Y1 and K2 for 2Y, while energising 1Y2. 1Y2 causes
the 4/3-way valve to reverse, and the piston rod of cylinder 1A retracts.
Due to the fact that 2Y has become de-energised, the 4/2-way valve is
reversed by spring force and the piston rod of cylinder 2A also retracts.
Only after both piston rods have reached their retracted end positions is
1Y2 de-energised, and the 4/3-way valve is brought into its mid-position
by spring force.
Fig.13/4:
Practical assembly,
hydraulic
C-65
Solution 13
Item no.
Qty.
Description
0Z1
0Z2
Pressure gauge
0V
1V1
1V2, 1V3
1A, 2A
Cylinder, 16/10/200
2V1
Branch tee
12
Components list,
hydraulic

Pump safety valve
One-way flow control valve 1V2 as desired
Qty.
Description
Relay, 3-fold
Components list,
electrical
C-66
Solution 13
Fig.13/5
Practical assembly,
hydraulic
S = START-pushbutton
D-1
Appendix
Part D Appendix
Storage tray
D-2
Mounting systems
D-3
Sub-base
D-5
Coupling system
D-6
Data sheets
Pressure gauge
152841
152843
Non-return valve, 1 bar, 5 bar
152845, 152846
Branch tee
152847
Pressure relief valve, pressure sequence valve
152848
152851
152852
Cylinder, 16/10/200
152857
152858
Hose line with quick release coupling,

600/1000 mm
152960, 152970
152962
Loading weight, 9kg
152972
Relay, 3-fold
162241
162242
162244
Pressure switch
167080
167082
4/3-way solenoid valve with closed in mid-position
167083
183322
183345
D-2
Appendix
Storage tray
All the components of the equipment set for the technology package
TP601 are retained in a storage tray.
This storage tray serves both as packaging for despatch purposes and
as a drawer insert for the Didactic furniture range.
Equipment set TP601
in storage tray
D-3
Appendix
Mounting systems
The components of the equipment set are mounted on the Festo Didactic profile plate. The profile plate has 14 parallel T-grooves equally
spaced 50 mm apart.
There is a choice of four alternative systems for mounting the components on the profile plate:
Variant A:
Detent system, used without additional devices.

Clamping mechanism with lever and spring
which can be moved along the T-groove,
for light non-load-bearing components
Variant B:
Rotary system, used without additional devices.

Grip nut with locking disc and T-head bolt,
vertical or horizontal alignment,
for medium-weight load-bearing components
Variant C:
Screw-in system, used with additional devices.

Cheese-head bolt with T-head nut,
vertical and horizontal alignment,
for heavy load-bearing components or components which
are rarely removed from the profile plate.
(Mounting-system variant C is not used in the equipment
set TP 601).
Variant D:
Plug-in system, used with adapters.

Components with locating pins for plug-in assembly
boards, can be insert in a T-groove,
for light non-load-bearing components
The signal input unit and indicator and relay plates can also be mounted
in the mounting frame for ER units.
D-4
Appendix
In the case of variant A, a slide engages in the T-groove of the profile

plate. This slide is pre-tensioned by a spring. When the blue lever is
pressed, the slide is retracted to allow the component to be removed
from or fitted to the profile plate. Components are aligned with the
groove and can be moved along this.
In the case of variant B, the component is secured to the profile plate
by a T-head bolt and a blue grip nut. A locking disc which can be positioned in steps of 90 is used to position the components, allowing these
to be aligned either parallel to or at right angles to the grooves.
After the locking disc has been set to the desired position, the component is placed on the profile plate. When the grip nut is turned clockwise, the T-head bolt is turned through 90in the T-groove by thread
friction. The grip nut is then turned further to clamp the component to
the profile plate.
Variant C is used with heavy components or components which are to
be secured to the profile plate once only or seldom removed. In this
case, components are secured by means of internal-hex-head bolts and
T-head nuts.
In the case of variant D, our well-proven ER units, on plug-in assembly
boards with locating pins on a 50 mm grid pattern, can be attached to
the profile plate by means of adapters. A black plastic adapter is required for each locating pin. The adapters are positioned in the Tgrooves at intervals of 50 mm and secured by rotating them through
90. The locating pins of the ER units are then inserted into the holes in
the adapters.
D-5
Appendix
Sub-base
The hole pattern of the sub-base for valves of nominal size 4 (DN 4)
conforms to ISO/DIN 4401 size 02. Due to the similarity between this
hole pattern and the one for size 03, it has been possible by changing
the dimensions slightly and providing additional mounting holes to allow
valves of nominal size 6 (DN 6) to be used as well.
Sub-base
D-6
Appendix
Coupling system
All hydraulic components are equipped with self-closing couplings.
These have been designed in particular enabling circuits to be assembled and dismantled with nearly no oil leakage, while at the same time
allowing connections to be made with very little effort.
A coupling consists of a nipple and socket. Connections are made by
pushing a socket onto a nipple. The sliding sleeve then engages to provide a secure connection. This sleeve is pushed back to detach a connection. A spring then pushes the socket away from the nipple.
Coupling nipples can be screwed into the sub-bases. All valves mounted
on sub-bases can thus be connected up via nipples. All other components should preferably also be equipped with nipples, and hoses lines
should therefore be fitted with two sockets. Components such as shutoff valves or non-return valves which are connected on one side to
hoses and on the other to components are equipped with coupling nipples and coupling sockets respectively.
Self-closing coupling
Coupling
nipple
Sliding
sleeve
Coupling
socket
D-7
Appendix
Since the couplings close to create a leakproof seal, it may occur that
pressure is trapped inside a component. If this happens, the force
required to operate the coupling will increase to such an extent that the
component cannot subsequently be coupled up again. The remedy in
cases of this kind is to use a pressure relieving device. This is of similar
design to a coupling socket but incorporates an adjustment spindle. The
spindle should initially be rotated fully out and the device then pushed
onto a nipple until the sliding sleeve engages. The spindle can be
rotated inward to push back the sealing pin of the nipple and open the
seal. The pressure behind the nipple will then be relieved; a drop of oil
may escape during this operation. The pressure relieving device can be
removed again by pushing back the sliding sleeve.
D-8
Appendix
152841
Pressure gauge
Design
Pressure gauge, branch tee, 2 connections (A = nipple, B = socket)
Function
The branch tee can be interposed at any desired point or connected close to a
measuring point to allow pressure measurement. The pressure causes a spiral
Bourdon tube to open out. This motion is applied to the pointer of the pressure
gauge. The position of the pointer is therefore proportional to the pressure applied.
Note
The pressure gauge has a glycerine filled to protect it against impacts, condensation
and the entry of water during cleaning.
Technical data
Festo Didactic GmbH & Co., 11/2000
Hydraulic
Medium
Mineral oil, recommended viscosity 22 cSt (mm/s)
Accuracy
1,6 % of full-scale value
Indicating range
10 MPa (100 bar)
Operating pressure
Static:
3/4 of full-scale value
Dynamic:
2/3 of full-scale value
Damping fluid
Glycerine
Actuation
Hydraulic via a spiral Bourdon tube
Connections
For coupling nipple/socket
Subject to change
1/1
152843
3
B 4
Design
Valve housing (1), rotary knob (2), throttle valve (3), valve seat (4), sealing ball (5),
spring (6), nipple (A), socket (B).
Function
A one-way flow control valve is a combination of a throttle valve and non-return

valve. In the flow direction from A to B, the hydraulic fluid flows only through the
throttle point (3), the size of which is adjustable by means of the rotary knob (2). The
valve seat (4) is closed by the sealing ball (5) and the spring (6). In the opposite
direction, the non-return valve is open and the full flow cross-section is available.
Note
The valve ports identified by letters A and B are the working ports.
Subject to change
1/2
152843
10
15
20
25
n : 30 cSt
J : 46 C
p (MPa)
27
qV : A B
5
4
28
3
2
30
40
0
0
qV (l/min)
Pressure-drop/flow-rate characteristic for various rotary-knob settings
Technical data
2/2
Hydraulic
Medium
Operating pressure p
6 MPa (60 bar)
Max. permissible pressure pmax
12 MPa (120 bar)
Nominal flow rate
9 l/min
Opening pressure
70 kPa (0.7 bar)
Actuation
Manual
Connections
Subject to change
152845, 152846
2 1
Design
Housing (1), sealing ball (2), spring (3), nipple (A), socket (B)
Function
A non-return valve prevents flow in one direction, while allowing free flow in the
opposite direction. In the closed position, the spring (3) presses the sealing ball (2)
onto the valve seat. Flow begins when the pressure in the flow direction exceeds a
value of approx. 1 bar or 5 bar. The sealing ball (2) is then lifted off the valve seat
against the force of the spring (3).
Note
Circuits must always be depressurised before a non-return valve is coupled up. It is

not possible in this case to release pressure by means of the pressure relief device
(Order no. 152971).
Subject to change
1/2
152845, 152846
0.9
n : 30 cSt
J : 42 C
p (MPa)
5 bar
0.7
0.6
0.5
0.4
0.3
0.2
1 bar
0.1
0
Pressure-drop/flow-rate characteristic
Technical data
2/2
Hydraulic
152845
Medium
6 MPa (60 bar)
12 MPa (120 bar)
Opening pressure
0.1 MPa (1 bar)
Actuation
Hydraulic
Connections
Subject to change
152846
0.5 MPa (5 bar)
152847
Branch tee
3
1
Design
Branch tee with 3 connections (1 = socket, 2 and 3 = nipples).
Function
This component can be fitted at any desired point to create a branch.
0.6
n : 30 cSt
J : 53 C
a :12/13
p (MPa)
0.4
b :31/21
c :23/32
0.3
b
c
0.2
0.1
0
qV (l/min) 8
Technical data
Hydraulic
Medium
6 MPa (60 bar)
12 MPa (120 bar)
Connections
Subject to change
1/1
152848
Pressure relief valve, Pressure sequence valve
P
1 2
Design
The pressure relief valve is mounted on a function plate equipped with two quick
coupling connectors. The component is fitted to the grid system of the slotted
assembly board by means of the two blue levers (mounting variant A).
The valve consists of:
Sealing cone (1), valve seat (2), spring (3), rotary
knob (4), lock nut (5), screw spindle (6), spring disc (7),
cushioning piston (8).
Function
Used as a pressure-relief valve, this valve limits the pressure at port P and any
excess oil is discharged into the tank.
In the form of a pressure sequence valve, it connects the consuming devices at port
T once the pressure set at P has been reached.
This valve is normally closed. If the force from the differential pressure of port P and
T, times the front surface area of the piston, is greater than the spring force, the
sealing cone (1) lifts off the valve seat (2), and the hydraulic fluid is discharged via
port T. The valve closes again once the pressure at port P diminishes. The
cushioning piston, similar to a shock absorber, ensures greater stability.
Festo Didactic GmbH & Co. KG, 04/2003
Subject to change
1/2
152848
Pressure relief valve, Pressure sequence valve
7
: 22 cSt
: 35 C
p (MPa)
5
4
3
2
1
0
qV (l/min)
Pressure/flow-rate characteristic for various rotary-knob settings
Note
Technical data
2/2
The valve ports are identified by letters.

P
Supply port
T
Return-line port (tank connection)
Hydraulic
Medium
60 bar (6 MPa )
120 bar (12 Mpa)
Adjustment
Manual
Actuation
Hydraulic
Connections
Via 2 coupling sockets
Subject to change
152851
P
8
Design
The 2-way flow control valve is mounted on a function plate equipped with 2 quick
The valve consists of:
Control piston (1), spring (2), adjustable spindle
throttle point (3), adjusting spindle (4), rotary knob (5),
lock nut (6), control piston throttle point (7),
pilot hole (8).
Function
The flow control valve ensures a regular volumetric flow independent of the load
pressure of the consuming device.
Pressure is applied to the working piston (1) on the spring chamber side via a
cushioning throttle. At the same time, oil flows from port P via the adjustable flow
control valve to the other side of the piston and from there via a hole to connection
A. The pressure downstream of the adjustable throttle point is less than the
pressure at port P and therefore also less than the pressure in the
Subject to change
1/2
152851
spring chamber. As a result of this the piston is pushed against the spring force to
the right and restricts the discharge to port A. The differential pressure between port
P and the pressure downstream of the adjustable flow control valve thereby remains
constant and the volumetric flow rate flowing via the flow control valve constant.
6
: 22 cSt
: 35 C
qV (l/min)
4
3
2
1
0
0.5 1.0 1.5
2.0
2.5 3.0
3.5 4.0 4.5 5.0 5.5
p (MPa) 7.0
Flow-rate/pressure-drop characteristic for various rotary-knob settings
Note
Technical data
2/2

P
Supply port
A
Working port
Hydraulic
Medium
60 bar (6 Mpa)
120 bar (12 Mpa bar)
Adjustment
Manual
Actuation
Hydraulic
Connections
via 2 coupling sockets
Subject to change
152852
Design
This hydraulically piloted non-return valve is mounted on a function plate equipped

with three connection nipples. The component is fitted to the grid system of the
profile plate by means of the two blue levers (mounting variant A).
The valve consists of the following: Housing (1), release piston (2), valve seat (3),
sealing cone (4), spring (5), cartridge
housing (6).
Function
A hydraulically piloted non-return valve is used when a hermetic seal is required in

one direction. In contrast to the case of a normal non-return valve, it is possible with
this valve to enable flow in the non-return direction by applying pressure at port X.
Subject to change
1/4
152852
The sealing cone (4) is pressed lightly against the tapered seat (3) by the spring (5).
As soon as the pressure at port A becomes even slightly higher than that at port B,
the sealing cone (4) moves away from its seat and opens the way from port A to port
B. Flow in the opposite direction is closed by the sealing cone (4), which is pressed
against the tapered seat by the spring force and also the higher pressure at port B,
thus blocking flow. This part of the valve behaves like a normal non-return valve.
In order to enable flow in the non-return direction, the pressure at port X must be
higher in accordance with the ratio of the areas of the tapered seat (3) and the
release piston (2). The release piston (2) will then open the sealing cone (4).
1.4
: 22 cSt
: 30 C
p (MPa)
1.0
0.8
0.6
0.4
0.2
0
qV (l/min)
A}B
B } A pressurised to X
A } B pressurised to X
Note
The valve ports are identified by letters:

A, B Working ports
X
Pilot port
Difficulty may be experienced making connections to port B using quick couplings. In
one coupling operation, it is necessary to displace fluid behind the coupling nipple.
However, the fluid is not able to drain away due to the hermetic seal of the nonreturn valve.
The remedy is as follows: Pressurise port X to a very low level of approx. 0.5 Mpa.
This will release the non-return valve, and the quick coupling socket can now be
connected to port B without difficulty.
2/4
Subject to change
152852
Technical data
Hydraulic
Medium
6 MPa (60 bar)
12 MPa (120 bar)
Actuation
Hydraulic (3.3 : 1)
Connections
For 3 coupling sockets
Subject to change
3/4
4/4
Subject to change
152857, 184489, 184488

Cylinder 16/10/200, 16/10/300, 16/10/400
1 2
13 12
11
4 5 6
10
8 7
Design
This double-acting cylinder is equipped with a switching cam and two barbed fittings
and is mounted on a mounting plate. The unit is secured to the profile panel by the
twist-lock system using two blue finger nuts (mounting variant B).
The cylinder consists of: Piston (1), piston seal and guide (2), piston rod (3),
piston rod bearing (4), piston rod seal (5), scraper
ring (6), cylinder cap (7), connections (8 and 13), cylinder
barrel (9), piston rod chamber (10), piston chamber (11),
cylinder base (12).
Function
The piston chamber (11) is pressurised via connection (13). The action of the
pressure on the piston surface produces a force which sets the piston in motion.
This causes oil to be displaced from the piston rod chamber; the oil is discharged via
connection (8). In order to retract the piston again, the piston rod chamber (10) is
pressurised via connection (8). The displaced oil is discharged in this case via
connection (13). The piston seal (2) acts as a divider between the two chambers,
while the piston guide supports the piston. The piston rod seal (5) provides a seal
between the piston rod chamber (10) and the surrounding environment. The scraper
ring (6) keeps the rod seal (5) free of contamination. The piston rod bearing (4)
guides and supports the piston rod.
Subject to change
1/2
152857, 184489, 184488

Cylinder 16/10/200, 16/10/300, 16/10/400
Note
Technical data
2/2
If the cylinder is used in conjunction with the weight (Order no. 152972), ensure that
the cylinder is fully secured. For additional safety, the cover (Order no. 152973) can
be used with the cylinder (Order no. 152857).
Cylinder version (Order no.)
152857
Medium
Piston diameter
16 mm
Piston rod diameter
10 mm, with M 8
Stroke
200 mm
6 MPa (60 bar)
12 MPa (120 bar)
Connections
To accept 2 connector sockets
Subject to change
184489
300 mm
184488
400 mm
152858
Hydraulic motor
simplified symbol
Design
This hydraulic motor is mounted on a mounting plate. The component is fitted to the
profile plate using the rotary system by means of two blue grip nuts (mounting
variant B).
Subject to change
1/3
152858
Hydraulic motor
5
6
7
The motor consists of:
Function
2/3
Housing with control ducts (1), fixed, internal gear (2),

connections (3), shuttle valve (4), external gear (5),
cardan shaft (6), shaft with collector part (7).
The direction of rotation changes with the flow direction. The hydraulic fluid is
supplied at one of the connections. The external gear (5) is hereby placed into
rotation and drives the shaft (7) via the cardan shaft (6). The alternate supply and
discharge of the volumetric flow rate is controlled via the collector and the control
ducts of the housing. The leakage in the motor is fed to the low pressure connection
(3) via the shuttle valve (4).
Subject to change
152858
Hydraulic motor
Note
The flow-rate/rotary-speed indicator PN 183736 can be attached using the top

cheese-head bolt. Before doing this, however, screw the coupling adapter into the
end of the shaft.
qV=1 l/min
qV=2 l/min
qV=4 l/min
10
M (Nm)
8
qV=12 l/min
qV=16 l/min
N=1,5 kW
1 kW
0,5 kW
,p (MPa)
7
73%
6
4
0,25 kW
65%
nt = 55%
qV=8 l/min
250
500
750
70%
3
1000
1250
1500
-1
n (min )
2000
Torque/rotary-speed characteristic
Technical data
Hydraulic
Medium
Design
Orbital
Geometric displacement
8.2 cm
6 MPa (60 bar)
12 MPa (120 bar)
Max. permissible pressure in return line
5 MPa (50 bar)
pR max
-1
Max. rotary speed nmax
1950 min
Output shaft with spring
16 x 28, A5 x 5 DIN 6885
Max. permissible shaft load
radial:
axial:
Connections
For 2 coupling sockets
Subject to change
1600 N
800 N
3/3
152960, 152970, 159386, 158352

Hose line with quick release coupling (600, 1000, 1500, 3000 mm)
3
2
1
Design
Coupling socket (1), fitting (2), high-pressure hose (3), braided wire (4), inner hose
(5), cover sheath (6).
The high-pressure hose (3) is of 3-ply design. The inner hose (5) is made of synthetic
rubber, the 2nd ply of braided wire (4) and the cover sheath (6) of abrasion-resistant
synthetic rubber.
Function
The two coupling sockets (1) are self-closing when uncoupled. These sockets
provide a leakproof hydraulic connection in conjunction with the coupling nipple (7).
To make a connection, the coupling socket (1) is pushed onto the nipple until the
sliding sleeve (8) snaps forward. This sleeve is pulled back to separate the
connection. The coupling socket will then spring away from the nipple. Only the front
faces of the couplings come into contact with hydraulic fluid during the coupling
operation.
Subject to change
1/3
152960, 152970, 159386, 158352

Notes
Carry out coupling and decoupling only at zero pressure.

In order to obtain a long service life with the hose lines, ensure that they are not
twisted while assembling circuits and observe the specified minimum bending
radius and operating temperature.
The storage and use of hose lines are governed by the following safety regulations:
The maximum storage time is 4 years for hoses without fittings and 2 years for
hoses with fittings.
Hose lines should not be used for longer than 6 years, including a storage
period of a maximum of 2 years.
Hoses are marked with their date of production (quarter and year) e.g.: 1 Q 92.
Hose line fittings are marked with their date of production (month and year)
e.g.: 10 93.
Fittings (2) are stamped with their maximum operating pressure.
0.6
n : 30 cSt
p (MPa)
J : 42C
0.4
0.3
0.2
0.1
0
0
3000 mm
600 mm 1500 mm
qV (l/min)
Pressure/flow-rate characteristic
2/3
Subject to change
152960, 152970, 159386, 158352

Technical data
Type of Hose (Order No.)
152960
152970
Medium
Hose length
600 mm
Nominal size
6 mm
6 MPa (60 bar)
12 MPa (120 bar)
Temperature range
-40 +125 C
Bending radius, min.
100 mm
Connections
For 2 coupling nipples
1000 mm
Subject to change
159386
1500 mm
158352
3000 mm
3/3
152962, 159328
Hydraulic power pack 2 l/min
3 4 5
TS
13
Design
12
11
10
The power supply unit is fitted on a flange. The device is mounted on the profile
plate or another fixture by means of profile connectors (mounting variant C).
(1) Power supply plug,(2) ON/OFF switch, (3) Pressure port P, (4) Pressure-relief
valve, (5) Tank connection T, (6) Pressure gauge, (7) Tank connection (blue) for
reservoir TS, (8) Drain screw, (9) Tank, (10) Sight glass for level indicator, (11)
Flange, (12) Capacitor, (13) Electric motor.
14
15
16
13
Function
11
The hydraulic power pack converts electrical energy into hydraulic drive power. The
electric motor (13) drives a gear pump (14). The oil is fed from the tank (9) via the
suction pipe (15) and applied at pressure port.
The pressure can be read from the pressure gauge (6). The pump delivers a virtually
constant flow rate.
Subject to change
1/4
152962, 159328
The maximum pressure value is set by means of the pressure relief valve (4). This
pressure can only be maintained up to the maximum delivery rate of the pump. If the
connected hydraulic circuit requires a higher flow rate, the pressure will fail. The
pressure prevailing at this point adapts itself to the flow resistance of the connected
circuit, whereby the flow rate e.g. on a pump by-pass circuit, return at low pressure.
The return flow is effected via the tank connection T (5) through the return filter (16)
into the tank (9). A blue quick coupling socket (7) has been provided for the return
flow from the pressure reservoir. The filling level can be read from the sight
glass (10).
Commissioning
The hydraulic power pack is supplied without oil. The tank is to be filled with approx.
5 l of hydraulic oil before the initial switching on of the power pack. To fill the tank,
the air filter must be unscrewed. The air filter must not be replaced by a blanking
plug.
Holes have been drilled on three sides of the flange (11), whereby the power pack
can be installed in various positions. Profile connectors are used for mounting.
Three assembly positions are possible:
Positions
Description
Vertical, electric motor facing upwards.
Horizontal, pressure gauge facing upwards.
Horizontal, pressure gauge on side with connection T facing

downwards.
Caution!
In this assembly position, the filling level cannot be read from the
sight glass.
The power pack is connected to the power supply plug (1) by means of an extension
line. The power pack is switched on by means of pressing the green button and
switched off via the red button.
In the filled status, the power pack must always be positioned in such a way that the
pressurising/venting screw (red) is above the oil level.
2/4
Subject to change
152962, 159328
Note
The power pack must be operated using the pressurising/venting screw (red).
Caution!
Failing this, the tank may burst.
Regularly check the oil level. The pump must not run dry.
If an initial start-up of devices takes place, the oil level in the tank is reduced as a
result of the displacement. If the oil level can no longer be seen in the sight
glass (10), the hydraulic oil must be topped up until the level is visible.
The power pack is designed for a 50% duty cycle. If continuous operation is
required, an external oil cooler is to be used.
If the thermostatic switch of the electric motor is triggered, the red off switch
must be actuated after a cooling phase and after checking and eliminating the
cause. Normal operation can be re-started following this.
The hydraulic power pack is not suitable for the connection of a flow measuring
container order no. 162344.
If the hydraulic power pack is moved, carried or transported on a trolley, this can
lead to sloshing in the tank. This may cause a small quantity of oil to escape via
the air filter.
If the hydraulic power pack is incorrectly installed, whereby the air filter is below
the oil level, the tank will discharge, added to which the pump may run dry.
An increase in the flow rate by means of interconnecting several hydraulic power
packs is not feasible, since it is not possible to compensate the various filling
levels inside the tanks.
Subject to change
3/4
152962, 159328
Technical data
Electrical
152962
159328
Motor
AC current, single-phase, convection-cooled
Nominal power rating
650 W
550 W
Nominal voltage
230 V
110 V
Nominal current
3.1 A
8.4 A
Frequency
50 Hz
60 Hz
Nominal speed
1320 rpm
1680 rpm
Protection class
IP20
Duty cycle
50%
Actuation
Manual via ON/OFF switch
Connection
Power supply plug to DIN 49441/CEE7 with additional earthing

system.
Hydraulic
152962
159328
Medium
Mineral oil, recommended viscosity 22 cSt (mm /s)
Pump design
External gear pump
Volumetric delivery rate
1.6 cm
1.3 cm
Delivery rate at nominal speed
2.2 l/min
2.3 l/min
Operating pressure
0.5 6 MPa (5 60 bar)
Setting
Manual
Pressure gauge Indicating range
0 10 MPa (0 100 bar)
Pressure gauge accuracy class
1.6
Oil tank capacity
approx. 5 l
Return filter, grade of filtration
90 m
Connections
One quick coupling socket for P and T, one coupling for tank line
of reservoir (order no. 152859).
Mechanical
Dimensions
Weight
Length
Width
580 mm
300 mm
Height
180 mm
empty
19 kg
filled with oil 24 kg
4/4
Subject to change
152972
Design
Steel block, painted, with castors and locking device, rod eye and clevis.
Function
Applying loads to a cylinder.

The weight is locked into a profile groove by turning it through 90.
It can then be attached to the piston rod of the cylinder using the rod eye and clevis.
Note
Observe general safety rules. Use the protective cover order no. 152973.
Technical data
Mechanical
Mass
9 kg
Dimensions
Length
Width
Height
Subject to change
150 mm
100 mm
80 mm
1/1
162241
Relay, 3-off
Design
This component consists of three relays with connections and two bus-bars for the
power supply. All electrical connections are in the form of 4 mm sockets. The unit
can be mounted in a mounting frame or on the profile plate using four plug-in
adapters.
1
4
5
A1 A2
Function
4 2
The relay consists of a coil with a core (1) and winding (3) with connection lugs (7),
an armature (4), a return spring (2) and a contact assembly with four changeover
contacts (5) and connection lugs (6). When power is applied to the coil connections,
current flows through the winding, creating a magnetic field. The armature is pulled
onto the coil core and the contact assembly is actuated. Electrical circuits are
opened or closed via this assembly.
When the electrical current is removed, the magnetic field collapses and the
armature and contact assembly are returned to their original position by a return
spring.
Subject to change
1/4
162241
Relay, 3-off
A1
14
24
34
44
11
21
31
41
1
A2
A1
12
22
32
42
2
A2
A1
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
3
A2
Note
2/4
The switching status of the relays is indicated by LEDs, which are protected against
incorrect polarity.
The four changeover contacts of the contact assembly can be used as normally-open
contacts (1), normally-closed contacts (2) or changeover contacts (3).
Subject to change
162241
Relay, 3-off
= Normally-open contact
2
S = START push-button
Example of application: Circuit diagram, electrical
+24V-
2
13
12
14
K
14
11
A1
Y
A2
2
Example of application: Practical assembly, electrical
A1
12
14
A1
12
14
K
A2
11
Changeover switch
connected as n.o. contact
A2
11
Changeover switch
connected as n.c. contact
Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate
Subject to change
3/4
162241
Relay, 3-off
Technical data
Electrical
Voltage
24 V DC
Contact assembly
4 changeover contacts
Contact rating
Max. 5 A
Contact interrupt rating
Max. 90 W
Pichup time
10 ms
Drop-off time
8 ms
Connections
For 4 mm safety connector plug
Electromagnetic compatibility
4/4
Emitted interference
tested to EN 500 81-1
Noise immunity
Subject to change
162242
Signal input plate,electrical
13
14
11
S
12
13
14
11
S
12
Design
This component consists of two illuminated pushbuttons in the form of momentarycontact switches and one illuminated pushbutton in the form of a detented switch.
All electrical connections are in the form of 4 mm safety connectors. The unit can be
mounted in a mounting frame or on the profile plate using four plug-in adapters.
Function
The illuminated pushbutton in the form of a detented switch consists of a contact

assembly with two normally-open contacts and two normally-closed contacts,
together with a colourless transparent pushbutton cap with a miniature lamp. The
contact assembly is actuated by pressing this cap. Electrical circuits are opened or
closed via the contact assembly. When the cap is released, the switching status is
maintained. The contact assembly is returned to its initial position by pressing the
pushbutton a second time.
The illuminated pushbuttons in the form of momentary-contact switches consist of
a contact assembly with two normally-open contacts and two normally-closed
contacts, together with a colourless transparent pushbutton cap with a miniature
lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are
opened or closed via the contact assembly. When the cap is released, the contact
assembly returns to its initial position.
Note
When power is applied to the connections of the visual indicator, the switching
status is displayed by the built-in miniature lamp in the pushbuttons.
Subject to change
1/3
162242
2
+24V-
2
13
12
14
K
11
14
A1
Y
A2
2/3
Subject to change
162242
A1
12
14
A1
12
14
K
A2
A2
11
Changeover switch
connected as n.o. contact
11
Changeover switch
connected as n.c. contact
Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate
Technical data
Electrical
Voltage
24 V DC
Contact assembly
2 normally-open contacts, 2 normally-closed contacts
Contact rating
Max. 1 A
Power consumption (miniature lamp)
0.48 W
Connections
Noise immunity
Subject to change
3/3
162244
Indicator and distributor plate, electrical
Design
This component consists of an acoustic indicator and four visual indicators with
connections and three busbars for the power supply. All electrical connections are in
the form of 4 mm safety connectors. The unit can be mounted in a mounting frame or
on the profile plate using four plug-in adapters.
Function
The acoustic indicator outputs a buzzing tone when power is applied to its
connections.
The visual indicator consists of a housing and a colourless transparent cap with a
miniature lamp. When power is applied to its connections, its operating status is
indicated by the built-in miniature lamp. A bridged pair of sockets is provided for
each lamp, allowing the component to be used also as a distributor.
Note
To ensure that the acoustic indicator operates correctly, check the polarity of the
power supply.
Subject to change
1/2
162244
Indicator and distributor plate, electrical
H1
H2
2
+24V-
2
13
12
14
K
11
14
A1
H1
H2
A2
Technical data
Electrical
Voltage
24 V DC
Power consumption (acoustic indicator)
0.04 W
Visual indicator
1.2 W
Frequency (acoustic indicator)
420 Hz
Connection
2/2
Noise immunity
Subject to change
167080
Pressure switch
1/1
Design
The pressure switch is attached to a branch tee. The three electrical connections are equipped with safety connectors.
Housing (1), diaphragm (2), spring (3), spindle (4),
microswitch (5) and connector socket (6).
Function
When pressure is applied to the diaphragm (2), this expands
against the spring (3) and actuates the microswitch (5). The initial
tension of the spring (3) can be adjusted by means of the spindle
(4), thus also varying the pressure required to stretch the diaphragm (2). Once the pressure value corresponding to the spindle
setting is reached, the contact of the microswitch (5) is actuated.
Note
The branch tee with attached pressure switch can be interposed at any desired
point in the hydraulic circuit or fitted close to a measuring or reference point.
Medium
Mineral oil,
recommended viscosity 22 cSt (mm2/s)
Design
Diaphragm switch
1 - 7 MPa (10-70 bar)
12 MPa (120 bar)
Hysteresis
~15%
Voltage
Up to 250 V
Max. continuous load rating
2A
Connections, hydraulic
For coupling sockets/nipples
Connections, elektrical
Adjustment
Manuel, using 2.5 mm Allen key
Actuation
Hydraulic
Subject to change
Festo Didactic
Technical data
Festo Didactic
167082
Y1
Y1
8 9
T
6
Design
The 4/2-way solenoid valve is mounted on a function plate equipped with four quick
The valve consists of: Piston (1), housing (2), spring (3), solenoid coil (4),
plunger (5), emergency manual override (6), nut (7),
stem (8) spring disc (9).
Subject to change
1/4
167082
Function
This directional control valve comprises two switching positions for the control of
flow rates. It is directly actuated via a DC solenoid coil. Characteristic of this valve is
the spring return normal position.
The valve is shown in its normal position in the sectional view, whereby ports P and
A as well as ports B and T are connected. The piston (1) is clamped in the housing
between the springs and spring discs when the solenoid is de-energised. If voltage is
applied to the solenoid coil Y1 (4), the plunger (5) presses the piston (1) against the
opposite spring via the stem (8), thereby connecting port P to B and port A to T. The
switching solenoid consists of a pressure tube, the push-on coil body is attached via
the nut (7) and the stem (8). The electrical connection is effected via a valve plug
socket.
An emergency manual override (9) facilitates actuation without electrical energy.
1.4
: 22 cSt
: 35 C
p (MPa)
1.0
0.8
0.6
0.4
0.2
0
qV (l/min)
P}B}A}T
P}A}B}T
2/4
Subject to change
167082
Note

A, B Working ports
P
Supply port
T
The electrical connections are protected against overvoltage. The switching status is
indicated by an LED.
The manual override must not be actuated by means of sharped-edged objects (e.g.
screwdrivers) so that its smooth operation and leak-proofness is maintained. A stiff
manual override may result in malfunction of the solenoid valve.
Technical data
Hydraulic
Medium
60 bar (6 Mpa)
120 bar (12 Mpa)
Voltage
24 V DC
Power rating
6.5 W
Actuation
Electrical
Connections, electrical
Via 4 mm safety connector plug
Subject to change
3/4
4/4
Subject to change
167083
4/3-way solenoid valve, closed in mid-position
Y1
Y2
Y1
Y2
10
T
8
Design
The 4/3-way solenoid valve is mounted on a function plate equipped with four quick
The valve consists of: Piston (1), housing (2), spring (3), solenoid coil (4),
plunger (5), spring disc (6), stem (7), emergency
manual override (8), nut (9), pressure tube (10).
Subject to change
1/4
167083
Function
This directional control valve comprises 3 switching positions for the control of flow
rates and is directly actuated via DC solenoid coils. Characteristic of this valve is its
mid-position, whereby ports A, B, P and T are closed.
The valve is shown in its mid-position in the sectional view. The valve assumes this
position via the two compression springs, if neither of the two solenoids are
energised (spring force). By applying voltage (energising) to the solenoid coil Y2 (4),
the plunger (5) presses the piston (1) against the spring opposite via the stem. This
causes port P to be connected to port A via the annular groove of the piston (1) and
port B simultaneously to port T via the second annular groove.
By energising the solenoid coil Y1, the piston is pushed into the opposite direction.
This causes port P to be connected to port B via the annular groove of the piston (1)
and port A to port T via the second annular groove.
The switching solenoid consists of the pressure tube (10), the push-on coil body
which is attached by means of the nut (9) and the stem (7). The electrical connection
is effected via a valve plug socket.
An emergency manual override (8) also facilitates actuation without electrical
energy.
1.6
: 22 cSt
: 35 C
qV : P } B } A } T
p (MPa)
1.2
1.0
0.8
0.6
0.4
0.2
0
qV (l/min)
2/4
167083
Note

A, B Working ports
P
Supply port
T
The electrical connections are protected against overvoltage. The switching status is
indicated by an LED.
The emergency manual override must not be actuated by means of sharp-edged
objects (e.g. screwdriver) so that its smooth operation and leak-proofness are
maintained. A stiff manual override may result in malfunction of the solenoid valve.
Technical data
Hydraulic
Medium
60 bar (6 Mpa)
120 bar (12 Mpa)
Voltage
24 V DC
Power rating
6.5 W
Actuation
Electrical
Connections, electrical
Via 4 mm safety connector plug
Subject to change
3/4
4/4
183322
4
1
2 4
2
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic

housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant B).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.
The switch contacts are used to open or close a circuit. The microswitch returns to
its original position when the roller lever is released.
Note
The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds
are high, the limit switch should be actuated by the trip cam of a cylinder only in the
specified direction. The limit switch must not be actuated from the front.
Subject to change
1/2
183322
Technical data
Electrical
Design
Mechanically-actuated electrical microswitch in limit-switch

housing
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
Reproducible switching accuracy
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
For 4 mm safety connector plug or 3-pin plug socket
2/2
Noise immunity
Subject to change
183345
4
1
2 4
2
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic

housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant B).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.
The switch contacts are used to open or close a circuit. The microswitch returns to
its original position when the roller lever is released.
Note
The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds
are high, the limit switch should be actuated by the trip cam of a cylinder only in the
specified direction. The limit switch must not be actuated from the front.
Subject to change
1/2
183345
Technical data
Electrical
Design
Mechanically-actuated electrical microswitch in limit-switch

housing
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
Reproducible switching accuracy
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
For 4 mm safety connector plug or 3-pin plug socket
2/2
Noise immunity
Subject to change

WB Electrohidrúalica Basica

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Electrohydraulics

Authorised applications and liability

TP601 Festo Didactic

T Basic Packages provide fundamental knowledge which is not limited

T Technology Packages deal with the important areas of open-loop and

T Function Packages explain the basic functions of automation systems.

TP601 Festo Didactic

The modular structure of the Learning System permits applications to be

The hardware consists of industrial components and installations,

T Textbooks (with exercises and examples)

T OHP transparencies, electronic transparencies for PCs and videos

TP601 Festo Didactic

Latest information about the technology package TP601.

T Industrial components on the profile plate.

T Training of team skills, willingness to co-operate, willingness to learn,

Reference to the text book

Function diagrams, circuits, descriptions of

Storage tray, mounting technology

TP601 Festo Didactic

TP601 Festo Didactic

Training aims/exercise table (Table 1)

Equipment set for Basic Level TP 601

Equipment set for Advanced Level TP 602

List of additional components for TP600

Component/exercise table (Table 2)

Methodological structure of exercises

Exercise 2: Component selection on conveyor belt

Exercise 3: Lifting station

Exercise 4: Bending device

Exercise 5: Press-fitting device

TP601 Festo Didactic

Exercise 6: Stamping machine

Exercise 7: Door control

Control circuits with limit switches

Exercise 9: Feed for drilling machine

Exercise 10: Press

Exercise 11: Feed device

Control circuits with two actuators

Exercise 13: Lifting device for packages

TP601 Festo Didactic

2: Component selection on conveyor belt

9: Feed for drilling machine

Solution 10: Press

Solution 11: Feed device

Solution 12: Assembly device

Solution 13: Lifting device for packages

TP601 Festo Didactic

TP601 Festo Didactic

A Festo Didactic profile plate or a laboratory trolley

The Training Package TP 601 specifies fundamental training contents.

T Physical interrelationships in electrical engineering and hydraulics

T Comparison of the use of various valves and other components

TP601 Festo Didactic

The technical requirements for safe operation of the components are as

T A hydraulic power pack to provide an operating pressure between

T A profile plate to mount the components

T Electrohydraulics Basic Level

Sets of OHP transparencies and electronic transparencies for PCs

TP601 Festo Didactic

T Do not operate electrical limit switches directly by hand when carrying

T Use only an extra-low voltage of 24 to operate the components.

TP601 Festo Didactic

TP601 Festo Didactic