Basic Level
Workbook TP 601
Festo Didactic
094470 en
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.
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 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
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Hardware
Courseware
Software
Courses
Content
Part A
Course
Exercises
Part B
Fundamentals
Part C
Solutions
Part D
Appendix
Table of contents
Introduction
11
Notes on safety
13
Notes on operation
14
Technical notes
15
Training contents
21
22
23
26
27
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29
Part A Course
Simple control circuits without limit switches
Exercise 1: Sorting device
Double-acting cylinder,
directly actuated, manually
A-3
A-13
A-23
A-29
A-33
A-39
A-43
A-49
A-53
A-59
A-63
A-69
A-75
Part B Fundamentals
Teil C Solutions
Solution
1: Sorting device
C-3
Solution
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
C-39
C-45
C-49
C-55
C-61
Part D Appendix
Storage tray
D-2
Mounting systems
D-3
Sub-base
D-5
Coupling system
D-6
Data sheets
...
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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:
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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:
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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.
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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.
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 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 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
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
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
20
Electrical
Power supply:
230 VAC, 50 Hz
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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:
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)
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Advanced Level
(TP602)
22
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
23
Order No.
Qty.
Pressure gauge
152841
152843
152845
152846
Branch tee
152847
152848
152851
152852
152857
152858
Loading weight, 9 kg
152972
Relay, 3-fold*
162241
162242
162244
167082
167083
183322
183345
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.
24
Symbols for
equipment setTP 601
Pressure gauge
Weight, 9 kg
Relay, 3-fold
25
Symbols for
equipment setTP 601
26
Description
Order-No.
Qty.
Relay, 3-fold*
162241
162243
162355
162244
Pressure switch
167080
Branch tee
152847
152849
152850
167082
152857
152859
183347
178574
178575
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
Order-No.
120778
Throttle valve
152842
Shut-off valve
152844
152960
152962
152970
152971
152973
158352
159386
159396
159411
162417
167081
167084
167085
167091
Coupling nipple
342047
Coupling socket
346491
TP602
Additional
components
28
Exercise
1
10 11 12 13
Pressure gauge
Relay, 3-fold
Signal input unit, electrical
1
1
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.
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30
A-1
Part A Course
Simple control circuits without limit switches
Exercise 1: Sorting device
Double-acting cylinder,
directly actuated, manually
A-3
A-13
A-23
A-29
A-33
A-39
A-43
A-2
A-49
A-53
A-59
A-63
A-69
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
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Training aims
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Problem definition
A-4
Exercise 1
Exercise
Fig. 1/1:
Positional sketch
A-5
Exercise 1
WORKSHEET
A-6
Exercise 1
A-7
Exercise 1
WORKSHEET
1.
2.
3.
4.
5.
A-8
Exercise 1
Fig. 1/5:
Signal input unit;
front panel
A-9
Exercise 1
WORKSHEET
Description
Hydraulic power pack, 2 l/min
List of
hydraulic components
A-10
Exercise 1
Qty.
Description
Signal input unit, electrical
Cable set, universal with safety plugs
Power supply unit, 24V
A-11
Exercise 1
WORKSHEET
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
Title
Training aims
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Problem definition
A-14
Exercise 2
Exercise
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:
One-way flow control valve
B
4
6
1.
2.
3.
4.
5.
6.
A
B
A-16
Exercise 2
A-17
Exercise 2
WORKSHEET
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
Winding
Armature
Core
Changeover
contact assembly
Fig. 2/6:
Relay
A-20
Exercise 2
A-21
Exercise 2
WORKSHEET
Description
Hydraulic power pack, 2 l/min
Pressure gauge
Pressure relief valve
Branch tee
Hose line with quick-release coupling, 600 and 1000
List of
hydraulical components
A-22
Exercise 2
= Normally-closed contact
= Normally-closed contact
List of
electrical components
Qty.
Description
A-23
Exercise 3
Electrohydraulics
Subject
Lifting station
Title
Training aims
gle-acting cylinder
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Problem definition
Define the required components
Draw the hydraulic and electrical circuit diagrams
Label the connections
Number the components in the circuit assembly
Carry out practical assembly of the hydraulic and electrical control
circuits
Problem definition
A-24
Exercise 3
Exercise
Fig. 3/1:
Positional sketch
A-25
Exercise 3
WORKSHEET
4/2-way valve
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:
Circuit diagram, hydraulic
Description
Hydraulic power pack, 2 l/min
Pressure gauge
Loading weight, 9 kg
Branch tee
Hose line with quick-release coupling, 600 and 1000
List of
hydraulical components
A-28
Exercise 3
Qty.
Description
Relay, 3-fold
Signal input unit, electrical
Indicator and distributor unit, electrical
Cable set, universal with safety plugs
Power supply unit
A-29
Exercise 4
Electrohydraulics
Subject
Bending device
Title
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Training aims
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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
Description
List of
hydraulical components
A-32
Exercise 4
Description
S1
S2
K1
1Y
Qty.
Description
A-33
Exercise 5
Electrohydraulics
Subject
Press-fitting device
Title
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Training aims
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Problem definition
A-34
Exercise 5
Exercise
Fig. 5/1:
Positional sketch
A-35
Exercise 5
WORKSHEET
Time
Components
Step
Description
Code
Pushbutton
Status
ON
Cylinder
Fig. 5/2:
Function diagram
A-36
Exercise 5
Qty.
Description
A-37
Exercise 5
WORKSHEET
S1 = START pushbutton
1B = Pressure switch
Description
List of
electrical components
A-38
Exercise 5
What must you bear in mind when disconnecting hose lines fitted with
quick-acting couplings?
Yes
No
A-39
Exercise 6
Electrohydraulics
Subject
Stamping machine
Title
Training aims
acting cylinder
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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
Description
List of
hydraulical components
A-42
Exercise 6
S1 = START pushbutton
S2 = RETURN pushbutton
Qty.
Description
A-43
Exercise 7
Electrohydraulics
Subject
Door control
Title
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Training aims
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Problem definition
A-44
Exercise 7
Exercise
Fig. 7/1:
Positional sketch
A-45
Exercise 7
WORKSHEET
A-46
Exercise 7
Qty.
1
Description
A-47
Exercise 7
WORKSHEET
Description
List of
electrical components
A-48
Exercise 7
A-49
Exercise 8
Electrohydraulics
Subject
Machining unit
Title
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Training aims
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Problem definition
A-50
Exercise 8
Exercise
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
Description
List of
hydraulical components
A-52
Exercise 8
Qty.
Description
A-53
Exercise 9
Electrohydraulics
Subject
Title
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Training aims
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Problem definition
A-54
Exercise 9
Exercise
Fig. 9/1:
Positional sketch
Rapidtraverse
feed
Return
stroke
Working
feed
A-55
Exercise 9
WORKSHEET
START pushbutton
ON
RETURN pushbutton
Cylinder
4/2-way valve
2/2-way valve
A-56
Exercise 9
Qty.
Description
A-57
Exercise 9
WORKSHEET
Description
List of
electrical components
A-58
Exercise 9
What do these transparent models illustrate more clearly than the components mounted on the profile plate?
Yes
No
A-59
Exercise 10
Electrohydraulics
Subject
Press
Title
Training aims
switch
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T
Problem definition
A-60
Exercise 10
Exercise
Fig. 10/1:
Positional sketch
A-61
Exercise 10
WORKSHEET
Description
List of
hydraulical components
A-62
Exercise 10
S1 = START pushbutton
1S = Limit switch
1B = Pressure switch
Qty.
Description
A-63
Exercise 11
Electrohydraulics
Subject
Feed device
Title
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Training aims
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Problem definition
A-64
Exercise 11
Exercise
Fig. 11/1:
Positional sketch
A-65
Exercise 11
WORKSHEET
Time
Components
Step
Description
Code
Status
ON
S1 = START pushbutton
1S1, 1S2 = Limit switch
Fig. 11/2:
Function diagram
A-66
Exercise 11
Qty.
Description
A-67
Exercise 11
WORKSHEET
S1 = START pushbutton
1S1, 1S2 = Limit switches
Description
List of
electrical components
A-68
Exercise 11
How old is the equipment which you are using for training?
A-69
Exercise 12
Electrohydraulics
Subject
Assembly device
Title
Training aims
ently
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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
Time
Components
Step
Description
START pushbutton
Code
Status
ON
RETURN pushbutton
Cylinder
4/3-way valve
Motor
S1 = START pushbutton
S2 = RETURN pushbutton
1B = Pressure switch, p1 = 2.5 Mpa = 25 bar
Fig. 12/2:
Function diagram
A-72
Exercise 12
Qty.
Description
A-73
Exercise 12
WORKSHEET
A-74
Exercise 12
WORKSHEET
Qty.
Description
Author
Title
Publisher
A-75
Exercise 13
Electrohydraulics
Subject
Title
Training aims
cylinders
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Problem definition
A-76
Exercise 13
Exercise
Fig. 13/1:
Positional sketch
1A
A-77
Exercise 13
WORKSHEET
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
Qty.
Description
A-79
Exercise 13
WORKSHEET
A-80
Exercise 13
A-81
Exercise 13
WORKSHEET
A-82
Exercise 13
Qty.
Description
How do you remove the components from the profile plate or mounting
frame?
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
Simple control circuits without limit switches
Solution 1:
Solution 2:
Solution 3:
Solution 4:
Solution 5:
Solution 6:
Solution 7:
Sorting device
Double-acting cylinder,
directly actuated, manually
C-3
C-7
Lifting station
Single-acting cylinder,
directly actuated, manually
C-11
Bending device
Double-acting cylinder, latching
C-15
Press-fitting device
Double-acting cylinder, latching,
return stroke using pressure switch
C-19
Stamping machine
Double-acting cylinder,
differential circuit
C-23
Door control
Double-acting cylinder,
interlock, INCHING operation
C-27
C-2
Solution 9:
Solution 10:
Machining unit
Differential circuit,
return stroke using limit
C-33
C-39
Press
Pressure control circuit with limit switch
and pressure switch
C-45
Solution 13:
Feed device
Pressureless pump bypass with limit switch
C-49
Assembly device
Pressure-dependent sequence control with
cylinder and hydraulic motor
C-55
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.
C-5
Solution 1
Fig.1/3:
Practical assembly,
hydraulic
Item no.
Qty.
Description
0Z
1V
1A
Cylinder, 16/10/200
Components list,
hydraulic
C-6
Solution 1
Fig.1/4:
Practical assembly,
electrical
S = START pushbutton
Components list,
electrical
Qty.
Description
C-7
Solution 2
Fig.2/1:
Circuit diagram,
hydraulic
Fig.2/2:
Circuit diagram,
electrical
S1 = START pushbutton
= Normally-closed contact
= Normally-opened contact
C-8
Solution 2
Solution description
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
4.5 s
2.8 s
2.0 s
1.2 s
Fig.2/4:
Practical assembly,
electrical
S1 = START pushbutton
= 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
C-11
Solution 3
Lifting station
Fig.3/1:
Circuit diagram,
hydraulic
Fig.3/2:
Circuit diagram,
electrical
S1 = START pushbutton
C-12
Solution 3
Solution description
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
Loading weight, 9 kg
Branch tee
Description
Components list,
hydraulic
C-14
Solution 3
= 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
S1 = START pushbutton
S2 = RETURN pushbutton
C-16
Solution 4
Solution description
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
S1 = START pushbutton
S2 = RETURN pushbutton
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.
C-19
Solution 5
Press-fitting device
Fig.5/1:
Circuit diagram,
hydraulic
Fig.5/2:
Circuit diagram,
electrical
S1 = START pushbutton
1B = Pressure switch
C-20
Solution 5
Solution description
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
S1 = START pushbutton
1B = Pressure switch
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
S1 = START pushbutton
S2 = RETURN pushbutton
C-24
Solution 6
Solution description
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
S1 = START pushbutton
S2 = RETURN pushbutton
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
C-28
Solution 7
Solution description
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
Components list,
electrical
Qty.
Description
Relay, 3-fold
C-31
Solution 7
Alternative solution
Fig.7/5:
Alternative solution
Practical assembly,
hydraulic
C-32
Solution 7
Fig.7/6
Alternative solution
Practical assembly,
hydraulic
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.
Solution description
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
C-38
Solution 8
Components list,
electrical
Further work
Qty.
Description
Relay, 3-fold
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.
Solution description
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
+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
S1 = START pushbutton
1S = Limit switches
1B = Pressure switch
C-46
Solution 10
Solution description
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
3.
0V2
4.
0V1
5.
1B
Commissioning:
After switching on the electrical and hydraulic power supplies, press the
START pushbutton repeatedly to restore the circuit to its initial setting.
The following settings must be made:
1.
0Z1
2.
0V4
3.
0V2
4.
0V1
5.
1B
C-47
Solution 10
Fig.10/3:
Practical assembly,
hydraulic
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
S1 = START pushbutton
1S = Limit switches
1B = Pressure switch
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
S1 = START pushbutton
1S1, 1S2 = Limit switches
Fig.11/1:
Function diagram
C-50
Solution 11
Fig.11/2:
Circuit diagram,
hydraulic
Fig.11/3:
Circuit diagram,
electrical
S1 = START pushbutton
1S1, 1S2 = Limit switches
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.
Solution description
C-52
Solution 11
Fig.11/4:
Practical assembly,
hydraulic
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
S1 = START pushbutton
1S1, 1S2 = Limit switches
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
S1 = START pushbutton
S2 = RETURN pushbutton
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
S1 = START pushbutton
S2 = RETURN pushbutton
1B = Pressure switch
C-57
Solution 12
Solution description
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
Qty.
Description
Relay, 3-fold
Components list,
electrical
C-60
Solution 12
C-61
Solution 13
Lifting device for packages
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.13/1:
Function diagram
C-62
Solution 13
Fig.13/2:
Circuit diagram,
hydraulic
C-63
Solution 13
Fig.13/3:
Circuit diagram,
electrical
S = START pushbutton
1S1, 1S2 = Limit switches
2S1, 2S2 = Limit switches
C-64
Solution 13
Solution description
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
Qty.
Description
Relay, 3-fold
Components list,
electrical
C-66
Solution 13
Fig.13/5
Practical assembly,
hydraulic
S = START-pushbutton
1S1, 1S2 = Limit switches
2S1, 2S2 = Limit switches
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
152845, 152846
Branch tee
152847
152848
152851
152852
Cylinder, 16/10/200
152857
152858
152960, 152970
152962
152972
Relay, 3-fold
162241
162242
162244
Pressure switch
167080
167082
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:
Variant B:
Variant C:
Variant D:
The signal input unit and indicator and relay plates can also be mounted
in the mounting frame for ER units.
D-4
Appendix
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
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
Hydraulic
Medium
Accuracy
Indicating range
Operating pressure
Static:
Dynamic:
Damping fluid
Glycerine
Actuation
Connections
Subject to change
1/1
152843
One-way flow control valve
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
Note
The valve ports identified by letters A and B are the working ports.
Subject to change
1/2
152843
One-way flow control valve
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)
Technical data
2/2
Hydraulic
Medium
Operating pressure p
9 l/min
Opening pressure
Actuation
Manual
Connections
Subject to change
152845, 152846
Non-return valve, 1 bar, 5 bar
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
Subject to change
1/2
152845, 152846
Non-return valve, 1 bar, 5 bar
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
Operating pressure p
Opening pressure
Actuation
Hydraulic
Connections
Subject to change
152846
152847
Branch tee
3
1
Design
Function
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
Pressure-drop/flow-rate characteristic
Technical data
Hydraulic
Medium
Operating pressure p
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.
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)
Note
Technical data
2/2
Hydraulic
Medium
Operating pressure p
60 bar (6 MPa )
Adjustment
Manual
Actuation
Hydraulic
Connections
Subject to change
152851
2-way flow control valve
P
8
Design
The 2-way flow control valve is mounted on a function plate equipped with 2 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:
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
2-way flow control valve
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
2.0
2.5 3.0
p (MPa) 7.0
Note
Technical data
2/2
Hydraulic
Medium
Operating pressure p
60 bar (6 Mpa)
Adjustment
Manual
Actuation
Hydraulic
Connections
Subject to change
152852
Non-return valve, piloted
Design
Function
Subject to change
1/4
152852
Non-return valve, piloted
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
Pressure-drop/flow-rate characteristic
Note
2/4
Subject to change
152852
Non-return valve, piloted
Technical data
Hydraulic
Medium
Operating pressure p
Actuation
Hydraulic (3.3 : 1)
Connections
Subject to change
3/4
4/4
Subject to change
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
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).
152857
Medium
Piston diameter
16 mm
10 mm, with M 8
Stroke
200 mm
Operating pressure p
Connections
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
Function
2/3
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
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
Operating pressure p
pR max
-1
1950 min
radial:
axial:
Connections
Subject to change
1600 N
800 N
3/3
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
Notes
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
Technical data
152960
152970
Medium
Hose length
600 mm
Nominal size
6 mm
Operating pressure p
Temperature range
-40 +125 C
100 mm
Connections
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
Hydraulic power pack 2 l/min
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.
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
Hydraulic power pack 2 l/min
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
Hydraulic power pack 2 l/min
Technical data
Electrical
152962
159328
Motor
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
Connection
Hydraulic
152962
159328
Medium
Pump design
1.6 cm
1.3 cm
2.2 l/min
2.3 l/min
Operating pressure
Setting
Manual
1.6
approx. 5 l
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
4/4
Subject to change
152972
Loading weight, 9 kg
Design
Steel block, painted, with castors and locking device, rod eye and clevis.
Function
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-closed contact
= Normally-open contact
2
S = START push-button
+24V-
2
13
12
14
K
14
11
A1
Y
A2
= Normally-closed contact
= Normally-open contact
2
S = START push-button
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
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
Max. 90 W
Pichup time
10 ms
Drop-off time
8 ms
Connections
Electromagnetic compatibility
4/4
Emitted interference
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
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
Signal input plate,electrical
= Normally-closed contact
= Normally-open contact
2
S = START push-button
+24V-
2
13
12
14
K
11
14
A1
Y
A2
= Normally-closed contact
= Normally-open contact
S = START push-button
2/3
Subject to change
162242
Signal input plate,electrical
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
Technical data
Electrical
Voltage
24 V DC
Contact assembly
Contact rating
Max. 1 A
0.48 W
Connections
Electromagnetic compatibility
Emitted interference
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
= Normally-closed contact
= Normally-open contact
2
S = START push-button
+24V-
2
13
12
14
K
11
14
A1
H1
H2
A2
= Normally-closed contact
= Normally-open contact
S = START push-button
Technical data
Electrical
Voltage
24 V DC
0.04 W
Visual indicator
1.2 W
420 Hz
Connection
Electromagnetic compatibility
2/2
Emitted interference
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
Operating pressure p
Hysteresis
~15%
Voltage
Up to 250 V
2A
Connections, hydraulic
Connections, elektrical
Adjustment
Actuation
Hydraulic
Subject to change
Festo Didactic
Technical data
Festo Didactic
167082
4/2-way solenoid valve
Y1
Y1
8 9
T
6
Design
The 4/2-way solenoid valve is mounted on a function plate equipped with four 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: 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
4/2-way solenoid valve
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
Pressure-drop/flow-rate characteristic
2/4
Subject to change
167082
4/2-way solenoid valve
Note
Technical data
Hydraulic
Medium
Operating pressure p
60 bar (6 Mpa)
Voltage
24 V DC
Power rating
6.5 W
Actuation
Electrical
Connections, electrical
Connections, hydraulic
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
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: 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
4/3-way solenoid valve, closed in mid-position
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)
Pressure-drop/flow-rate characteristic
2/4
167083
4/3-way solenoid valve, closed in mid-position
Note
Technical data
Hydraulic
Medium
Operating pressure p
60 bar (6 Mpa)
Voltage
24 V DC
Power rating
6.5 W
Actuation
Electrical
Connections, electrical
Connections, hydraulic
Subject to change
3/4
4/4
183322
Limit switch, electrical, actuated from the left
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
Function
Note
Subject to change
1/2
183322
Limit switch, electrical, actuated from the left
Technical data
Electrical
Design
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
Electromagnetic compatibility
2/2
Emitted interference
Noise immunity
Subject to change
183345
Limit switch, electrical, actuated from the right
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
Function
Note
Subject to change
1/2
183345
Limit switch, electrical, actuated from the right
Technical data
Electrical
Design
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
Electromagnetic compatibility
2/2
Emitted interference
Noise immunity
Subject to change