Bosch Group Practice for Professionals Electropneumatics Trainer’s Manual Version 1.3@ @ Practice for Professionals Electropneumatics Trainer's Manual @ Rexroth Bosch Group c®Rexroth BIBB, BIBB, Rexroth BIBB, BIBB, BIBB, Rexroth BIBB, BIBB, Rexroth BIBB, BIB, Contents Literary References General Information ‘Safety, Instructions on Performing Exercises, Commissioning (Overview of Components, Exercises Topic Exercise At Pilot control of a single-acting cylinder with spring return valve Exercise A2 Pilot control of a double-acting cylinder with spring retum valve Exercise A3 Holding-element control of a double-acting cylinder with impulse valve, directly controlled Exercise A4 Holding-element control of a double-acting cylinder with impulse valve, relay Exercise AS Basic circuit with AND Function Exercise A6 Basie circuit with OR Function Exercise A7 Basic circuit with electric latching circuits Exercise AB Displacement-dependent control of a double-acting cylinder with 1 electric limit switch Exercise Ag Displacement-dependent control of a double-acting cylinder, impulse valve, cylinder switch Exercise A10 Displacement-dependent control of a double-acting cylinder with spring return valve, cylinder switch Exercise A11 Stop control of a double-acting cylinder with a 5/3 directional control valve in closed mid-position Exercise A12 Time-dependent control of a double-acting cylinder with switch-on time delay Exercise A13 Time-dependent control ofa double-acting cylinder with switch-off time delay Exercise Ad Pressure-dependent control ofa double-acting cylinder Exercise A15 Two-hand safety contol, electic Exercise A16 Sequential control of 2 double-acting cylinders with impulse valve Exercise A17 Sequential control of 2 double-acting cylinders with impulse valves and signal overlapping Exercise A18 Sequential control of 2 double-acting cylinders with spring return valves and step sequence Exercise A19 Sequential control of 3 double-acting cylinders with impulse valves and step sequence Exercise A20 Sequential control of 3 double-acting cylinders with spring return valves and step sequence 12 18 a 24 ar 30 33 36 39 45 48 51 s7 60 63 orao Electropneumatics Pra Introduction General information ‘The exercises in this brochure "Bosch Rexroth Practice for Professionals, Electropneumatics" teacher's manual, correspond to the exercises from the practice series "Steuerungstechnik Elektropneumatik” (Control Technol- ‘ogy, Electropneumatics) published by the Bundesinsttut fur Berufsbildung Berlin (BIBB), the Federal institute for Vocational Training in Berlin. “The exercises were extended to reflect the technological further developments in control technology and the series ‘were supplemented with additional ‘exercises in electropneumatis, exer- cises dealing with PLC programming and exercises with pneumatic control technology. ‘This exercise series deals mainly with relay controls, which are stil wide spread. The state of the art, however, is the use of PLCs (programmable logic controllers), which are becoming more and more popular due to their price. In order to understand the function and way these PLC controls work, above all the programming, basic knowledge of relay controls is necessary. A practice system as well as the fol- lowing kits are available for practical Basic kit, Pneumatics BIBB ‘Order no, 0827 003 365 Supplementary kit BIBB, Electropneumatics; boxes with tandem snap-in Order no. 1 827 003 578 To ensure Optimum practical refer- ‘ence, the kits contain only industrial ‘components. The components are ‘equipped with a patented "Snap-in* system and can be easily and quickly attached to the base plate and onto the electronics attachment by the user in the exercises. ‘The following features characterize the Bosch Rexroth practice system: w= The base plate is a grooved plate. It provides the advantage of being able to position the components infinitely and allows a variable ar- rangement on the piate. '= The grooved plate can be used horizontally on a lab table to do practical exercises. The air service Unit can be tiled to a 45 degree angle and thus can be optimally ‘mounted on the horizontal plate. ‘= The mobile "DS3 synergy” system, in contrast, uses various table and accessory modules to create various set-ups. The use of grooved plate is then in a vertical or tted position, ‘= An optional power supply unit can ‘be mounted in the upper side panel of the mobile DS3 frame. = The "Snapsin" system allows all pneumatic, electrical and electronic ‘components to be easily attached and in some cases be turned at a 90 degree angle. In this manner the ‘space on the plate can be used more effectively ‘= The optional electro-attachment S allows up to a maximum of 13 e- modules, which can be attached with tandem snap-in device, 1 Valves of various nominal sizes with ‘uick-release couplings attached are Used. The elements are connected by plastic tubes of the same diam ter. 1 All cylinders used have a piston diameter of 25 mm. Single-acting cylinders have a stroke length of '50 mm, the double-acting cylinders ‘of 100 mm and are spring cush- joned. «= For exercises in connection with electropneumatic components, the double-acting cylinders are equipped with proximity switching through an annular magnet encap- sulated in the piston, Further details on the pneumatic teaching and practice system can be found in the catalogue "DS3 synergy’. ‘As a supplement to this exercise si ries "Bosch Rexroth Practice for Pro- fessionals. Electropneumatics Teacher's Manual", the brochure "Bosch Rexroth Practice for Profes- sionals. Electropneumatics. Trainee's Manual" is also available.oT Safety ‘This exercise series uses pneumatic ‘components as well as electrical equipment, which are operated with functional extra-low voltage of 24 V DC (extra-low voltages are max. 50 V AC and max. 120 V DC). ‘Completing the exercise series does ot entitle the participant to work on ‘equipment designed for higher voltage 'No switch cabinets or equipment that run on voltage over 50 V AC are allowed to be opened No wiring is to be done by those without proper knowledge, nor are any electrical tests to be run on appliances intended for voltage above 50 Volts, AC. There is generally no special danger when dealing with pneumatic compo- nents. Nevertheless, all piping work should principally be carried out with the pressure off (ball valve on the air service unit closed), Practical notes: '= The plugs on the quick-release ‘couplings of distributor and compo- ‘nents must be snapped in securely! ' Plastic tubes that come loose from Quick-release couplings when Pressure is applied have a “lashing effect" (protect eyes!) ‘= When detaching tubes under pres- sure, use one hand to press the release ring and the other to pull out the end of the tube, holding it tightly. 1 Itis possible that cyinders will independently start to move when turning on the air pressure, ‘= Do not try and touch any moving parts (piston rod, switching cam), This could cause painful injuries by pinching your finger between the roller lever and trip cam, Instructions on Performing Exercises, ‘= For optimum, synergetic and suc- cessful learning within a reasonable exercise time, two students should ‘ork together at a practice unit ‘The equipment to be used is lsted in the equipment is in this brochure, The position of the equipment on the base plate and on the electro- attachment S should be executed ‘according to the arrangement sketch that goes with each exercise, ‘= The components are attached by ‘snapping them properly into the {grooves in the grooved plate or on the electro-attachment. The pneumatic components are interconnected according to the Circuit diagram with plastic tubes and T-piece connectors, The plastic tubes are attached to the quick- release couplings by applying light Pressure. To detach the tubes, ‘simply press the release ring with fone hand and pull the tube out with the other. '= Note: to avoid the plastic tubes from gelting stuck, frequently cut off the tend of the tube with the tube cutter. '= The electrical and electronic compo- nents are operated with functional extra-low voltage of 24 V DC (direct voltage). There are several requ- lated, short-circuit-proof power supply units available for this pur- pose in modular or panel mounting versions, 1» The electrical connection takes place via 4 mm laboratory cables with or without protection against accidental contact and 4 mm plugs. The laboratory cables are available in different lengths and in the colors black and red (+ potential) Commissioning Rexroth '=For each exercise unit, a pressure supply of 6 to 8 bar, without lubrica- tion, should be available, with a Suction capacity of 50 to 100 Ni/min. ‘= The system pressure at the work- station is set on the pressure regula- tor atthe standard of pe = 5 bar. '=When setting up the exercises, the pressure should principally be turned off (ball valve on the air service unit closed) and the supply voltage tumed off (power-supply unit off) ‘= Any air escaping through open quick- release couplings or from plastic tubes at a workstation causes a drop in pressure at all other workstations. ‘= After turing on the voltage, observe the operational status display on the power-supply unit (short circuit!) '=Pay attention to optimum error detection: even in the case of compli- cated circuits which have already been set up, itis not necessary to reconnect the complete exercise, but carefully search for errors by using systematic error detection analysis and eliminate them, '=Further instructions for carrying out the exercises and their written and {graphical evaluation can be found in the descriptions of each exercise,Ea Eo Components required from the B: Kit Pnoumatics BIBB, Order No. 1 827 003 365 | Qty. |Description Order No. | Comp. No. | 1. [Air service unit with 3/2 directional control ball valve, G 1/8, 0.5 - 10 bar 1827003410 | 1 Distibutor, 601, seltlocking couplings vexro0sait | [2 1 | Cylinder, single-acting with return spring, @ = 25 mm, stroke = 50 mm re27o03371 |B 3 Cylinder, double-acting, with adjustable spring'cushioning and for proximity switching, |1 827003372 | [4] = 26 mm, stoke = 100 mm 2 One-way flow contro! valye G 1/8, hose version - 1827 003 379 15] | 1 [Quick exhaust valve G 4/4" 1.827 003 381 16] [Blanking plug, tube diameter 4 mm _ — Sm | Plastic tubing 4 x 1; calibrated on the outside; PU black = = 2m [Pasi tbing 6 x 1; caibrated on the outside; PU black — — [4 cut 1 823 391 390 _ Extension kt BIBB for Electropneumatics, Order No.1 827 003 578, boxes with tandem snap-in | Qty. |Description - Order No. [Comp. No. 1. [3/2 direct. control valve M5, electric. controlled, closed neutral position, with solenoid |1627003412 | [0] _| 3 [8:2 directional contol valve G 1/8, electically controled, wth solenoid 1827003413 | Bt | 3 [5/2 direct. control valve G 1/8, electrically controlled impulse valve, with 2 solenoids [1827003414 | [32] 1 [578 direct. contol valve G 18, elect. cont, mid-postion closed, with solenoids [1627003415 | [a] __ 6 _|Relay 24 VDC, 4 changeover contacts, with LED display 1827003563 | a] 1 [Timing relay 24 V DG, switch-on delay, 11n.6.6/1 n.., with LED display, 05-188 |1627 003560 | [5] | 1. | Timing relay 24 V DC, switch-off delay, 1 n.c.c./1 n.o.c., with LED display, 0.5-15s | 1 827 003 585 Be] 12. [control switch, 2 push button eciinoe 1827003588 | [37 "6 | Cylinder switch with holder, 1 normally open contact, visual display, protective circuit |1827 003437 | [BB Electric limit switch with roller lever, 1 changeover contact, 1827003421 | [39] | 1 |PIE pressure switch, 1 changeover cont., adjustable response press., pe=0.5-8bar | 1827 003 428 [40] 1 [Display unit, 4 LED displays, 1 acoustic signal 1827 003 586 | [&t 2 | Electric manifold, 10 x + pole, 10 x - pole - a ~—_-|1.827 003 587 [42]Carrier elements, kits and accessories Description Builtin power supply unit 230 V AC, 24 V DC, for mounting in the DS3 side plate, max 4.5 A, regulated, short-circuit-proof, two pairs of safety sockets, power switch Power supply unit 230 V AG, 24 V DG, regulated, shor-cicuit;proof, max. 3 A et of cables for electropneumatics Basic kit Pneumatics BIBB Grooved plate L 83 basic frame Grooved plate ERGO Electro-attachment S Mobile fle Writing pad Information board (A4 page holder) Digital mutt: measuring device Order No. | Comp. No. R 961 000 170 1 827 001 64 1827 003436 | — 1.827 003 365 1.827 003 702 1.827 003 R 961 000 16 1827 003703 | | — R 961 000 287 827 003 705 | — 1 827 003 721Rexroth Electropneumatics Practice Exercise A 1 Command-variable control of a single-acting cylinder with spring return valve Objective This exercises conveys basic knowledge and skills on setting up and ‘commissioning an electropneumatic control using the example of a direct, electric activation of a single-acting cylinder. List of equipment Pos. Qly. Description 031 Single-acting cylinder 30 13/2 directional control valve, electrically controlled, closed neutral position 37 4 Unit, 4 controt switch, 2 push buttons 501 Power supply unit 42 1 Unit, electric manifold 01 1 Preumatic air service unit 021 Compressed air distributor Accessories: laboratory cable, tubes ‘Suggestion for positioning the equipment 27|| 37 7 Task '= When push button S1 is actuated, assuming that the switch SO is "on", the piston rod of the single-acting cylinder Z1 should extend and re- ‘main extended as long as button SO remains actuated = The pneumatic circuit diagram is to bbe drawn up using symbols and port identification symbols accord- ing to ISO 1219 and RP6BP. = The detached representation of the electric circuit diagram is presented (or supplemented using the circuit symbols of electric equipment ac- cording to DIN/ISO.