Electroneumatica PDF

Fundamentals of
Electropneumatics
Collection of
Transparencies
3
2
3
2
095011 GB
Order No.:
Description:
Designation:
Edition:
Author:
Graphics:
Layout:
095011
EL-PN.FOLIEN-GS
D:OT-TP201-GB
02/2000
Frank Ebel
Doris Schwarzenberger
10.05.2000, Beatrice Huber
Festo Didactic GmbH & Co., D-73770 Denkendorf, 2000

Internet: www.festo.com/didactic
e-mail: did@festo.com
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 registration.
Foreword
The Collection of Transparencies is conceived for the basic material of the TP200
Electropneumatic Technology Package. The transparency collection and technology
package form part of the The Learning System for Automation from Festo Didactic
GmbH & Co.
The transparencies are designed from a didactical and methodological point of view.
For each transparency, there is a short accompanying text that provides the speaker
with a quick overview of the contents. More information you will find in the textbook
Electropneumatics.
Syllabus
Physical fundamentals of electropneumatics

Function and application of electropneumatic components
Designation and drawing of electropneumatic symbols
Drawing of pneumatic and electrical circuit diagrams in accordance with
standards
Presentation of motion sequences and switching conditions
Direct and indirect manual controls
Direct and indirect direction-dependent controllers
Logical AND/OR functions
Pressure-dependent controls with pressure switches
Troubleshooting in simple electropneumatic control systems
The text pages contain a complete picture of the transparency with some additional
explanations and items which the speaker can mark on the transparency during
instruction.
The advantages of this concept are:
The speaker can add to the transparencies step-by-step during instruction.
Instruction is livelier.
The accompanying texts provided reduce preparation time.
New!
Electronic presentation
The enclosed CD-ROM contains all the overhead transparencies and accompanying
text of this edition in an electronically presentable form in the files
Electropneumatics _ transparencies.pdf and Electropneumatics _text.pdf. In
addition to the screen presentation, which can be made in any order, the contents
can be printed out and text and graphics can be used for your own training
preparations, insofar as the functionality of the required Adobe Acrobat Reader

permits this. This freely distributable software is available on the CD-ROM in the
currently valid English version for Windows 95/98/NT for installation in the directory
Acrobat_Reader. Please start the file rs405eng.exe and follow the subsequent
dialogue.
Festo Didactic GmbH & Co. Electropneumatics
Contents
System Elements
Elements of a Control Chain __________________________________ Transparency 1
Pneumatic Components
Single-Acting Cylinder _______________________________________
Double-Acting Cylinder ______________________________________
Non-return, Flow Control and Pressure Control Valves_____________
Pressure Regulating Valve____________________________________
One-Way Flow Control Valve __________________________________
Quick Exhaust Valve_________________________________________
Transparency 2
Transparency 3
Transparency 4
Transparency 5
Transparency 6
Transparency 7
Electropneumatic Components
Conversion of Electrical Signals into Pneumatic Signals ___________ Transparency 8
Conversion of Pneumatic Signals into Electrical Signals ___________ Transparency 9
Switching Symbols for Valves ________________________________ Transparency 10
Directional Control Valves: Ports and Switching Positions_________ Transparency 11
Function Principle of a Solenoid Coil __________________________ Transparency 12
2/2-Way Solenoid Valve without Pilot Control __________________ Transparency 13
Solenoid Valves with Pilot Control ____________________________ Transparency 14
3/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 15
5/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 16
5/2-Way Double Solenoid Valve with Pilot Control_______________ Transparency 17
5/3-Way Solenoid Valve ____________________________________ Transparency 18
Electrical Components
Power Supply Units ________________________________________ Transparency 19
Switching Contacts and Types of Actuation _____________________ Transparency 20
Types of Actuation of Switching Elements ______________________ Transparency 21
Switching Symbols for Solenoid Coils and Relays________________ Transparency 22
The Relay ________________________________________________ Transparency 23
Magnetic Proximity Switches (Reed Switches) __________________ Transparency 24
Electrical Output Devices____________________________________ Transparency 25
Logic Functions
The AND Logic Function _____________________________________ Transparency 26
The OR Logic Function ______________________________________ Transparency 27
Contents
Electropneumatic Controller
Control Chain _____________________________________________ Transparency 28
Direct Actuation of a Single-Acting Cylinder ____________________ Transparency 29
Indirect Actuation of a Double-Acting Cylinder __________________ Transparency 30
Electrical Memory Circuit Dominant Set ______________________ Transparency 31
Electrical Memory Circuit Dominant Reset ____________________ Transparency 32
Electropneumatic Memory Circuit with Double Solenoid Valve _____ Transparency 33
Stroke-Dependent Control___________________________________ Transparency 34
Pressure-Dependent Control _________________________________ Transparency 35
Circuit Diagram Design
The Electropneumatic Circuit Diagram _________________________ Transparency 36
Circuit Diagram Structure ___________________________________ Transparency 37
Displacement-Step Diagram _________________________________ Transparency 38
Terminal Connection Diagram
Terminal Connection Diagram ________________________________ Transparency 39
Checklist for the Terminal Connection Diagram__________________ Transparency 40
Special Features with the Connection of Solenoid Coils
Protective Circuits for Inductive Loads _________________________ Transparency 41
Programmable Logic Controllers
Alterable Controls__________________________________________ Transparency 42
Elements of a Control Chain

The principle of the control chain is used for the preparation of the circuit diagram.
Every element of a control chain has a certain task to perform in the processing and
further transmission of signals.
This structuring of a system into functional blocks has proven itself in the following
tasks:
Arrangement of the elements in the circuit diagram
Definition of the nominal sizes, nominal current and nominal voltage of
components
Set-up and commissioning of the controller
Identification of the components for maintenance work
Pneumatics/
Hydraulics
Electrics/
Electronics
Cylinders
Motors
Components
Working elements
Electric motors
Solenoids
Linear motors
Directional
control valves
Control elements
Power contactors
Power transistors
Power thyristors
Directional
control valves
Isolating valves
Pressure valves
Switches
Push button
actuators
Limit switches
Program
module
Sensors
Processing
elements
(Control elements)
Input elements
Contactors
Relays
Electronic modules
Switches
Push button actuators
Limit switches
Program module
Sensors
Indicators/generators
Elements of a Control Chain
Pneumatics/
Hydraulics
Electrics/
Electronics
Cylinders
Motors
Components
Working elements
Electric motors
Solenoids
Linear motors
Control elements
Power contactors
Power transistors
Power thyristors
Directional
control valves
Directional
control valves
Isolating valves
Pressure valves
Switches
Push button
actuators
Limit switches
Program
module
Sensors
Festo Didactic GmbH & Co.
Processing
elements
(Control elements)
Input elements
Contactors
Relays
Electronic modules
Switches
Push button actuators
Limit switches
Program module
Sensors
Indicators/generators
TP 201, Transparency 01
Single-Acting Cylinder
Compressed air is applied to only one side of the single-acting cylinder.
The piston rod side of the cylinder is vented to atmosphere.
Single-acting cylinders can perform work in only in the advance direction of travel.
The piston rod is driven inwards by the force of a built-in spring or by external forces.
Piston
End cap
Reset spring
Bearing cap
Piston rod
Exhaust port
Sealing ring
Supply port
Cylinder barrel
Single-Acting Cylinder
Double-Acting Cylinder
The double-acting cylinder is actuated in both directions with compressed air.
It can perform work in both directions of movement.
The force transmitted to the piston rod is greater during the advance stroke than
during the return stroke.
Cylinder barrel
Scraper ring
Bearing cap
Piston
Piston rod
End cap
Double-Acting Cylinder
Non-return, Flow Control and Pressure Control Valves

Non-return valves block the flow in one direction and release it in the opposite
direction. A distinction is made between:
Non-return valves
Shuttle valves (OR)
Dual pressure valves (AND)
One-way flow control valves
Quick exhaust valves
Pressure control valves influence the pressure or are controlled through the size of
the pressure. A distinction is made between:
Pressure regulating valves
Pressure relief valves
Pressure sequence valves
Sloping arrow the valve is adjustable
Non-return valves
Non-return valve (check valve)

Non-return valve, spring-loaded
Shuttle valve (OR function)
Dual pressure valve (AND function)
Quick exhaust valve

One-way flow control valve
Flow control valve Flow control valve (throttle valve),
adjustable
Pressure control
valve
Adjustable pressure regulating valve

without relief port
2
1

with relief port
2
1
Pressure sequence valve

with external supply line
12
2
1
Pressure-relief valve
2
Pressure sequence
valve-combination
1
12
Non-return, Flow Control and Pressure Control Valves

Non-return valves
Non-return valve (check valve)

Non-return valve, spring-loaded
Shuttle valve (OR function)
Dual pressure valve (AND function)
Quick exhaust valve

One-way flow control valve
Flow control valve Flow control valve (throttle valve),
adjustable
Pressure control
valve

without relief port
2
1

with relief port
Pressure sequence valve

with external supply line
1
12
2
1
Pressure-relief valve
2
Pressure sequence
valve-combination
1
12
Pressure Regulating Valve

Pressure regulators have the function of keeping the output pressure mainly
constant, independent of variations in the input pressure and the air consumption.
If the pressure rises at the outlet, the diaphragm moves against the spring force and
the flow cross-section at the valve seat is reduced or closed.
If the pressure drops at the outlet, the spring presses against the diaphragm and the
passage cross-section at the valve seat is enlarged or opened.
The output pressure is adjustable.
The input pressure must be higher than the output pressure.
P1
P2
P1
P2
Pressure Regulating Valve
P1
P2
P1
P2
1
One-Way Flow Control Valve

The check element blocks the flow of air in one direction, so that it flows across an
adjustable throttle in this direction.
The air flow from the opposite direction lifts the seal of the check element from the
seat. The compressed air can flow almost unrestricted in this direction.
The valve should be installed as close as possible to the cylinder.
1A
1V2
1V1
1V3
1Y1
1Y2
1
One-Way Flow Control Valve

1A
1V2
1V1
1Y1
1V3
1Y2
Quick Exhaust Valve

Quick exhaust valves are used to achieve the maximum advance and retract speed
of pneumatic cylinders.
To increase the effectiveness of the valve, it should be mounted directly on the
cylinder or in the immediate vicinity of the supply or exhaust ports of the cylinder.
1A
1
1V2
1
1V1
2
1
1V1
1Y1
1A
1Y2
1
1V2
Quick Exhaust Valve

3
1A
1
1V2
1
1V1
1Y1
1V1
1A
1Y2
1V2
3
Conversion of Electrical Signals into Pneumatic Signals

If control systems are using compressed air and electricity as working mediums,
converter systems must be used.
Solenoid valves convert electrical signals into pneumatic signals.
Solenoid valves consist of:
A pneumatic valve
A coil which switches the valve
3
2
3
2
1
unactuated
1
actuated
Conversion of Electrical Signals into Pneumatic Signals

2
3
2
3
2
1
unactuated
1
actuated
Conversion of Pneumatic Signals into Electrical Signals

The PE converter is actuated with compressed air. When the pressure reaches a
preset value, an electric signal is generated.
The pressure of a pneumatic signal works against an adjustable spring.
If the pressure working against the diaphragm overcomes the spring force, a stem
actuates an electrical switch contact.
The electrical switching element can be normally closed, normally open or
changeover contact.
14
14
actuated
14
unactuated
Conversion of Pneumatic Signals into Electrical Signals

14
14
actuated
14
unactuated
10
Switching Symbols for Valves

Pneumatic components are normally shown in the deenergized condition in circuit
diagrams.
Valve switching positions are represented by a square.
The number of squares corresponds to the number of switching positions.
Functions and modes of operation are drawn inside the square:
Lines indicate the flow paths.
Arrows indicate the flow direction.
Closed ports are represented by two lines drawn at right angles to one another.
The connecting lines are drawn outside on the square.
The valve switching position is shown by a square.
Lines indicate the flow paths, arrows indicate the direction of flow.
Closed ports are shown by two lines drawn at right angles to one another.
The connecting lines for supply and exhaust air are drawn outside the square.
Switching Symbols for Valves

The valve switching position is shown by a square.
Lines indicate the flow paths, arrows indicate the direction of flow.
Closed ports are shown by two lines drawn at right angles to one another.
The connecting lines for supply and exhaust air are drawn outside the square.
11
Directional Control Valves: Ports and Switching Positions

Information about the type of valve can be established from the following features:
Number of ports
Number of switching positions
Port numbering
The following applies to the numbering of the ports:
Air supply port
1
Exhaust ports
3, 5
Working or outlet ports
2, 4
Number of ports
2
2/2-way valve, normally open position

1
2
3/2-way valve, normally closed position

1
3
2

4/2-way valve
flow from 1 2 and from 4 3
5/2-way valve
5
4
5/3-way valve, mid-position closed

5
Directional Control Valves:

Ports and Switching Positions
Number of ports
2

1
2
3/2-way valve, normally closed position

3
1
2

4/2-way valve
5/2-way valve
5/3-way valve, mid-position closed

5
12
Function Principle of a Solenoid Coil

When an electric current flows through a coil, a magnetic field is generated.
The following applies to the strength of the magnetic field:
Increasing the number of windings increases the field.
Increasing the strength of the current increases the field.
Lengthening the coil reduces the field.
A soft iron core (armature) is drawn into a coil through which a current is flowing.
Coil winding
Soft iron core
Function Principle of a Solenoid Coil

Coil winding
Soft iron core
13
2/2-Way Solenoid Valve without Pilot Control

Normally-closed position, spring return
Solenoid coil deenergized
Port 1 is blocked.
Port 2 is blocked.
Exhausting is not possible.
Solenoid coil energized
The armature is raised.
Compressed air flows from port 1 to port 2.
2/2-Way Solenoid Valve without Pilot Control
2
14
Solenoid Valves with Pilot Control

Solenoid valves with pilot control consist of:
An electromagnetically-actuated pilot control valve.
A pneumatically-actuated main valve.
In comparison with solenoid valves without a pilot control, solenoid valves with a
pilot control are distinguished by:
Lower force required to actuate the armature.
Smaller dimensions of the coil head.
Lower power consumption.
Less heat generated.
An electrical signal is
applied to the solenoid
coil
The solenoid coil
actuates the pilot
control valve
The pilot control

actuates the valve
Solenoid Valves with Pilot Control
An electrical signal is
applied to the solenoid
coil
15
3/2-Way Single Solenoid Valve with Pilot Control

Normally-closed position, spring return, manual override
Port 1 is blocked.
Port 2 is vented to port 3.
The pilot control channel is blocked by the armature seal on the valve side.
The space above the valve piston is vented through the armature guide tube.
The armature is lifted and the armature seal on the coil side blocks the vent hole
in the armature guide tube, while the armature seal on the valve side opens the
pilot control channel.
Compressed air from port 1 flows through the pilot control channel and actuates
the valve piston.
Port 3 is blocked.
3
2
3
2

2
3
2
3
2
16

Spring returned, manual override
Compressed air flows from port 1 to 2.
Port 4 is vented to 5.
Port 3 is blocked.
The pilot control channel is blocked.
The space above the valve piston is vented through the armature guide tube.
The armature is lifted and the armature seal on the coil side blocks the vent in
the armature guide tube, while the armature seal on the valve side opens the
pilot control channel.
Compressed air from port 1 flows through the pilot control channel and actuates
the valve piston.
Port 5 is blocked.
14
5
84
14
84
14
84
14
84

4
14
5
84
14
84
14
84
14
84
3
17
5/2-Way Double Solenoid Valve with Pilot Control

Manual override
Solenoid coil Y1 energized, solenoid coil Y2 deenergized
The valve switches over.
Port 3 is blocked.
Compressed air flows from Port 1 to Port 2.
Port 4 is vented to Port 5.
Both solenoid coils deenergized
The valve retains its previous switching position.
Solenoid coil Y2 energized, solenoid coil Y1 deenergized
The valve switches over.
Port 5 is blocked.
14
12
5
84
14
82
12
84
82
2
12
14
84
14
82
12
84
82
5/2-Way Double Solenoid Valve with Pilot Control

4
14
12
5
84
14
82
12
84
82
14
12
84
14
82
12
84
82
18
5/3-Way Solenoid Valve

The three switching positions of an electrically-actuated pilot-controlled
5/3-way valve:
1. In the normal position, the solenoid coils are deenergized and the piston is
centered in its mid-position by the two springs. Ports 2 and 3 as well as 4 and 5
are connected. Port 1 is blocked.
2. If current is applied to the lefthand solenoid coil, the piston moves to the right.
Ports 1 and 4 as well as 2 and 3 are connected with each other.
3. If current flows through the righthand solenoid coil, the piston moves to the left.
In this position, Ports 1 and 2 as well as 4 and 5 are connected.
Each of the two actuated switching positions is held as long as current flows through
the corresponding solenoid coil. If the flow of current is interrupted, the piston
switches back to the mid-position.
13
14
12
84
14
82
12
84 5 4
2 3 82
5
84
1 3
14
14
12
12
84 5 4
2 3 82
82
1 3
82
14
12
84
14
12
84 5 4
2 3 82
5/3-Way Solenoid Valve

4
14
14
12
84
14
13
82
12
84 5 4
2 3 82
14
14
12
12
84 5 4
2 3 82
13
82
4
14
14
12
84
14
14
5
84
13
82
12
84 5 4
2 3 82
19
Power Supply Units

It is necessary to distinguish between an alternating current and a direct current
power supply.
Alternating current
Direct current
Is supplied by power supply devices
Is supplied from the mains

3-phase or single-phase form
Sinusoidal-shaped voltage of fixed frequency
Relatively constant amplitude
Voltage change through transformers
Modules of direct current power supply devices

Mains transformer
Rectifier
Stabilization
Batteries and rechargeable batteries
Used for buffering in case of mains failure.
Used in portable devices.
Alternating current
Battery
Direct current
Transformer
Rectifier
Stabilizer
Power supply unit
Power Supply Units

Alternating current
Battery
Direct current
Transformer
Rectifier
Stabilizer
Power supply unit

20
Switching Contacts and Types of Actuation

The following switch contact designs are used as input and processing elements:
Normally-open contact
Normally-closed contact
Changeover contact
Types of actuation for switching elements are:
Manual
Mechanical
Relay
Magnet field
Normally-open
contacts
Normally-closed
contacts
Push-button with
normally open contacts
manually actuated
by pushing
Changeover
switch
Rotary switch with

manually actuated
by turning
Mechanically connected
contacts
Limit switch with normally open

or normally closed contacts,
mechanically actuated
Switching Contacts and Types of Actuation

Normally-open
contacts
Normally-closed
contacts
Push-button with
manually actuated
by pushing
Changeover
switch
Rotary switch with

manually actuated
by turning
Mechanically connected
contacts
Limit switch with normally open

or normally closed contacts,
mechanically actuated
21
Types of Actuation of Switching Elements

Frequently used types of actuation are
Pushbuttons
Roller levers
Roller lever with idle return
Two types of actuation are shown
Pushbutton, as changeover switch
Latching rocker switch, as normally-open contact
Identifying letters in electrical circuit diagrams: S (S1, S2, ...)
Type of actuation
(push-button)
1
Connection
(normally-closed contact)
Switching element
Connection
(normally-open contact)
3
3
4
Types of Actuation of Switching Elements

2
Type of actuation
(push-button)
Connection
(normally-closed contact)
Switching element
Connection
(normally-open contact)
3
4
4
22
Switching Symbols for Solenoid Coils and Relays

In electropneumatics, the solenoid coil is the element that switches the valves.
Identifying letters in electrical circuit diagrams: Y (Y1, Y2, ...)
A relay switches 1, 2 or more contacts. The relay can also be a time or temperaturecontrolled element.
Identifying letters in electrical circuit diagrams: K (K1, K2, ...)
Electro-magnetically
actuated on both sides
actuated on one side,
with spring return
Representation in
electrical circuit
diagrams
Y1
actuated,
with pilot control
Contactor or relay with

3 normally open contacts
and 1 normally closed contact
K1
Switching Symbols for Solenoid Coils and Relays

actuated on both sides
actuated on one side,
with spring return
Representation in
electrical circuit
diagrams
Y1
actuated,
with pilot control
Contactor or relay with

3 normally open contacts
and 1 normally closed contact
K1
23
The Relay
In practice, the construction of a relay can be very different, but the function is
nevertheless the same in principle:
When a voltage is applied to the relay coil through contacts A1 and A2, an
electric current flows through the windings. A magnetic field is built up and pulls
the armature against the core of the coil.
Switch contact 1 is connected with switch contact 4.
After removing the voltage, the armature is brought back into its initial position
by a spring.
Switching contact 1 is connected with switching contact 2.
A relay can have multiple switching contacts which can be actuated simultaneously.
There are the following types, for example:
Polarised relay
Current impulse relay
Time relay
Thermal relay
12 14 22 24
A1
Return spring
Relay coil
A2
11
21
Armature
Coil core
Insulation
Contact
A1 A2
4 2
The Relay
A1
Return spring
Relay coil
12 14 22 24
A2
11
21
Armature
Coil core
Insulation
Contact
A1 A2
4 2
1
24
Magnetic Proximity Switches (Reed Switches)

Reed switches are actuated through a magnetic field. In industrial applications, most
reed switches are used with LED displays.
The illustration shows a three-wire reed switch. It has three connections:
One connection for the positive power supply
One connection for the negative power supply
One signal or switch output
The reed switch is attached directly to the body of a cylinder. It is actuated by a
magnetic ring on the cylinder piston.
When the magnetic ring moves past the reed switch, the switching contacts are
closed as a result of the magnetic field and thus provide an output signal.
Identifying letters in electrical circuit diagrams: B (B1, B2, ...)
+24V
BN
BK
BU
0V
Magnetic Proximity Sensors (Reed Switches)

+24V
BN
BK
BU
0V
25
Electrical Output Devices

Supply acoustic signals:
For example, horns, sirens
Identifying letters in electrical circuit diagrams:
H (H1, H2, ...)
Supply optical signals:

For example, lamps, LEDs
H (H1, H2, ...)
Do work:
For example, electric motors
M (M1, M2, ...)
Signalling device
Audible indicator:
Horn
Illuminating
indicators:
Lamp
Siren
Bell
Light emitting diode (LED)
Motors
DC motor
M
Electrical Output Devices

Signalling device
Audible indicator:
Horn
Illuminating
indicators:
Lamp
Motors
Siren
Bell
Light emitting diode (LED)
DC motor
M
26
The AND Logic Function

The AND logic function consists of at least two switching elements connected in
series:
The AND logic function can have two or more inputs. A combination of switches
and sensors may be involved.
The function is represented through a logic symbol with two inputs and one
output.
Both input signals must be present to switch the output.
+24V
S1
Input 1
(S1)
Input 2
(S2)
S2
&
Output
(lamp H1)
H1
0V
The AND Logic Function

1
+24V
S1
Input 1
Input 2
S2
&
Output
H1
0V
27
The OR Logic Function

The OR logic function consists of at least two switching elements connected in
parallel:
The OR logic function can have two or more inputs. A combination of switches
and sensors may be involved.
The function is represented through a logic symbol with two inputs and one
output.
Only one input signal needs to be present to switch the output.
+24V
S1
S2
Input 1
(S1)
Input 2
(S2)
Output
(lamp H1)
H1
0V
The OR Logic Function

1
+24V
S1
2
S2
Input 1
Input 2
Output
H1
0V
28
Control Chain
The structure of the control chain supports:
The allocation of components with comparable functions to a group of elements.
The avoidance of lines crossing each other in pneumatic and electrical circuit
diagrams.
The preparation of clearly structured and uniformly designed circuit diagrams.
The principle of the control chain should be understood as being only a guideline.
The signal flow of the control system defines the structure of the control chain:
In the pneumatic circuit diagram, the signal flow is represented from bottom to
top.
In the electrical circuit diagram, the signal flow is represented from top to
bottom.
+24V
2
Signal
input
Signal flow
S1
1V1
S2
1Y1
1
K1
K1
1Y1
Signal
processing
Signal flow
1A
Signal
output
0V
2
Control Chain
1A
+24V
2
Signal input
S1
1V1
S2
1Y1
1
K1
K1
1Y1
Signal processing
Signal output
0V
2
29
Direct Actuation of a Single-Acting Cylinder

After actuating S1, current flows through the coil 1Y1, which switches the valve 1.1.
Compressed air flows from port 1 to port 2, and the piston rod advances.
If S1 is no longer actuated, there is no current through coil 1Y1. Valve 1.1 switches
back into the initial position.
The cylinder is vented through port 3 of valve 1.1, and the piston rod retracts.
1A
+24V
S1
1V1
1Y1
1
1Y1
0V
Direct Actuation of a Single-Acting Cylinder

1A
+24V
S1
1V1
1Y1
1Y1
0V
30
Indirect Actuation of a Double-Acting Cylinder

The use of indirect actuation depends upon:
The force which is required for the actuation of the positioner
The complexity of the circuit
The switching power of the contacts
Whether or not the system is remote controlled
1A
+24V
S1
1V1
2
13
14
K1
13
14
1Y1
5
A1
K1
1Y1
A2
0V
Indirect Actuation of a Double-Acting Cylinder

1A
+24V
S1
1V1
1Y1
2
13
14
1Y1
0V
31
Electrical Memory Circuit Dominant Set

A relay can be held in the switched condition if a holding current path is switched in
parallel to the ON pushbutton through an internal normally-open contact in the
relay.
An OFF pushbutton must be built into the memory circuit. The installed position of
the OFF pushbutton determines the function of the memory circuit.
A memory circuit in which a pushbutton (S2, normally-closed) is connected in series
with a relay holding contact (normally-open) is a dominating set memory circuit.
In this dominating set memory circuit, the pushbutton S1 dominates the pushbutton
S2.
If S1 and S2 are pressed simultaneously, current flows through the relay coil K1.
+24V
S1
K1
13
14
K1
23
24
S2
K1
H1
0V
2
3
Electrical Memory Circuit Dominant Set

1
+24V
S1
K1
13
14
3
K1
23
24
S2
K1
H1
0V
2
3
32
Electrical Memory Circuit Dominant Reset

A relay can be held in the switched condition if a holding current path is switched in
parallel to the ON pushbutton to the relay coil through an internal normally-open
contact in the relay.
An OFF pushbutton must be built into the memory circuit. The installed position of
the OFF pushbutton determines the function of the memory circuit.
A memory circuit in which a pushbutton (S1, normally-open) and a relay holding
contact (normally-open) are connected in parallel and then in series with a
pushbutton (S2, normally-closed) is a dominating reset memory circuit.
In this dominating reset memory circuit, the pushbutton S2 dominates the
pushbutton S1.
If S1 and S2 are pressed simultaneously, no current flows through the relay coil K1.
+24V
S1
K1
13
14
K1
23
24
S2
K1
H1
0V
2
3
Electrical Memory Circuit Dominant Reset

1
+24V
S1
K1
13
14
3
K1
23
24
S2
K1
H1
0V
2
3
33
Electropneumatic Memory Circuit with Double Solenoid Valve

Double solenoid valves are also called bistable valves or memory valves:
The valve illustrated is actuated by two solenoid coils.
The valve retains the switched position brought about through energising one of
the coils, even when the signal to switch the valve is cancelled.
The switched position is reversed only when a signal is applied to the opposite
coil or a manual override is operated.
To reverse the switched position, a signal only needs to be applied to one coil.
1A
+24V
1S2
1S2
S1
1V1
1Y1
K1
K2
1Y2
1
K1
K2
1Y1
1Y2
0V
3
Electropneumatic Memory Circuit with Double Solenoid Valve

1A
+24V
1S2
S1
1V1
1Y1
1S2
K1
4
K2
1Y2
K1
K2
1Y1
1Y2
0V
3
34
Stroke-Dependent Control
Limit switches with roller lever actuation are frequently used to check the position of
pneumatic actuators in simple circuits.
The use of limit sensors in a control depends upon the required accuracy of the
sensor.
Decisive factors are:
The reliability
The safety
The complexity of the circuit
1A
1S1
+24V
1S2
1S2
S1
1V1
1Y1
K1
K2
1S1
1Y2
K1
1Y1
K2
1Y2
0V
3
Stroke-Dependent Control
1A
1S1
+24V
1S2
S1
1V1
1Y1
1S2
K1
4
K2
1S1
1Y2
K1
K2
1Y1
1Y2
0V
3
35
Pressure-Dependent Control
A pneumatic-electric signal converter measures the air pressure in the supply line of
cylinder 1A and compares it with a preset value.
As soon as this value is reached, the signal converter generates an electrical signal.
1A
1B2
+24V
1B2
1B1
S1
1B1
p
K1
K2
K3
1V1
1Y1
K1
1Y2
1
K2
K3
1Y1
1Y2
0V
5
Pressure-Dependent Control
1A
1B2
+24V
1B2
1B1
1B1
p
S1
K1
7
K2
K3
1V1
1Y1
K1
1Y2
K2
1Y1
K3
1Y2
0V
5
36
The Electropneumatic Circuit Diagram

The pneumatic and electrical parts of an electropneumatic circuit diagram are
prepared separately, but their contents are closely related.
In the pneumatic part, signal flow is presented from bottom to top.
In the electrical part, signal flow is presented from top to bottom.
In the electrical circuit diagram, the current paths are numbered consecutively from
left to right.
The common circuit diagram elements form the interfaces between the pneumatic
and the electrical circuits. In this case, they are the coils 1Y1 and 2Y1, as well as the
limit sensors 1B1, 1B2, 2S1 and 2S2.
1B1
1A
1V1
1B2
2A
2V1
1Y1
1B1
1B2
2S2
2Y1
5
+24V
2S1
6
K3
Start
K2
K4
9
2S2
10
K5
11
12
K3
2S1
13
K4
K1
K3
K6
K1
K2
K3
K4
K4
K5
K5
K6
K5
1Y1
2Y1
0V
5
6
7
12
8
9
13
13 10
11
The Electropneumatic Circuit Diagram

1B1
1A
1V1
1Y1
+24V
1B1
1B2
1B2
2A
2V1
6
K3
Start
2Y1
K2
K4
2S1
2S2
9
2S2
10
K5
11
12
K3
2S1
13
K4
K1
K3
K6
K1
K2
K3
K4
K4
K5
K5
K5
K6
1Y1
2Y1
0V
5
6
7
12
8
9
13
13 10
11
37
Circuit Diagram Structure

The electropneumatic circuit diagram consists of two parts:
Pneumatic
Electrical
Pneumatic
The arrangement of the components follows the signal flow accordingly from
bottom to top.
Cylinders and valves are drawn horizontally.
The outward travel motion of cylinders should be from left to right.
Electrical
The arrangement of the components follows the signal flow accordingly from top
to bottom.
The electrical circuit diagram can be subdivided into a control part and a power
part.
Control section
1A
+24V
1S2
Power section
S1
1S2
K1
K2
1V2
K2
1V1
1Y1
1Y2
5
0Z
K1
K2
1Y1
1Y2
0V
3
Circuit Diagram Structure
1A
+24V
1S2
1S2
S1
K1
4
K2
1V2
K2
1V1
1Y1
1Y2
0Z
K1
1Y2
0V
3
1Y1
K2
38
Displacement-Step Diagram
In a displacement-step diagram, the motion sequences of an actuator in a control
system are presented graphically:
Movements of the cylinder within a step are represented by a line moving
diagonally upwards (advancing) or downwards (retracting).
Horizontal lines represent the position of the cylinder in the advanced or
retracted end position.
If the movements of several actuators are to be represented, they are arranged
under each other for every individual step.
This arrangement clarifies the relationship between the movements of the
individual actuators in every step.
Step
1
5=1
1
1A
0
1
2A
0
Displacement-Step Diagram
Step
1
5=1
1A
0
1
2A
0
39

The terminal connection diagram shows the physical implementation of the current
circuit.
The identifications used in the circuit diagram are used in the terminal connection
diagram.
The terminal points and the cables are numbered. This facilitates the setting-up of
the controller as well as troubleshooting and maintenance.
1A
Machine
Control cabinet
X1-1
X1-9
K1
X1-10
K1
A1
A2
X1-6
K2
4
11
14
A1
A2
X1-7
1S2
X1-15
K2
1
2
K2
11
14
X1-16
1Y1
X1-17
X1-8
0V
3
+24V
X1-4
X1-14
3
X1-13
X1-3
X1-12
S1
X1-5
X1-2
1B1
X1-11
4
5
21
0V
24
1B1
1B1
1B1
S1
S1
1S2
1S2
1Y1
1Y1
+
3
4
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Connection
code
Component
code
+24V
Terminal no. X1
Jumper
1Y1
Connection
code
1V1
Component
code
Target
1S2
Target
1B1
X1
X1
X1
K2
X1
K1
K2
X1
X1
K1
X1
X1
K1
X1
K2
K2
X1
9
12
14
21
11
A2
A2
17
1
A1
5
2
11
3
11
24
8

Machine
Control cabinet
+24V
X1-1
X1-2
X1-3
X1-9
X1-12
X1-14
1B1
S1
X1-13
X1-11
X1-10
K1
X1-5
K1
A1
A2
X1-6
K2
1S2
4
11
14
A1
A2
X1-7
K2
4
5
Target
+24V
X1-4
1
2
K2
11
14
X1-16
1Y1
X1-17
X1-8
0V
3
X1-15
0V
21
24
1B1
1B1
1B1
S1
S1
1S2
1S2
1Y1
1Y1
+
3
4
1
2
Terminal no. X1
1Y1
Jumper
Connection
code
1V1
Component
code
Target
1S2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Connection
code
1A
Component
code
1B1
X1
X1
X1
K2
X1
K1
K2
X1
X1
K1
X1
X1
K1
X1
K2
K2
X1
9
12
14
21
11
A2
A2
17
1
A1
5
2
11
3
11
24
8
40
Checklist for the Terminal Connection Diagram

In the preparation of a terminal connection diagram, the structure of the control
should be checked once again:
Is every current path connected to the positive +24V bus bar through a terminal?
Is every current path connected to the negative 0 V bus bar through a terminal?
Are all external components, such as switches, sensors and valve coils connected
with one terminal per connection to the current circuit?
Are all connections to the +24 V and 0 V shown in the terminal connection
diagram?
Are all external components included in the terminal connection diagram
provided with their connection identifications?
Check all current paths systematically and complete the terminal connection
diagram.
Note that not all connections such as the relay contacts, for example must be
included in the terminal connection diagram.
Each current path must be connected
to the positive +24 V rail via a terminal.

to the negative 0 V rail via a terminal.

External components, such as switches,
sensors and solenoids are each
connected via one terminal per unit.
Enter all external components with the
designation of the connection in the

terminal connection diagram.
Systematically check all current paths
and complete the wiring diagram.

Note:
Not all of the connections have to be

entered in the wiring diagram
(e.g. relay connections are exempt).
Identify the connection point for +24 V

and 0 V in the wiring diagram.
Checklist for the Terminal Connection Diagram

Enter all external components with the
Systematically check all current paths
External components, such as switches,
Note:
to the positive +24 V rail via a terminal.
to the negative 0 V rail via a terminal.

sensors and solenoids are each
connected via one terminal per unit.
Identify the connection point for +24 V
designation of the connection in the

terminal connection diagram.
and complete the wiring diagram.
Not all of the connections have to be

entered in the wiring diagram
(e.g. relay connections are exempt).
and 0 V in the wiring diagram.
41
Protective Circuits for Inductive Loads

If the current flowing to an inductive load, for example, a solenoid coil, is
interrupted, the magnetic field collapses.
A high induction voltage can be generated which can have the following effects:
Damage to the coil insulation
Burning of contacts
This can be avoided through protective circuits using diodes.
I1
IM = I1
+24V
0V
I1 = 0
ID = 0
IM
+24V
0V
ID = IM
Protective Circuits for Inductive Loads
I1
IM = I1
+24V
0V
I1 = 0
ID = 0
IM
+24V
0V
ID = IM
42
Alterable Controls
Relay-controlled systems are hard wired. The relay control can be replaced in whole
or in part by a programmable controller.
The structure of a system that is controlled via a programmable logic controller (PLC)
is similar to that of a relay-controlled system. Both systems can be subdivided as
follows:
Signal input
Signal processing
Signal output
The signal processing part is the part that can be hard wired or freely programmable.
Signal
input
Signal processing
Switch
Relays
Contacts
S1
K1
S2
K2
S3
K3
S4
K4
K1
K2
H1
K3
K4
H2
S1
S2
S3
S4
Signal
output
Inputs
E1
E2
Program:
WHEN
THEN
OTHERWISE
WHEN
E3
E4
THEN
OTHERWISE
AND
E0.1
E0.2
SET
RESET
A0.1
A0.1
AND
E0.3
E0.4
SET
RESET
A0.2
A0.2
A1
A2
H1
H2
Processor
Outputs
Alterable Controls
Signal
input
Signal processing
Switch
Relays
K1
S2
K2
S3
K3
S4
K4
S1
S2
S3
S4
Contacts
S1
Inputs
E1
E2
E3
E4
Signal
output
Program:
WHEN
K1
K2
H1
K3
K4
H2
AND
E0.1
E0.2
THEN
SET
OTHERWISE RESET
A0.1
A0.1
WHEN
E0.3
E0.4
AND
THEN
SET
OTHERWISE RESET
Processor
A0.2
A0.2
H1
A1
H2
A2
Outputs

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Fundamentals of

Festo Didactic GmbH & Co., D-73770 Denkendorf, 2000

Physical fundamentals of electropneumatics

preparations, insofar as the functionality of the required Adobe Acrobat Reader

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co. Electropneumatics

Elements of a Control Chain

Festo Didactic GmbH & Co. Electropneumatics

Elements of a Control Chain

Festo Didactic GmbH & Co.

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co.

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co.

Non-return, Flow Control and Pressure Control Valves

Non-return valve (check valve)

Dual pressure valve (AND function)

Quick exhaust valve

Adjustable pressure regulating valve

Adjustable pressure regulating valve

Pressure sequence valve

Festo Didactic GmbH & Co. Electropneumatics

Non-return, Flow Control and Pressure Control Valves

Non-return valve (check valve)

Quick exhaust valve

Adjustable pressure regulating valve

Adjustable pressure regulating valve

Pressure sequence valve

Pressure Regulating Valve

Festo Didactic GmbH & Co. Electropneumatics

Pressure Regulating Valve

One-Way Flow Control Valve

Festo Didactic GmbH & Co. Electropneumatics

One-Way Flow Control Valve

Festo Didactic GmbH & Co.

Quick Exhaust Valve

Festo Didactic GmbH & Co. Electropneumatics

Quick Exhaust Valve

Festo Didactic GmbH & Co.

Conversion of Electrical Signals into Pneumatic Signals

Festo Didactic GmbH & Co. Electropneumatics

Conversion of Electrical Signals into Pneumatic Signals

Conversion of Pneumatic Signals into Electrical Signals

Festo Didactic GmbH & Co. Electropneumatics

Conversion of Pneumatic Signals into Electrical Signals

Switching Symbols for Valves

The valve switching position is shown by a square.

The number of squares corresponds to the number of switching positions.

Festo Didactic GmbH & Co. Electropneumatics

Switching Symbols for Valves

The number of squares corresponds to the number of switching positions.

Festo Didactic GmbH & Co.

Directional Control Valves: Ports and Switching Positions

2/2-way valve, normally open position

3/2-way valve, normally closed position

3/2-way valve, normally open position

5/3-way valve, mid-position closed