Advanced Pneumatics

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

Name: Date:
Mode of operation of a stepper sequencer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

the table below.
2 5/2-way pneumatic double pilot valve
3/2-way valve with selector switch, normally closed
3/2-way pneumatic valve, normally closed
Pneumatic predetermining counter
Shuttle valve (OR)
1 Manifold
Equipment list

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


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

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

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

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

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

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

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

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

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

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

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


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

5. Check the equipment list.

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

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

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

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

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


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

5. Check the equipment list.

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

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

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

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

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

Name: Date:
Checking the equipment list Sheet 1 of 1
an equipment list.
– Check the equipment list by comparing the number of components listed in the
table below with your circuit design.
1 Cylinder, single-acting
One-way flow control valve
3/2-way toggle lever valve with idle return, normally closed
3/2-way back pressure valve, normally closed
Shuttle valve (OR)
1 Manifold
Equipment list

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


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Contents

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

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

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

Project task 1. Complete the pneumatic circuit diagram.

© Festo Didactic GmbH & Co. KG • 541089 A-3

1. The opening and closing function is to be started using a pushbutton 1S1.

A-4 © Festo Didactic GmbH & Co. KG • 541089

Exercise 1: Opening and closing of an oven door

Completing the pneumatic circuit diagram Sheet 1 of 1

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541089 A-5

Exercise 1: Opening and closing of an oven door

Compiling the equipment list Sheet 1 of 1

A-6 © Festo Didactic GmbH & Co. KG • 541089

Exercise 1: Opening and closing of an oven door

Carrying out additional exercises Sheet 1 of 2

– What faults can occur when tubing up the circuit?

© Festo Didactic GmbH & Co. KG • 541089 A-7

Exercise 1: Opening and closing of an over door

Carrying out additional exercises Sheet 2 of 2

A-8 © Festo Didactic GmbH & Co. KG • 541089

Project task 1. Complete the pneumatic circuit diagram.

© Festo Didactic GmbH & Co. KG • 541089 A-9

A-10 © Festo Didactic GmbH & Co. KG • 541089

© Festo Didactic GmbH & Co. KG • 541089 A-11

Exercise 2: Separating of drinks bottles

Designing the displacement-step diagram Sheet 1 of 1

– Design the displacement-step diagram for the process described.

A-12 © Festo Didactic GmbH & Co. KG • 541089

Exercise 2: Separating of drinks bottles

Completing the pneumatic circuit diagram Sheet 1 of 1

– Complete the pneumatic circuit diagram.

1V2 1 1 1V3 2V2 1 1 2V3

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541089 A-13

Exercise 2: Separating of drinks bottles

Compiling the equipment list Sheet 1 of 1

A-14 © Festo Didactic GmbH & Co. KG • 541089

Exercise 2: Separating of drinks bottles

Carrying out additional exercises Sheet 1 of 1

– What happens if both limit switches on the cylinder are moved?

© Festo Didactic GmbH & Co. KG • 541089 A-15

A-16 © Festo Didactic GmbH & Co. KG • 541089

Training aims • To be able to design indirect circuit actuation.

Project task 1. Complete the pneumatic circuit diagram.

© Festo Didactic GmbH & Co. KG • 541089 A-17

Automatic drilling machine

A-18 © Festo Didactic GmbH & Co. KG • 541089

© Festo Didactic GmbH & Co. KG • 541089 A-19

Exercise 3: Drilling of valve manifold blocks

Designing the displacement-step diagram Sheet 1 of 1

– Design the displacement-step diagram.

A-20 © Festo Didactic GmbH & Co. KG • 541089

Exercise 3: Drilling of valve manifold blocks

Completing the pneumatic circuit diagram Sheet 1 of 1

– Complete the pneumatic circuit diagram.

2B1 2 1B2 2 1B1 2 2B2 2

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541089 A-21