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The training system from Festo Didactic has been developed and manufactured for training and vocational education in the field of automation technology. The respective training companies andor trainers must ensure that all trainees observe the safety precautions which are described in this workbook. Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company andor any third parties, which occur during use of the equipment sets in situations which serve any purpose other than training andor vocational education, unless such damages have been caused by Festo Didactic due to malicious intent or gross negligence.
D-1 Appendix Part D – Appendix Storage tray D-2 Mounting systems D-3 Sub-base D-5 Coupling system D-6 Data sheets Pressure gauge 152841 One-way flow control valve 152843 Non-return valve, bar, bar 152845, 152846 Branch tee 152847 Pressure relief valve, pressure sequence valve 152848 2-way flow control valve 152851 Non-return valve, piloted 152852 Cylinder, 16/10/200 152857 Hydraulic motor, l/min 152858 Hose line with quick release coupling, 600/1000 mm 152960, 152970 Hydraulic power pack, l/min 152962 Loading weight, 9kg 152972 Relay, 3-fold 162241 Signal input unit, electrical 162242 Indicator and distributor unit, electrical 162244 Hydraulic labelling sets 162383 Pressure switch 167080 4/2-way solenoid valve 167082 4/3-way solenoid valve with closed in mid-position 167083 Limit switch, electrical, actuated from the left 183322 Limit switch, electrical, actuated from the right 183345 TP601 • Festo Didactic D-2 Appendix Storage tray All the components of the equipment set for the technology package TP601 are retained in a storage tray This storage tray serves both as packaging for despatch purposes and as a drawer insert for the Didactic furniture range Equipment set TP601 in storage tray TP601 • Festo Didactic D-3 Appendix Mounting systems The components of the equipment set are mounted on the Festo Didactic profile plate The profile plate has 14 parallel T-grooves equally spaced 50 mm apart There is a choice of four alternative systems for mounting the components on the profile plate: Variant A: Detent system, used without additional devices Clamping mechanism with lever and spring which can be moved along the T-groove, for light non-load-bearing components Variant B: Rotary system, used without additional devices Grip nut with locking disc and T-head bolt, vertical or horizontal alignment, for medium-weight load-bearing components Variant C: Screw-in system, used with additional devices Cheese-head bolt with T-head nut, vertical and horizontal alignment, for heavy load-bearing components or components which are rarely removed from the profile plate (Mounting-system variant C is not used in the equipment set TP 601) Variant D: Plug-in system, used with adapters Components with locating pins for plug-in assembly boards, can be insert in a T-groove, for light non-load-bearing components The signal input unit and indicator and relay plates can also be mounted in the mounting frame for ER units TP601 • Festo Didactic D-4 Appendix In the case of variant A, a slide engages in the T-groove of the profile plate This slide is pre-tensioned by a spring When the blue lever is pressed, the slide is retracted to allow the component to be removed from or fitted to the profile plate Components are aligned with the groove and can be moved along this In the case of variant B, the component is secured to the profile plate by a T-head bolt and a blue grip nut A locking disc which can be positioned in steps of 90° is used to position the components, allowing these to be aligned either parallel to or at right angles to the grooves After the locking disc has been set to the desired position, the component is placed on the profile plate When the grip nut is turned clockwise, the T-head bolt is turned through 90°in the T-groove by thread friction The grip nut is then turned further to clamp the component to the profile plate Variant C is used with heavy components or components which are to be secured to the profile plate once only or seldom removed In this case, components are secured by means of internal-hex-head bolts and T-head nuts In the case of variant D, our well-proven ER units, on plug-in assembly boards with locating pins on a 50 mm grid pattern, can be attached to the profile plate by means of adapters A black plastic adapter is required for each locating pin The adapters are positioned in the Tgrooves at intervals of 50 mm and secured by rotating them through 90° The locating pins of the ER units are then inserted into the holes in the adapters TP601 • Festo Didactic D-5 Appendix Sub-base The hole pattern of the sub-base for valves of nominal size (DN 4) conforms to ISO/DIN 4401 size 02 Due to the similarity between this hole pattern and the one for size 03, it has been possible by changing the dimensions slightly and providing additional mounting holes to allow valves of nominal size (DN 6) to be used as well Sub-base TP601 • Festo Didactic D-6 Appendix Coupling system All hydraulic components are equipped with self-closing couplings These have been designed in particular to be free of leaks, enabling circuits to be assembled and dismantled with virtually no oil leakage, while at the same time allowing connections to be made with very little effort A coupling consists of a nipple and socket Connections are made by pushing a socket onto a nipple The sliding sleeve then engages to provide a secure connection This sleeve is pushed back to detach a connection A spring then pushes the socket away from the nipple Coupling nipples can be screwed into the sub-bases All valves mounted on sub-bases can thus be connected up via nipples All other components should preferably also be equipped with nipples, and hoses lines should therefore be fitted with two sockets Components such as shutoff valves or non-return valves which are connected on one side to hoses and on the other to components are equipped with coupling nipples and coupling sockets respectively Self-closing coupling Coupling nipple Sliding sleeve Coupling socket TP601 • Festo Didactic D-7 Appendix Since the couplings close to create a leakproof seal, it may occur that pressure is trapped inside a component If this happens, the force required to operate the coupling will increase to such an extent that the component cannot subsequently be coupled up again The remedy in cases of this kind is to use a pressure relieving device This is of similar design to a coupling socket but incorporates an adjustment spindle The spindle should initially be rotated fully out and the device then pushed onto a nipple until the sliding sleeve engages The spindle can be rotated inward to push back the sealing pin of the nipple and open the seal The pressure behind the nipple will then be relieved; a drop of oil may escape during this operation The pressure relieving device can be removed again by pushing back the sliding sleeve The coupling systems consist of the following components: Description Order No Coupling nipple 342 047 Coupling socket 034 649 Pressure relieving device 152 971 TP601 • Festo Didactic D-8 Appendix TP601 • Festo Didactic 152841 Pressure gauge 1/1 B A Design Pressure gauge, branch tee, connections (A = nipple, B = socket) Function The branch tee can be interposed at any desired point or connected close to a measuring point to allow pressure measurement The pressure causes a spiral Bourdon tube to open out This motion is applied to the pointer of the pressure gauge The position of the pointer is therefore proportional to the pressure applied Note The pressure gauge has a glycerine filled to protect it against impacts, condensation and the entry of water during cleaning Medium Mineral oil, recommended viscosity 22 cSt (mm2/s) Accuracy 1.6 % of full-scale value Indicating range 10 MPa (100 bar) Operating pressure: Static Dynamic 3/4 of full-scale value 2/3 of full-scale value Damping fluid Glycerine Actuation Hydraulic via a spiral Bourdon tube Connections For coupling nipple/socket Subject to change Festo Didactic Technical data Festo Didactic 162242 Signal input plate, electrical 2/2 + S K K Y _ contact = Normally-closed Öffner Example of application: Circuit diagram, electrical contact = Normally-open Schließer push-button SS == Start START - Taster +24V _ 13 12 S 14 K 11 14 A1 K Y A2 0V contact = Normally-closed Öffner Example of application: Practical assembly, electrical contact = Normally-open Schließer push-button SS== Start START - Taster + + A1 12 14 K 12 14 K A2 Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate A1 11 Changeover switch Wechsler als Schließer connected as n.o contact angeschlossen A2 11 Changeover switch Wechsler als Öffner connected as n.c contact angeschlossen Festo Didactic 162244 Indicator and distributor plate, electrical 1/2 H Design This component consists of an acoustic indicator and four visual indicators with connections and three busbars for the power supply All electrical connections are in the form of mm safety connectors The unit can be mounted in a mounting frame or on the profile plate using four plug-in adapters Function The acoustic indicator outputs a buzzing tone when power is applied to its connections The visual indicator consists of a housing and a colourless transparent cap with a miniature lamp When power is applied to its connections, its operating status is indicated by the built-in miniature lamp A bridged pair of sockets is provided for each lamp, allowing the component to be used also as a distributor Note To ensure that the acoustic indicator operates correctly, check the polarity of the power supply Voltage 24 V DC Power consumption (acoustic indicator) 0.04 W Visual indicator 1.2 W Frequency (acoustic indicator) 420 Hz Connection For mm safety connector plug Electromagnetic compatibility Emitted interference tested to EN 500 81-1 Noise immunity tested to EN 500 82-1 Subject to change Festo Didactic Technical data H 162244 Indicator and distributor plate, electrical 2/2 + S K K Y H1 H2 _ Normally-closed contact = Öffner Example of application: Circuit diagram, electrical Normally-open contact = Schließer S =START Start push-button S = - Taster +24V _ 13 12 14 K S 11 14 A1 Y K H1 H2 A2 0V Normally-closed contact = Öffner Example of application: Practical assembly, electrical Normally-open contact = Schließer Start push-button S S= =START - Taster Festo Didactic 162383 Hydraulic labelling sets 1/1 Attach adhesive foil A B P T Y Clip angle plate onto valve A B P T Y1 Y2 A B P T Design 14 identical U-shaped retaining plates Self-adhesive foil with 14 pre-punched identification labels Remove the identification labels from the foil and affix these to the retaining plate Function Additional identification labels may be clipped onto the directional control valves listed The labels are to be allocated according to part number and variants, A, B, C, Note In practice, hydraulic valves which are identical in their function are in some cases attributed different symbols by different manufacturers, e.g cross position left or right with 4/2-way valves This is permissible according to DIN ISO standard 1219 Part 1, dated November 1993, "Fluid power, graphic symbols and circuit diagrams" Additional identification labels for 4/2-way and 4/3-way valves: As with the original identification labels, the additional type describes the function of directional control valves Normal position and ports A and B have been interchanged Additional identification plates for 2/2- and 3/2-way valves: These are clipped onto the 4/2-way valves One hydraulic port is not connected This is possible since the quick coupling nipples are self-sealing Festo Didactic A B P T A B P T A B P T Festo Didactic 167080 Pressure switch 1/1 Design The pressure switch is attached to a branch tee The three electrical connections are equipped with safety connectors Housing (1), diaphragm (2), spring (3), spindle (4), microswitch (5) and connector socket (6) Function When pressure is applied to the diaphragm (2), this expands against the spring (3) and actuates the microswitch (5) The initial tension of the spring (3) can be adjusted by means of the spindle (4), thus also varying the pressure required to stretch the diaphragm (2) Once the pressure value corresponding to the spindle setting is reached, the contact of the microswitch (5) is actuated Note The branch tee with attached pressure switch can be interposed at any desired point in the hydraulic circuit or fitted close to a measuring or reference point Medium Mineral oil, recommended viscosity 22 cSt (mm2/s) Design Diaphragm switch Operating pressure p - MPa (10-70 bar) Max permissible pressure pmax 12 MPa (120 bar) Hysteresis ~15% Voltage Up to 250 V Max continuous load rating 2A Connections, hydraulic For coupling sockets/nipples Connections, elektrical For mm safety connector plug Adjustment Manuel, using 2.5 mm Allen key Actuation Hydraulic Subject to change Festo Didactic Technical data Festo Didactic 167082 4/2-way solenoid valve 1/2 A B P T Y Y1 A P B T Design The 4/2-way solenoid valve is mounted on a function plate equipped with four nipple connectors The component is fitted to the grid system of the profile plate by means of the two blue levers (mounting variant “A”) The valve consists of: Piston (1), spring (2), housing (3), solenoid coil (4), armature (5) Function The normal position of the valve, with flow from P to A and B to T, is shown in the sectional view The piston (1) is held by the spring (2) in the position shown in the sectional view Hydraulic fluid flows from the supply port P via the annular groove of the piston (1) to the working port A At the same time, the working port B is connected to the return-line port T A position with flow from P to B is achieved by applying power to the solenoid coil (4) The armature (5) presses the piston (1) against the spring (2) This links the supply port P to the working port B via the annular groove of the piston (1) and at the same time connects the working port A to the return-line port T Festo Didactic 167082 4/2-way solenoid valve 2/2 1.2 ν: 30 cSt ϑ: 49°C p (MPa) P B A T P A 0.8 0.6 0.4 B T 0.2 0 Pressure-drop/ flow-rate characteristic qV (l/min) Note The valve ports are identified by letters A, B Working ports P Supply port T Return-line port (tank connection) The electrical connections are protected against overvoltage The switching status is indicated by an LED Technical data Medium Mineral oil, recommended viscosity 22 cSt (mm2/s) Operating pressure p MPa (60 bar) Max permissible pressure pmax 12 MPa (120 bar) Voltage 24 V DC Power rating 12 W Actuation Electrical Connections, electrical For mm safety connector plug Connections, hydraulic For coupling sockets Subject to change Festo Didactic 167083 4/3-way solenoid valve, closed in mid-position 1/2 A B P T Y1 Y2 Y1 Y2 A P B T Design The 4/3-way solenoid valve is mounted on a function plate equipped with four connection nipples The component is fitted to the grid system of the profile plate by means of the two blue levers (mounting variant “A”) The valve consists of: Piston (1), housing (2), springs (3), (4), solenoid coil (5), (6), armatures (7), (8) Function The sectional view shows the mid-position, with ports P, T, A and B closed The switching position with flow from P to A is achieved by applying power to the solenoid coil Y2 (5), in which the armature (7) moves the piston (1) against the spring (4) The result is that the supply port P is linked to the working port A via the annular groove of the piston (1), while at the same time the working port B is linked to the return-line port T via the second annular groove The switching position with flow from P to B is achieved by applying power to the solenoid coil Y1 (6), in which the armature (8) moves the piston (1) against the spring (4) The result is that the supply port P is linked to the working port B via the annular groove of the piston (1), while at the same time the working port A is linked to the return-line port T via the second annular groove Festo Didactic 167083 4/3-way solenoid valve, closed in mid-position 2/2 1.2 ν: 30 cSt ϑ: 46°C qV: P B p (MPa) 0.8 A T 0.6 0.4 0.2 0 Pressure-drop/ flow-rate characteristic qV (l/min) Note The valve ports are identified by letters A, B Working ports P Supply port T Return-line port (tank connection) The electrical connections are protected against overvoltage The switching status is indicated by an LED Technical data Medium Mineral oil, recommended viscosity 22 cSt (mm2/s) Operating pressure p MPa (60 bar) Max permissible pressure pmax 12 MPa (120 bar) Voltage 24 V DC Power rating 12 W Connections, electrical For mm safety connector plug Connections, hydraulic For coupling sockets Actuation Electrical Subject to change Festo Didactic 183322 Limit switch, electrical, actuated from the left 1/1 S 1 Design A microswitch with roller lever and electrical connections is installed in a plastic housing The electrical connection is effected by means of safety connectors or via a 3-pin plug socket The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant “B”) Note The microswitch can be connected up to act as a normally-open contact (1), normallyclosed contact (2) or changeover contact (3) In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction The limit switch must not be actuated from the front Mechanically-actuated electrical microswitch in limit-switch housing Voltage 24 V DC Contact rating Max A Switching frequency Max 200 Hz Reproducible switching accuracy 0.2 mm Switch travel 2.7 mm Actuation force 5N Connections For mm safety connector plug or 3-pin plug socket Electromagnetic compatibility Emitted interference tested to EN 500 81-1 Noise immunity tested to EN 500 82-1 Subject to change Festo Didactic 2 The two electrical limit switches, PN 183322 for actuation from the left and PN 183345 for actuation from the right, have the same symbol in the circuit diagram Function This electrical limit switch consists of a mechanically-actuated microswitch It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder The switch contacts are used to open or close a circuit The microswitch returns to its original position when the roller lever is released Design Technical data Festo Didactic 183345 Limit switch, electrical, actuated from the right 1/1 S 1 Design A microswitch with roller lever and electrical connections is installed in a plastic housing The electrical connection is effected by means of safety connectors or via a 3-pin plug socket The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant “B”) Note The microswitch can be connected up to act as a normally-open contact (1), normallyclosed contact (2) or changeover contact (3) In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction The limit switch must not be actuated from the front Mechanically-actuated electrical microswitch in limit=switch housing Voltage 24 V DC Contact rating Max A Switching frequency Max 200 Hz Reproducible switching accuracy 0.2 mm Switch travel 2.7 mm Actuation force 5N Connections For mm safety connector plug or 3-pin plug socket Electromagnetic compatibility Emitted interference tested to EN 500 81-1 Noise immunity tested to EN 500 82-1 Subject to change Festo Didactic 2 The two electrical limit switches, PN 183345 for actuation from the left and PN 183322 for actuation from the right, have the same symbol in the circuit diagram Function This electrical limit switch consists of a mechanically-actuated microswitch It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder The switch contacts are used to open or close a circuit The microswitch returns to its original position when the roller lever is released Design Technical data Festo Didactic ... tested to EN 500 82-1 Subject to change Festo Didactic 14 A1 24 34 44 A2 A1 11 12 21 22 31 32 41 42 A2 11 A1 12 21 31 14 22 24 32 34 42 41 44 A2 Electromagnetic compatibility Emitted interference... (120 bar) Connections To accept connector sockets Subject to change Festo Didactic PN 1 844 89 300 mm PN 1 844 88 40 0 mm Technical data Festo Didactic 152858 Hydraulic motor, l/min 1/2 vereinfachtes... Description Order No Coupling nipple 342 047 Coupling socket 0 34 649 Pressure relieving device 152 971 TP601 • Festo Didactic D-8 Appendix TP601 • Festo Didactic 152 841 Pressure gauge 1/1 B A Design