Leseprobe en

Electrohydraulics
Basic Level
Workbook
TP 601
CD-ROM included
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Festo Didactic
551150 EN
Order no.:
Date:
Author:
Graphics
Layout:
551150
05/2011
Renate Aheimer, Eberhard Bauer, Frank Ebel,
Christine Lffler, Dieter Merkle, Helmut Werner
Doris Schwarzenberger
09/2011, Beatrice Huber, Susanne Durz
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Table of contents
Use for intended purpose __________________________________________________________________ V
Preface _________________________________________________________________________________ VI
Introduction ____________________________________________________________________________ VIII
Work instructions and safety precautions _____________________________________________________ IX
Training package for electro-hydraulics, basic level (TP 601) ____________________________________ XI
Learning objectives, electro-hydraulics ______________________________________________________ XII
Allocation of learning objectives to exercises__________________________________________________ XIV
Equipment set _________________________________________________________________________ XVII
Allocation of components to exercises _______________________________________________________ XXI
Notes for the teacher/trainer______________________________________________________________ XXII
Structure of the exercises ________________________________________________________________ XXIII
Component designations _________________________________________________________________ XXIII
CD ROM contents _______________________________________________________________________ XXIV
Exercises and solutions

Exercise 1:
Exercise 2:
Exercise 3:
Exercise 4:
Exercise 5:
Exercise 6:
Exercise 7:
Exercise 8:
Exercise 9:
Exercise 10:
Exercise 11:
Exercise 12:
Exercise 13:
Exercise 14:
Exercise 15:
Setting up a hydraulic workstation________________________________________________1

Commissioning a two-column hydraulic press ____________________________________ 11
Feeding pressings ___________________________________________________________ 19
Sorting out crates ___________________________________________________________ 35
Actuating a lifting platform ____________________________________________________ 51
Clamping valve manifolds _____________________________________________________ 65
Clamping engine blocks ______________________________________________________ 83
Bending metal tubing ________________________________________________________ 95
Press fitting a gear unit bearing _______________________________________________ 107
Chamfering workpieces ______________________________________________________ 123
Opening and closing a hardening furnace door ___________________________________ 135
Deep drawing sheet metal parts _______________________________________________ 151
Transporting containers _____________________________________________________ 177
Eliminating a malfunction at a container handling unit _____________________________ 191
Festo Didactic GmbH & Co. KG 551150
III
Exercises and worksheets

Exercise 1:
Exercise 2:
Exercise 3:
Exercise 4:
Exercise 5:
Exercise 6:
Exercise 7:
Exercise 8:
Exercise 9:
Exercise 10:
Exercise 11:
Exercise 12:
Exercise 13:
Exercise 14:
Exercise 15:
IV

Use for intended purpose

The training package for basic level electro-hydraulics may only be used:
For its intended purpose in teaching and training applications
When its safety functions are in flawless condition
The components included in the training package are designed in accordance with the latest technology, as
well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and
the components may be impaired, if they are used improperly.
The training system from Festo Didactic has been developed and manufactured exclusively for training and
vocational education in the fields of automation and technology. The respective training companies and/or
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
and/or any third parties, which occur during use of the equipment set in situations which serve any purpose
other than training and/or vocational education, unless such damages have been caused by Festo Didactic
due to malicious intent or gross negligence.
Preface
Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. Correspondingly, the training system is broken down as follows:
Technology oriented training packages
Mechatronics and factory automation
Process automation and control technology
Mobile robotics
Hybrid learning factories
The training system for automation and technology is continuously updated and expanded in accordance
with developments in the field of education, as well as actual professional practice.
The technology packages deal with various technologies including pneumatics, electro-pneumatics,
hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,
electrical engineering, electronics and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and
electric drives is possible.
VI
All training packages are comprised of the following elements:

Hardware
Media
Seminars
Hardware
Hardware included in the training packages consists of industrial components and systems that are
specially designed for training purposes. The selection and design of the components encompassed by the
training packages are especially well matched to the projects included in the accompanying media.
Media
The media provided for the individual groups of topics are allocated to the teachware and software
categories. The practically oriented teachware includes:
Technical books and textbooks (standard works for imparting basic knowledge)
Workbooks (practical exercises with supplementary instructions and sample solutions)
Lexicons, manuals and technical books
(which provide technical information on groups of topics for further exploration)
Transparency sets and videos (for easy-to-follow, dynamic instruction)
Posters (for clear-cut representation of facts)
From the software category, programmes are made available for the following applications:
Digital training programmes (didactically and medially prepared learning content)
Simulation software
Visualisation software
Software for measurement data acquisition
Project engineering and design engineering software
Programming software for programmable logic controllers
The teaching and learning media are available in several languages. They are intended for use in classroom
instruction, but are also suitable for self-study.
Seminars
Comprehensive seminar offerings covering the contents of the training packages round out the programme
for training and vocational education.
Do you have suggestions or criticism regarding this manual?

If so, send us an e-mail at did@de.festo.com.
The authors and Festo Didactic look forward to your feedback.
VII
Introduction
This workbook is part of the training system for automation technology from Festo Didactic GmbH & Co. KG.
The system provides a solid basis for practice oriented training and vocational education. Training packages
TP 601 and TP 602 include electro-hydraulic controllers only.
The TP 601 basic level is suitable for fundamental training in the field of electro-hydraulic control
technology. On the basis of practically oriented problems, the workbook imparts knowledge regarding the
basic physical principles of electro-hydraulics, function and use of electro-hydraulic components and typical,
basic electrical circuits. Simple electro-hydraulic controllers can be set up with the equipment set. Basic
knowledge of hydraulic device technology is a prerequisite. The TP 602 advanced level is targeted at
vocational training in the field of electro-hydraulic control technology. More advanced electro-hydraulic
circuits can be set up with this equipment set.
Technical prerequisites for setting up the controllers include:
A Learnline or Learntop-S workstation equipped with a Festo Didactic slotted profile plate. The slotted
profile plate has 14 parallel T-slots at 50 mm intervals.
A hydraulic power unit (operating voltage: 230 V, 50 Hz, operating pressure: 6 MPa (60 bar),
volumetric flow: 2 l/min.)
A power pack with short-circuit protection (input: 230 V, 50 Hz, output: 24 V, max. 5 A)
Laboratory safety cables
Each of the circuits for all 15 exercises is set up using the TP 601 equipment set. The theoretical
fundamentals for understanding these exercises are included in the textbooks:
Hydraulics, basic level
Electro-hydraulics, basic level
Data sheets for the individual components are also available (cylinders, valves, sensors etc.).
VIII
Work and safety instructions
General
Trainees should only work with the circuits under the supervision of a trainer.
Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
Faults which may impair safety must not be generated in the training environment and must be
eliminated immediately.
Mechanical system
Only reach into the setup when it is at a complete standstill.
Mount all of the components securely onto the slotted profile plate.
Limit switches may not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Set all components up so that activation of switches and disconnectors is not made difficult.
Adhere to the instructions regarding positioning of the components.
Always set up cylinders together with the appropriate cover.
Electrical specifications
Use extra-low voltage only (max. 24 V DC).
Electrical connections may only be established in the absence of voltage.
Electrical connections may only be interrupted in the absence of voltage.
Only use connecting cables with safety plugs for electrical connections.
Pull the plug only when disconnecting connector cables never pull the cable.
Hydraulics
Limit system pressure to 6 MPa (60 bar).
Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).
In the case of double-acting cylinders, pressure could be increased relative to surface area ratio due to
pressure boosting. With a surface area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), this may
result in a pressure value of greater than 10 MPa (100 bar).
All valves, devices and hose lines are equipped with self-sealing quick-release couplings.
IX
Danger of injury when switching on the hydraulic power unit!

Cylinders may advance and retract automatically.
Hose line couplings
Never connect or disconnect hose lines when the hydraulic power unit is running, or while under
pressure!
Couplings must be connected in the unpressurised state.
Set the coupling socket vertically onto the coupling nipple!
The coupling socket and the coupling nipple must not be fitted askew.
Setting up hydraulic circuits
The hydraulic power unit and the electrical power pack must be switched off when assembling the
circuit.
Before commissioning, make sure that all tank lines have been connected and that all couplings
have been securely fitted.
Make sure that hose lines connected to the cylinder are rinsed with oil if the volume of oil
accommodated by the cylinder is less than the volume which can be contained by the hose lines.
Commissioning
Cylinders may only be commissioned with their covers in place.
Switch on the electrical power pack first, and then the hydraulic power unit.
Dismantling hydraulic circuits
Assure that pressure has been relived before dismantling the circuit.
Switch off the hydraulic power unit first, and then the electrical power pack.
If connections are decoupled while under pressure, pressure is trapped in the device by the non-return
valve in the coupling. This pressure can be vented with the pressure relief unit.
Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight devices which cannot be subjected to loads (e.g. directional control valves and sensors).
Simply clip the components into the slots on the slotted profile plate. Release the components from the
slots by actuating the blue lever.
Variant B, bolt system
Components with medium load capacity (e.g. hydraulic cylinders). These components are clamped to
the slotted profile plate with T-head bolts. The blue, knurled nut is used for clamping and loosening.
Variant C, screw system
For devices with high load capacity and devices which are seldom removed from the slotted profile plate
(e.g. the hydraulic power unit). These devices are fastened with socket head screws and T-head nuts.
Required accessories
A digital multimeter is required in order to ascertain the contact ratings of pushbuttons.
Current is measured with the digital multimeter.
Training package for electro-hydraulics, basic level (TP 601)

The TP 601 training package consists of a multitude of individual training materials. The subject matter of
this package is electro-hydraulic controllers. Individual components from training package TP 601 may also
be included in other packages.
Important TP 601 components
Permanent workstation with Festo Didactic slotted profile plate
Equipment sets or individual components (e.g. cylinders, valves and pressure gauges)
Complete laboratory setups
Media
The teachware for the TP 601 training package consists of a textbook and a workbook. The textbook imparts
fundamental electrical and hydraulics knowledge regarding electro-hydraulic controllers in a vivid, clear-cut
fashion. The workbook includes exercise sheets and worksheets for each of the 15 exercises, the solutions
to each individual worksheet and a CD-ROM. A set of ready-to-use exercise sheets and worksheets is
included in each workbook for all of the exercises.
Data sheets for the hardware components are made available along with the equipment set.
Media
Textbooks
Hydraulics, basic level

Electro-hydraulics, basic level
Workbooks
Electro-hydraulics, basic level (TP 601)

Electro-hydraulics, advanced level (TP 602)
DVD
Electro-pneumatics and electro-hydraulics, basic level
Set of posters
Hydraulics
Simulation programme
FluidSIM Hydraulic
Digital training programme
Web-based training, hydraulics basic hydraulics principles

Web-based training, electro-hydraulics basic electro-hydraulics principles
Web-based training, electrical engineering 1 basic electrical engineering principles
Web-based training, GRAFCET introduction to GRAFCET
Overview of media for training packages TP 601 and TP 602
Training programmes including hydraulics, electro-hydraulics and electrical engineering 1 are available as
software for training package TP 601. These training programmes concern themselves in detail with the
basic principles of hydraulics, electro-hydraulics and electrical engineering. The GRAFCET training
programme provides a comprehensive introduction to the new GRAFCET standard. Training content is
elucidated on the basis of practical case studies in a systematic, applications-oriented fashion.
The media are offered in several languages. You will find further training materials in our catalogues and on
the Internet.
XI
Learning objectives
XII
Circuits
Be able to safely commission hydraulic controllers.
Be able to explain and set up direct actuation.
Be able to plan and set up load-dependent speed controllers.
Be able to make use of indirect actuation.
Be able to select and make use of hydraulic and electrical components in accordance with economic
considerations.
Become familiar with two ways of storing signals: with double solenoid valves and by means of
electrical self-latching loops.
Be able to explain and set up signal storage in the hydraulic power section.
Be able to select solenoid valves based on control technology requirements.
Be able to depict the motion sequence of a controller as a function diagram.
Be able to make use of a limit switch for end-position monitoring.
Become familiar with basic logic functions, and be able to make use of them and set them up.
Be able to create and make use of a sequence table.
Be able to plan and set up speed controllers which are independent of load.
Be able to explain and set up an electrical latching circuit with dominant breaking signal.
Become familiar with latching circuits with varying performance features.
Be able to plan and set up pressure dependent speed controllers.
Be able to plan and set up bypass circuits.
Be able to lock relay controller signals electrically and mechanically.
Be able to plan and set up circuits for pulling loads.
Be able to plan and set up a pressure level controller for two levels.
Become familiar with various types of end-position control for cylinders and be able to select the
appropriate type.
Be able to reduce a systems energy consumption by means of pressure-free pump circulation.
Become familiar with simple operating modes and be able to take them into consideration in the
controller.
Be able to expand existing controllers and revise the respective documentation accordingly.
Be able to implement sequence control with two cylinders.
Be able to represent a simple sequence in GRAFCET.
Be able to detect and eliminate errors in simple electro-hydraulic controllers.
Components
Become familiar with the setup and function of a hydraulic pump.
Become familiar with the most important characteristics of a hydraulic pump.
Be able to select a hydraulic power unit on the basis of specified requirements.
Be familiar with the various types and possible uses of pressure-relief valves.
Become familiar with the setup and function of a double-acting cylinder.
Become familiar with the setup and function of a 4/2-way solenoid valve.
Become familiar with the setup and function of electrical pushbuttons and switches.
Become familiar with the setup and function of a relay.
Become familiar with the setup and function of 2/2 and 3/2-way solenoid valves.
Become familiar with the setup and function of a 4/2-way double solenoid valve.
Become familiar with the setup and function of a limit switch.
Become familiar with the setup and function of an electronic pressure switch.
Become familiar with the setup and function of a 4/2-way double solenoid valve.
Measurements and calculations
Be able to measure and calculate electrical current in an electro-hydraulic system.
Become familiar with contact ratings of electrical signal generators and be able to take them into
consideration in the electrical circuit.
XIII
Allocation of learning objectives to exercises

Exercise
10
11
12
13
14
15
Learning objectives
Become familiar with the setup and function of a
hydraulic pump.
Become familiar with the most important

characteristics of a hydraulic pump.
Be able to select a hydraulic power unit on the

basis of specified requirements.
Be familiar with the various types and possible

uses of pressure-relief valves.
Be able to safely commission hydraulic
controllers.
double-acting cylinder.
4/2-way solenoid valve.
Become familiar with the setup and function of

electrical pushbuttons and switches.
Be able to explain and set up direct actuation.
Be able to plan and set up load-dependent speed

controllers.

relay.
Be able to make use of indirect actuation.
Be able to measure and calculate electrical

current in an electro-hydraulic system.
Become familiar with contact ratings of electrical

signal generators and be able to take them into
consideration in the electrical circuit.
2/2 and 3/2-way solenoid valves.
Be able to select and make use of hydraulic and

electrical components in accordance with
economic considerations.
XIV
Exercise
10
11
12
13
14
15
Learning objectives
4/2-way double solenoid valve.
Become familiar with two ways of storing

signals: with double solenoid valves and by
means of electrical self-latching loops.
Be able to explain and set up signal storage in
the hydraulic power section.
Be able to select solenoid valves based on

control technology requirements.
Be able to depict the motion sequence of a

controller as a function diagram.

limit switch.
Be able to make use of a limit switch for endposition monitoring.
Become familiar with basic logic functions, and

be able to make use of them and set them up.
Be able to create and make use of a sequence

table.
Be able to plan and set up speed controllers

which are independent of load.
Learn to explain and set up an electrical latching

circuit with dominant breaking signal.
Become familiar with latching circuits with

varying performance features.

an electronic pressure switch.
Be able to plan and set up pressure dependent

speed controllers.
Be able to plan and set up bypass circuits.
XV
Exercise
10
11
12
13
14
15
Learning objectives
various 4/3-way solenoid valves.
Be able to lock relay controller signals

electrically and mechanically.
Be able to plan and set up circuits for pulling

loads.
Be able to plan and set up a pressure level
controller for two levels.
Become familiar with various types of endposition control for cylinders and be able to
select the appropriate type.
Be able to reduce a systems energy

consumption by means of pressure-free pump
circulation.
Become familiar with simple operating modes

and be able to take them into consideration in
the controller.
Be able to expand existing controllers and revise
the respective documentation accordingly.
Learn to implement sequence control with two
cylinders.
Be able to represent a simple sequence in
GRAFCET.
Be able to detect and eliminate errors in simple
electro-hydraulic controllers.
XVI
Equipment set
The equipment set has been put together for basic training in the field of electro-hydraulic control
technology. It includes all of the components which are necessary for mastering the specified learning
objectives, and can be supplemented with any other equipment sets.
Equipment set for electro-hydraulics, basic level (TP 601) 573037

Designation
Order number
Quantity
2-way flow control valve
544338
4/2-way solenoid valve with spring return
544346
4/2-way double solenoid valve, detenting
544352
4/3-way solenoid valve, mid-position closed
544347
On-off valve
152844
Mounting kit for cylinders
544371
Double-acting cylinder, 16/10/200, with cover
572746
One-way flow control valve
152843
Pressure-relief valve
544335
Pressure gauge
152841
Pressure switch, electronic
548612
9 kg weight for cylinder
152972
Limit switch, electrical, actuated from the left
183322
Limit switch, electrical, actuated from the right
183345
Proximity switch, electronic
548589
Relay, 3-off
162241
Non-return valve with hose, opening pressure: 0.6 MPa (6 bar)
548618
Signal input, electrical
162242
T-distributor
152847
4-way manifold plate with pressure gauge
159395
XVII
Graphic symbols, equipment set

Component
Graphic symbol
4/2-way solenoid valve

with spring return
M1
M1
4/2-way double solenoid valve,

detenting
M1
M1
M2
M2
4/3-way solenoid valve,

mid-position closed
M1
M1
M2
M2
On-off valve
Double-acting cylinder,
16/10/200, with cover
XVIII
Component
Graphic symbol
Pressure gauge
EN 60617-7
ISO 1219-1
RD (1)
BK1 (4), SP1
BK2 (5), SP2
WH (2)
BU (3)
m
Electrical limit switch
1
RD (1)
BK (4)
BU (3)
XIX
Component
Graphic symbol
Relay, 3-off
A1
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
A2
A1
A2
A1
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
A2
Non-return valve with hose

Opening pressure: 0.6 MPa (6 bar)

13
21
14
22
13
21
14
22
13
21
14
22
13
21
14
22
T-distributor
4-way manifold plate

with pressure gauge
XX
Allocation of components to exercises

TP 601 equipment set
Exercise
10
11
12
13
14
15
Component
4/2-way solenoid valve with spring return
4/2-way double solenoid valve, detenting
1
1
4/3-way solenoid valve, normally closed

On-off valve
Mounting kit for cylinders

Double-acting cylinder with cover
Pressure gauge
1
1
Electrical limit switch
Non-return valve, 0.6 MPa (6 bar)
T-distributor
4-way manifold plate with pressure gauge
1
1

Relay, 3-off
1
1
10
11
12
13
14
15
Required accessories
Exercise
Component
Cover for weight
Digital multimeter
Hydraulic power unit
Hose line, 600 mm
Hose line, 1000 mm
Power pack, 24 V DC
Hose line, 1500 mm
XXI
Notes for the teacher/trainer

Learning objectives
The basic learning objective of this workbook is to understand, plan, set up and safely commission basic
electro-hydraulic circuits. This knowledge is gained by means of theoretical questions and by actually
setting up the circuits on the slotted profile plate. This direct interaction involving both theory and practice
ensures faster progress and longer-lasting learning. The more specific learning objectives are documented
in the matrix. Concrete, individual learning objective are assigned to each exercise.
Required time
The time required for working through the exercises depends on the learners previous knowledge of the
subject matter. A time of roughly 1 to 1 hours can be assumed for each exercise.
Equipment set components
The textbook, the workbook and the equipment set are matched to each other. Only the components
included in a single TP 601 equipment set are required for all 15 exercises.
Each exercise can be set up on a slotted profile plate with a width of 1100 mm.
Standards
The following standards are used in this workbook:
DIN ISO 1219-1
Fluid power systems and components Graphic symbols and circuit diagrams
EN 60617-2 to EN 60617-8 Graphic symbols for diagrams
EN 81346-2
Industrial systems, installations and equipment and industrial products
Structuring principles and reference designations
Identification within the workbook
Solution texts and supplements in graphics or diagrams appear in red.
Identification within the exercise book
Texts which require completion are identified with a grid or grey table cells.
Graphics which require completion include a grid.
Training notes
Additional information is provided here regarding the didactic-methodological procedure, the individual
components and the completed controllers. These notes are not included in the exercise book.
XXII
Solutions
The solutions specified in this workbook result from test measurements. The results of your measurements
may deviate from these.
Learning topics
The table below contains an overview of the learning topics offered by educational institutions for selected
professions on the subject matter of basic electro-hydraulic circuits.
Vocation
Topic
Mechatronics technician
Examination of the flow of energy and information in electrical, pneumatic and hydraulic assemblies
Implementing mechatronic subsystems
Industrial mechanic
Installation and commissioning of technical control systems
Electronics engineer for

automation technology
Controllers, analysis and adaptation

Systems implementation and safety testing
Structure of exercises
All 15 exercises have the same methodological layout. The exercises are broken down into:
Title
Learning objectives
Problem description
Layout
Assignments
Work aids
Worksheets
The workbook includes the solutions for all of the worksheets for all 15 exercises.
Component designations
Components are designated in circuit diagrams in accordance with DIN ISO 1219-2. All of the components
included in any given circuit have the same primary identifying number. Letters are assigned depending on
each respective type of component. Consecutive numbers are assigned if several components of the same
type are included within a single circuit.
Cylinders:
Valves:
Sensors:
Signal input:
Accessories:
1A1, 2A1, 2A2 ...

1V1, 1V2, 1V3, 2V1, 2V2, 3V1
1B1, 1B2 ...
S1, S2
0Z1, 0Z2, 1Z1
XXIII
CD-ROM contents
The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional
media.
The CD-ROM contains the following folders:
Operating instructions
Images
Data sheets
FluidSIM circuit diagrams
Presentations
Operating instructions
Operating instructions for various components in the training package are available. These instructions are
helpful with regard to component use and commissioning.
Images
Photos and graphics of components and industrial applications are made available. These can be used to
illustrate individual tasks. Project presentations can also be supplemented with these illustrations.
Data sheets
The data sheets for the components included in the training package are supplied along with the equipment
set, and are additionally available as PDF files.
FluidSIM circuit diagrams
The FluidSIM circuit diagrams for all 15 exercises included in the technology package are contained in this
directory.
Presentations
Short presentations for components included in the training package are included in this directory. They can
be used, for example, for the creation of project presentations.
XXIV
Exercise 1
Setting up a hydraulic workstation
Learning objectives
After completing this exercise:
You will be familiar with the setup and function of a hydro pump.
You will be familiar with the most important characteristics of a hydro pump.
You will be able to select a hydraulic power unit on the basis of specified requirements.
Problem description
A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.
Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable
hydraulic power unit must be selected.
Layout
Hydraulic workstation
Exercise 1 Setting up a hydraulic workstation
1.
2.
3.
4.
Assignments
Describe the setup and function of a hydro pump.
Calculate the volumetric flow rate of a hydro pump.
Calculate the efficiency of a hydro pump.
Select a hydraulic power unit on the basis of specified requirements.
Work aids
Data sheets
Hydraulics textbook
1. Describing setup and function of a hydro pump

Information
Hydro pumps are displacement pumps which function on the basis of suction and displacement.
We differentiate amongst three basic types of hydro pumps on the basis of displacement volume:
Constant displacement pump:

Constant displacement volume
Variable displacement pump:

Adjustable displacement volume
Control pump:
Displacement volume is controlled on the basis of pressure,
flow rate and power
The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and the
drive speed dictate the pumps delivery rate which is specified in litres per minute.
Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load
resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.
a) Describe the function of the gear pump shown in the figure.

1
2
3
Cutaway view of a gear pump, 1: trapped fluid, 2: pressure chamber, 3: suction chamber
Gear pumps are constant-displacement pumps, because the displaced volume which is determined by
the gear tooth gap is unchangeable.
The gear pump functions on the basis of the following principle:
One gear wheel is connected to the drive unit, and the other rotates along with it via the toothing.
As a result of the volume enlargement which occurs when a tooth leaves a gear tooth gap, a
partial vacuum is generated in the suction chamber.
The hydraulic fluid fills the tooth chambers and is conveyed along the housing wall and into the
pressure chamber.
Here, the hydraulic fluid is displaced from the tooth chambers and into the hydraulic lines by the
teeth which then enter the tooth gaps.
Training notes
Trapped fluid is located in the tooth gaps between the suction chamber and the pressure chamber. This is
fed to the pressure chamber via a slot, because pressure peaks would otherwise occur due to
compression of the trapped oil which would result in noise and destruction of the pump.
Pump leakage oil quantities are determined by the size of the gap (between housing, tooth crests and the
sides of the teeth), overlapping of the gears, viscosity and speed.
b) Name the circuit symbol shown below and briefly describe the function of its components.
1
3
P
4
Circuit symbols for a hydraulic power unit
1.
Electric motor with a single direction of rotation

Drive for hydro pumps
2.
Hydraulic pump
Pump with constant delivery rate. The volumetric flow rate is dictated by motor speed and
displacement volume per revolution.
3.
Pressure gauge
Indicates prevailing pressure with a specified tolerance.
4.
Adjustable pressure-relief valve without oil return port. The valve begins to open when an
adjustable pressure level is reached.
c)
Match up the individual components of the hydraulic power unit with the corresponding numbers in the
drawing.
10
11
9
8
7
3
6
Schematic diagram of a hydraulic power unit
Component
Designation
Drain screw
Suction chamber
Suction tube
10
Ventilation with air filter
Moderating plate
Filling filter
Fill-level indicator, maximum fill-level
Fill-level indicator, minimum fill-level
Motor and pump
11
Return
Return chamber
2. Calculating the volumetric flow rate of a hydro pump

Information
Displacement volume V (also known as delivery rate or swept volume) is a measure of the size of the
pump. It designates the liquid volume which is delivered by the pump per revolution (or stroke).
The delivered liquid volume per minute is designated volumetric flow rate q. This results from
displacement volume V and speed in RPM n:
q = n V
Calculate the volumetric flow rate of a gear pump.
Given
Speed
Displacement volume
n = 1450 RPM
V = 2.8 cubic cm (per revolution)
Desired
Flow rate q in l/min.
Calculation
q = n V = 1450
1
cm3
dm3
l
3
= 4.06
= 4.06
2.8 cm = 4060
min
min
min
min
3. Calculating the efficiency of a hydro pump

Information
Mechanical power is converted to hydraulic power by pumps, during which power losses occur that are
expressed in terms of the pumps degree of efficiency.
Effective power Phyd generated by the pump depends upon operating pressure p and effective volumetric
flow rate qeff. Effective power is calculated with the equation:
Phyd = p qeff
Volumetric efficiency is the relationship between the pumps effective volumetric flow rate and its
theoretically calculated volumetric flow rate.
vol =
qeff
qth
qth = Vth n
qeff = Vth n vol
Given
Speed
Displacement volume
Effective volumetric flow rate
n = 1450 RPM
l
qeff = 8.6
at 100 bar
min
Desired
Efficiency vol
Calculation
qth = 6.5 cm3 1450
vol
1
l
= 9.4
min
min
l
qeff 8.6 min
=
=
= 0.92 = 92 %
l
qth
9.4
min
4. Selecting a hydraulic power unit

Information
Excerpts from three data sheets for hydraulic power units are included below. Select the power unit
which fulfils the following conditions:
Drive motor with 230 V nominal voltage
Frequency: 50 Hz
Delivery rate at nominal speed: 2.2 l/min.
Weight without oil: max. 20 kg
General
HA-5L-230-50
HA-5L-110-60
HA-20L-400-50
Length
580 mm
580 mm
580
Width
Height
300 mm
180 mm
300 mm
180 mm
300
180 mm
Empty
With oil
19 kg
24 kg
19 kg
24 kg
19 kg
29 kg
HA-5L-230-50
HA-5L-110-60
HA-20L-400-50
Motor
Alternating current, singlephase
Alternating current, 3-phase
Nominal power
650 W
550 W
550 W
Nominal voltage
230 V
110 V
400 V
Frequency
50 Hz
60 Hz
50 Hz
Nominal speed
1320 RPM
1680 RPM
1390 RPM
Protection
IP 20
IP 20
IP 20
Duty cycle
50%
50%
100%
Dimensions
Weight
Hydraulics
HA-5L-230-50
Medium
Mineral oil, recommended: 22 cSt (sq. mm / s)
Pump design
External gear pump
Geometric delivery rate
1.6 cubic cm
1.6 cubic cm
1.6 cubic cm
Delivery rate at nominal speed
2.2 l/min.
2.7 l/min.
2.2 l/min.
Operating pressure
0.5 to 6 MPa (5 to 60 bar)
Adjustment
Manual
Pressure gauge indicating range
0 to 10 MPa (0 to 100 bar)
Pressure gauge quality class
1.6
Oil tank capacity
Approx. 5 litres
Return filter filtration grade
90 m
Connection
One quick coupling socket each for P and T, one coupling for the line to the storage tank, one
connection for the discharge measuring receptacle
HA-5L-110-60
HA-20L-400-50
Approx. 5 litres
Approx. 10 litres
Which hydraulic power unit have you chosen? Give reasons for your selection.
The hydraulic power unit with the designation HA-5L-230-50 was selected. It fulfils the following
specified conditions:
Frequency: 50 Hz
10
Table of contents
Exercises and worksheets
Exercise 1:
Exercise 2:
Exercise 3:
Exercise 4:
Exercise 5:
Exercise 6:
Exercise 7:
Exercise 8:
Exercise 9:
Exercise 10:
Exercise 11:
Exercise 12:
Exercise 13:
Exercise 14:
Exercise 15:

II
Exercise 1
Setting up a hydraulic workstation
Learning objectives
After completing this exercise:
You will be familiar with the setup and function of a hydro pump.
You will be familiar with the most important characteristics of a hydro pump.
You will be able to select a hydraulic power unit on the basis of specified requirements.
Problem description
A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.
Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable
hydraulic power unit must be selected.
Layout
Hydraulic workstation
1.
2.
3.
4.
Assignments
Describe the setup and function of a hydro pump.
Calculate the volumetric flow rate of a hydro pump.
Select a hydraulic power unit on the basis of specified requirements.
Work aids
Data sheets
Hydraulics textbook
1. Describing setup and function of a hydro pump

Information
Hydro pumps are displacement pumps which function on the basis of suction and displacement.
We differentiate amongst three basic types of hydro pumps on the basis of displacement volume:
Constant displacement pump:

Constant displacement volume
Variable displacement pump:

Adjustable displacement volume
Control pump:
Displacement volume is controlled on the basis of pressure,
flow rate and power
The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and the
drive speed dictate the pumps delivery rate which is specified in litres per minute.
Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load
resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.
Name: __________________________________ Date: ____________
a) Describe the function of the gear pump shown in the figure.

1
2
3
Cutaway view of a gear pump, 1: trapped fluid, 2: pressure chamber, 3: suction chamber
Name: __________________________________ Date: ____________
b) Name the circuit symbol shown below and briefly describe the function of its components.
1
3
P
4
Circuit symbols for a hydraulic power unit
Name: __________________________________ Date: ____________
c)
Match up the individual components of the hydraulic power unit with the corresponding numbers in the
drawing.
10
11
9
8
7
3
6
Schematic diagram of a hydraulic power unit
Component
Designation
Drain screw
Suction chamber
Suction tube
Ventilation with air filter
Moderating plate
Filling filter
Fill-level indicator, maximum fill-level
Fill-level indicator, minimum fill-level
Motor and pump
Return
Return chamber
Name: __________________________________ Date: ____________
2. Calculating the volumetric flow rate of a hydro pump

Information
Displacement volume V (also known as delivery rate or swept volume) is a measure of the size of the
pump. It designates the liquid volume which is delivered by the pump per revolution (or stroke).
The delivered liquid volume per minute is designated volumetric flow rate q. This results from
displacement volume V and speed in RPM n:
q = n V
Calculate the volumetric flow rate of a gear pump.
Given
Speed
Displacement volume
n = 1450 RPM
Desired
Flow rate q in l/min.
Calculation
Name: __________________________________ Date: ____________
3. Calculating the efficiency of a hydro pump

Information
Mechanical power is converted to hydraulic power by pumps, during which power losses occur that are
expressed in terms of the pumps degree of efficiency.
Effective power Phyd generated by the pump depends upon operating pressure p and effective volumetric
flow rate qeff. Effective power is calculated with the equation:
Phyd = p qeff
Volumetric efficiency is the relationship between the pumps effective volumetric flow rate and its
theoretically calculated volumetric flow rate.
vol =
qeff
qth
qth = Vth n
qeff = Vth n vol
Given
Speed
Displacement volume
Effective volumetric flow rate
n = 1450 RPM
l
qeff = 8.6
at 100 bar
min
Desired
Efficiency vol
Calculation
Name: __________________________________ Date: ____________
4. Selecting a hydraulic power unit

Information
Excerpts from three data sheets for hydraulic power units are included below. Select the power unit
which fulfils the following conditions:
Frequency: 50 Hz
General
HA-5L-230-50
HA-5L-110-60
HA-20L-400-50
Length
580 mm
580 mm
580
Width
Height
300 mm
180 mm
300 mm
180 mm
300
180 mm
Empty
With oil
19 kg
24 kg
19 kg
24 kg
19 kg
29 kg
HA-5L-230-50
HA-5L-110-60
HA-20L-400-50
Motor
Alternating current, 3-phase
Nominal power
650 W
550 W
550 W
Nominal voltage
230 V
110 V
400 V
Frequency
50 Hz
60 Hz
50 Hz
Nominal speed
1320 RPM
1680 RPM
1390 RPM
Protection
IP 20
IP 20
IP 20
Duty cycle
50%
50%
100%
Dimensions
Weight
Name: __________________________________ Date: ____________
Hydraulics
HA-5L-230-50
Medium
Mineral oil, recommended: 22 cSt (sq. mm / s)
Pump design
External gear pump
Geometric delivery rate
1.6 cubic cm
1.6 cubic cm
1.6 cubic cm
Delivery rate at nominal speed
2.2 l/min.
2.7 l/min.
2.2 l/min.
Operating pressure
0.5 to 6 MPa (5 to 60 bar)
Adjustment
Manual
Pressure gauge indicating range
0 to 10 MPa (0 to 100 bar)
Pressure gauge quality class
1.6
Oil tank capacity
Approx. 5 litres
Return filter filtration grade
90 m
Connection
One quick coupling socket each for P and T, one coupling for the line to the storage tank, one
connection for the discharge measuring receptacle
HA-5L-110-60
HA-20L-400-50
Approx. 5 litres
Approx. 10 litres
Which hydraulic power unit have you chosen? Give reasons for your selection.
Name: __________________________________ Date: ____________
10
Name: __________________________________ Date: ____________

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Electrohydraulics

Exercises and solutions

Setting up a hydraulic workstation________________________________________________1

Festo Didactic GmbH & Co. KG 551150

Exercises and worksheets

Setting up a hydraulic workstation________________________________________________1

Festo Didactic GmbH & Co. KG 551150

Use for intended purpose

Festo Didactic GmbH & Co. KG 551150

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All training packages are comprised of the following elements:

Do you have suggestions or criticism regarding this manual?

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Work and safety instructions

Festo Didactic GmbH & Co. KG 551150

Danger of injury when switching on the hydraulic power unit!

Festo Didactic GmbH & Co. KG 551150

Training package for electro-hydraulics, basic level (TP 601)

Hydraulics, basic level

Electro-hydraulics, basic level (TP 601)

Electro-pneumatics and electro-hydraulics, basic level

Digital training programme

Web-based training, hydraulics basic hydraulics principles

Overview of media for training packages TP 601 and TP 602

Festo Didactic GmbH & Co. KG 551150

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Allocation of learning objectives to exercises

Become familiar with the most important

Be able to select a hydraulic power unit on the

Be familiar with the various types and possible

Become familiar with the setup and function of

Be able to explain and set up direct actuation.

Be able to plan and set up load-dependent speed

Become familiar with the setup and function of a

Be able to make use of indirect actuation.

Be able to measure and calculate electrical

Become familiar with contact ratings of electrical

Be able to select and make use of hydraulic and

Festo Didactic GmbH & Co. KG 551150

Become familiar with two ways of storing

Be able to select solenoid valves based on

Be able to depict the motion sequence of a

Become familiar with the setup and function of a

Be able to make use of a limit switch for endposition monitoring.

Become familiar with basic logic functions, and

Be able to create and make use of a sequence

Be able to plan and set up speed controllers

Learn to explain and set up an electrical latching

Become familiar with latching circuits with

Become familiar with the setup and function of

Be able to plan and set up pressure dependent

Be able to plan and set up bypass circuits.

Festo Didactic GmbH & Co. KG 551150

Be able to lock relay controller signals

Be able to plan and set up circuits for pulling

Be able to reduce a systems energy

Become familiar with simple operating modes

Festo Didactic GmbH & Co. KG 551150

Equipment set for electro-hydraulics, basic level (TP 601) 573037

2-way flow control valve

4/2-way solenoid valve with spring return