Industrial Pneumatics

Industrial Pneumatics Industrial Training Manual 1 Level 1 Version 3.0 April 2015 This manual was developed for use with the following products: FluidSIM Pneumatics 5.0 English DEPCO Pneumatics Training Center

Copyright 2015 DEPCO All Rights Reserved Unauthorized Duplication Prohibited The information contained in this manual was accurate at the time of its printing. DEPCO reserves the right to change specifications and operational performance of its products without notice. Any changes or corrections to the information in this publication will be incorporated in the future issues. No part of this document or accompanying software may be reproduced or modified in any manner without express written consent of DEPCO. All DEPCO Format IT Manuals conform to strict quality control standards.

Contents Lesson 1 Training System Safety...5 Lesson 2 Single-Acting Cylinder...13 Lesson 3 3/2-Way Valve, Open and Closed...29 Lesson 4 Double-Acting Cylinder...45 Lesson 5 5/2-Way Valve, with Selection Switch...57 Lesson 6 5/2-Way Valve, Pneumatically Operated...65 Lesson 7 5/2-Way Impulse Valve, Pneumatically Operated...73 Lesson 8 Roller Lever Valve...83 Lesson 9 Flow Control Valve...93 Lesson 10 Two-Pressure Valve... 109 Reference...119

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Lesson 1 Training System Safety Objectives After successfully completing Lesson 1, you will be able to: Explain the importance of working safely with pressurized components. Attach different pneumatic components to the profile plate. Use the air supply manifold to power the components on the profile plate. Identify the various components contained in the Training Center. Connect and disconnect air supply lines to components on the profile plate. Use the pressure regulating valve and the gauge to set a system operating pressure.

6 Industrial Pneumatics Training System Safety Average Lesson Time = 60 Minutes 1 Ensure not to drop any of the pneumatic components when assembling circuits to avoid costly damage to individual components. As with any industrial training equipment, you must practice operating it in a safe manner to prevent personal injury to yourself and to those around you. Always wear safety glasses when operating or observing pressurized pneumatic components. Terminology bar component compressor hose whip profile plate psi quick-release connector S.I. Procedure Step 1. Locate the worksheet 1. Locate the Lesson 1 Worksheet. 2. Complete Part I of the Lesson 1 Worksheet. 3. Complete Part II of the Lesson 1 Worksheet. Step 2. Equipment and supplies Locate the following: 4 mm air hose (3) 3/2-way valve, normally closed #152860 Pressure regulator valve with gauge #539756 Safety glasses

Step 3. Mount the components Industrial Pneumatics Training System Safety 7 1. Put on the safety glasses. 2. On the start-up valve, ensure the red shut-off valve is in the horizontal, closed position. See figure 1-1. Safety Glasses 1 figure 1-1 3. Press the spring-loaded keeper on the 3/2-way valve with push button, normally closed, and then position the valve two slots below the manifold. See figure 1-2. figure 1-2

1 8 Industrial Pneumatics Training System Safety 4. Press the spring-loaded keeper on the pressure regulator valve with gauge, and then position the valve to the right of the 3/2-way valve, normally closed. See figure 1-3. figure 1-3 Step 4. Connect the components 1. Connect an air hose from a port on the manifold to port 1 of the pressure regulator valve with gauge. 2. Connect an air hose from port 2 of the pressure regulator valve, with gauge to port 1 of the 3/2-way valve, normally closed.

3. Connect an air hose to port 2 of the 3/2-way valve, normally closed and leave the opposite end disconnected. See figure 1-4. Industrial Pneumatics Training System Safety 9 1 figure 1-4 4. Ensure all of the pneumatic connections are secure. Step 5. Test the circuit 1. Check the pressure regulator gauge on the start-up valve to ensure the system is pressurized correctly. The system should never be pressurized beyond 60 psi. To adjust the supply regulator knob, lightly pull upward, and then turn until it indicates 60 psi on the gauge. See figure 1-5. figure 1-5

10 Industrial Pneumatics Training System Safety 2. Push the supply regulator knob down to lock in the pressure setting. 1 3. On the start-up valve, turn the red shut-off valve to the vertical, open position. 4. To adjust the gauge on the pressure regulator valve, lightly pull the knob upward. 5. Turn the knob clockwise or counterclockwise until the gauge indicates 30 psi. 6. Push the supply regulator knob down to lock in the pressure setting. 7. Push the green button on the 3/2-way valve, normally closed. Notice the effect of low-pressure hose whip. Imagine a longer length of hose with metal fittings at high pressure. 8. On the start-up valve, turn the red shut-off valve to the horizontal, closed position. Step 6. Clean up the work area 1. Remove the air hoses by pressing the blue quick-release tabs at the top of the ports. Note: Do not remove the 6 mm air hoses connected to the start-up valve. 2. Remove the components from the profile plate. Note: Do not remove the start-up valve or manifold. 3. Return all items to the proper storage location. 4. When the lesson is complete, turn in the worksheet to the instructor. Step 7. Return to MediaPLUS Click the Next arrow on the MediaPLUS screen. Summary Pressurized air can be dangerous to use if safety precautions are not followed. Wearing safety glasses is an important safety rule to protect your eyes when working with pressurized air supplies. The pressure used for all lessons should not exceed 60 psi. Ensure to keep body parts away from moving actuators to prevent hand or bodily injury. Never remove air hoses from components under pressure, because dangerous hose whip can occur.

Lesson 1 Review Industrial Pneumatics Training System Safety 11 Answer the following questions in the classroom management system or on a piece of notebook paper. 1. When suddenly released in the atmosphere, pressurized air can travel at. A. 300 feet per second B. supersonic speed C. 100 feet per second D. the speed of sound 1 2. The maximum pressure of experiments using the Training Center should be psi. A. 25 B. 80 C. 50 D. 60 3. Which abbreviation is used to indicate that values are in the metric system of measurement? A. M.S. B. S.I. C. MSI D. SIU 4. The pressure gauges supplied with the Training Center indicate pressure in both pounds per square inch and. A. square meters B. bars C. inches of mercury D. ounces of pressure 5. The air used to power the pneumatic devices on the profile plate comes from which of the following? A. air compactor B. volume reducer C. air compressor D. atmospheric amplifier

12 Industrial Pneumatics Training System Safety DEPCO, LLC

Lesson 2 Single-Acting Cylinder Objectives After successfully completing Lesson 2, you will be able to: List several industrial applications that use pneumatic power. Explain the advantages of using pneumatic power instead of electrical power. Explain the disadvantages of using pneumatic power. Describe an appropriate manufacturing application for a single-acting cylinder. Place simulation components in the drawing area. Apply connections to components. Simulate pneumatic circuit operations. Create a working pneumatic circuit using the Training Center.

14 Industrial Pneumatics Single-Acting Cylinder Average Lesson Time = 60 Minutes 2 In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using a single-acting cylinder. Compressed air at the front end of the cylinder causes the piston to extend and the internal return spring returns the piston to its starting position. The circuit will then be created using the Training Center. Terminology actuator Component Library diagram linear T-junction way Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics.

Industrial Pneumatics Single-Acting Cylinder 15 Step 2. Become familiar with the FluidSIM interface 1. Study figure 2-1 to become acquainted with the FluidSIM program. Menu Bar 2 Drawing Area Status Bar Component Library Pane 2. On the File menu, point to New, and then click File. figure 2-1

16 Industrial Pneumatics Single-Acting Cylinder Step 3. Place components in the drawing area 1. On the Component Library pane, expand Supply Elements. See figure 2-2. 2 Note: The plus sign (+) will expand properties; the minus sign (-) will collapse properties. figure 2-2 2. Click and drag the compressed air supply to the lower-left portion of the drawing area. See figure 2-3. figure 2-3 3. On the toolbar, click the Show Grid button. See figure 2-4. figure 2-4

4. To turn off the grid, click the Show Grid button. 5. Press F3 on the keyboard to open the Find Symbol box. Industrial Pneumatics Single-Acting Cylinder 17 6. In the Find Symbol box, under Search, type air service unit, simplified representation. See figure 2-5. 2 7. From the menu of available components, click Air service unit, simplified representation. 8. Click OK. figure 2-5 9. Place the component on the drawing area to the right of the compressed air supply. See figure 2-6. figure 2-6 10. On the Component Library pane, collapse Supply Elements. 11. On the Component Library pane, expand Actuators.

18 Industrial Pneumatics Single-Acting Cylinder 12. Drag the single acting cylinder to the upper-middle portion of the drawing area. See figure 2-7. 2 13. Collapse Actuators. figure 2-7 14. Expand Directional Valves, and then expand Mechanically Operated. 15. Drag the 3/2-way valve with pushbutton (I) to the drawing area, and position it below and slightly to the left of the single-acting cylinder. See figure 2-8. figure 2-8 Note: The Roman numeral (I) represents the first option in the menu. For example, the first 3/2-way valve with pushbutton will be represented by (I).

Step 4. Apply pneumatic connections 1. Move the pointer over the compressed air supply port. Notice that the port turns green. Industrial Pneumatics Single-Acting Cylinder 19 2. Click and drag to port 1 of the air service unit, simplified representation. Note: If the lines cross, or impede components, the line will turn orange. Drag the line until a clear connection is made. 2 3. Move the pointer over port 2 of the air service unit, simplified representation. 4. Drag to port 1 of the 3/2-way valve, normally closed. See figure 2-9. figure 2-9 5. Move the pointer over port 2 of the 3/2-way valve, normally closed.

20 Industrial Pneumatics Single-Acting Cylinder 6. Drag to port 1 of the single-acting cylinder. See figure 2-10. 2 Step 5. Simulate the pneumatic circuit figure 2-10 1. On the toolbar, click the Start button to view the simulated pneumatic circuit. See figure 2-11. The thick, dark blue lines represent pneumatic lines that are under pressure while the thin, light blue lines represent pneumatic lines that are not currently under pressure. figure 2-11 Note: To start simulation mode, F9 can also be pressed on the keyboard. Components cannot be edited during simulation.

2. Position the pointer over the push buttons of the 3/2-way valve, normally closed. See figure 2-12. Industrial Pneumatics Single-Acting Cylinder 21 2 figure 2-12 3. Click and hold the 3/2-way valve, normally closed to extend the cylinder. 4. Release the mouse button to retract the cylinder. 5. Using the previous instructions, extend and retract the piston a few more times to gain a better understanding of the system. Notice how the air flow in the valve changes when the push button is engaged and released. 6. On the toolbar, click the Stop button to end simulation mode. See figure 2-13. figure 2-13 Note: To end simulation mode, F5 can also be pressed on the keyboard.

22 Industrial Pneumatics Single-Acting Cylinder Step 6. Change the valve used in the pneumatic circuit 1. In the drawing area, click the 3/2-way valve, normally closed, and then right-click the valve. 2 2. On the submenu, click Delete. See figure 2-14. figure 2-14 3. On the Component Library pane, drag the 3/2-way valve with pushbutton, normally open to the drawing area, below and slightly to the left of the single-acting cylinder. See figure 2-15. figure 2-15

4. Click the connection line from the single-acting cylinder to the air service unit, simplified representation. See figure 2-16. Industrial Pneumatics Single-Acting Cylinder 23 2 Note: If lines cross or impede components, drag the line until a clear connection is made. 5. Press DELETE on the keyboard. figure 2-16 Step 7. Apply connections 1. Move the pointer over port 2 of the air service unit, simplified representation. 2. Drag to port 1 of the 3/2-way valve, normally open. 3. Move the pointer over port 2 of the 3/2-way valve, normally open.

24 Industrial Pneumatics Single-Acting Cylinder 4. Drag to port 1 of the single-acting cylinder. The circuit diagram should look similar to figure 2-17. 2 figure 2-17 Step 8. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice that the piston in the cylinder automatically extends due to the open starting position of the valve. 2. Position the pointer over the push button of the 3/2-way valve, normally open, and then click and hold the push button. Notice that the cylinder in the piston retracts. 3. Release the mouse button and the cylinder extends. 4. Extend and retract the piston a few times to gain a better understanding of how the system works. 5. On the toolbar, click Stop. Step 9. Equipment and supplies Locate the following: 4 mm air hose (2) 3/2-way valve, normally closed #152860 3/2-way valve, normally open #152861 Safety glasses Single-acting cylinder #152887

Step 10. Place the components on the trainer 1. On the start-up valve, turn the red shut-off valve to its horizontal, closed position. Industrial Pneumatics Single-Acting Cylinder 25 2. Press the spring-loaded keeper on the 3/2-way valve, normally closed, and then attach the component two slots below the manifold in the middle portion of the profile plate. 3. Attach the single-acting cylinder two slots below the 3/2-way valve,normally closed, in the middle portion of the profile plate. 2 4. The components should be arranged on the profile plate similar to figure 2-18. Step 11. Connect the components on the trainer figure 2-18 1. Insert an air hose from a port on the manifold to port 1 of the 3/2-way valve, normally closed. See figure 2-19. figure 2-19

26 Industrial Pneumatics Single-Acting Cylinder 2. Insert an air hose from port 2 of the 3/2-way valve, normally closed, to port 1 of the single-acting cylinder. 3. Carefully check all connection points to make sure they are secure. 2 Safety Glasses 4. Put on the safety glasses. 5. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. The system should never be pressurized beyond 60 psi. 6. Open the pressure regulator valve to supply air to the system. To open the valve, turn the red dial from its horizontal, closed position to the vertical, open position. 7. On the 3/2-way valve, normally closed, push the green button. See figure 2-20. Notice that you created a working pneumatic system identical to the circuit diagram created in the FluidSIM program. figure 2-20 8. On the 3/2-way valve, normally closed, continue to push the green button to view the pneumatic system. 9. Close the shut-off valve by returning the red dial to its horizontal, closed position. Step 12. Change the valve used in the pneumatic circuit 1. Remove the air hoses connected to the 3/2-way valve, normally closed, by pressing the blue quick-release tabs at the top of the ports. 2. On the 3/2-way valve, normally closed, press the spring-loaded keeper, and then remove the component from the profile plate.

3. Attach the 3/2-way valve, normally open, to the spot vacated by the normally closed valve. 4. Insert the air hose connected to the manifold into port 1 of the 3/2-way valve, normally open. Industrial Pneumatics Single-Acting Cylinder 27 5. Insert the opposite end of the air hose connected to the singleacting cylinder to port 2 of the 3/2-way valve, normally open. 6. Open the pressure regulator valve to supply air to the system. To open the valve, turn the red dial from its horizontal, closed position to its vertical, open position. The system should never be pressurized beyond 60 psi. Notice that the piston in the singleacting cylinder extends without pushing the green button. It extends because of the valve s open position, which allows air to flow straight through the valve to other components. See figure 2-21. 2 figure 2-21 7. On the 3/2-way valve, normally open, continue to push the green button to view the pneumatic system. 8. Close the shut-off valve by returning the red dial to its horizontal, closed position. 9. Remove the air hoses by pressing the blue quick-release tabs at the top of the ports. Note: Do not remove the 6 mm air hoses connected to the start-up valve. 10. Remove the components from the profile plate. Note: Do not remove the start-up valve or manifold. 11. Return all items to the proper storage location.

28 Industrial Pneumatics Single-Acting Cylinder Step 13. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click NO. 2 3. Click the Next butotn on the media screen. Summary In this lesson, you learned about single-acting cylinders. You placed components in the drawing area and applied connections to components before simulating the circuit. You also created the circuit using the Training Center. Lesson 2 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The actuator that creates linear motion is called a(n). A. linear extender B. cylinder C. air motor D. extension module 2. Which of the following components converts air supply energy into motion to perform work? A. automata B. extender C. rotator D. actuator 3. A major feature of the program is the close connection with familiarity and simulation. A. CAM B. CAT C. CAD D. DAT 4. The lists all of the functions needed for creation and simulation of circuit diagrams. A. component mix B. Main menu C. toolbar D. View menu 5. The contains pneumatic and electrical components for the creation of new circuit diagrams. A. project B. Component Mix C. Component Library D. none of the answers are correct

Lesson 3 3/2-Way Valve, Open and Closed Objectives After successfully completing Lesson 3, you will be able to: Identify different types of valves and provide application information. Identify the characteristics of directional control valves. Explain the designations used to describe a directional control valve. Build and operate a circuit that requires a 3/2-way valve, normally open and closed. Apply connections and simulate a pneumatic circuit. Describe the difference between initial and normal valve positioning.

30 Industrial Pneumatics 3/2-Way Valve, Open and Closed Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using 3/2-way valves, both closed and open. The closed valve must be actuated by the push button to allow airflow through the valve to other components. The open valve automatically allows air to flow freely through the valve to other components unless actuated by the push button, which causes the valve to close. The circuit will then be created using the Training Center. 3 Terminology 3/2-way connectors normally closed normally open directional control valve (DCV) exhaust port initial position Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. Step 2. Place components on the drawing area 1. On the Component Library pane, expand Supply Elements.

2. Drag the compressed air supply to the lower-left portion of the drawing area. See figure 3-1. Industrial Pneumatics 3/2-Way Valve, Open and Closed 31 3 figure 3-1 3. Drag the Air service unit, simplified representation, to the right of the compressed air supply. See figure 3-2. figure 3-2

32 Industrial Pneumatics 3/2-Way Valve, Open and Closed 4. Collapse Supply Elements. 5. Expand Actuators, and then drag the single-acting cylinder to the upper-middle portion of the drawing area. See figure 3-3. 3 figure 3-3 6. Collapse Actuators. 7. Expand Direction Control Valves, and then expand Mechanically Operated.

8. Drag the 3/2-way valve with pushbutton, normally closed, to the drawing area, and then place it under the single-acting cylinder. See figure 3-4. Industrial Pneumatics 3/2-Way Valve, Open and Closed 33 3 figure 3-4 9. Drag another 3/2-way valve with pushbutton, normally closed to the drawing area, and then place it under the first 3/2-way valve, normally closed. See figure 3-5. figure 3-5

34 Industrial Pneumatics 3/2-Way Valve, Open and Closed 10. Collapse Mechanically Operated, and then collapse Directional Valves. Step 3. Apply pneumatic connections 1. Move the pointer over the compressed air supply port. 2. Drag to port 1 of the air service unit, simplified representation. 3 3. Move the pointer over port 2 of the air service unit, simplified representation. 4. Drag to port 1 of the lower 3/2-way valve, normally closed. 5. Move the pointer over port 2 of the lower 3/2-way valve, normally closed. 6. Drag to port 1 of the upper 3/2-way valve, normally closed. 7. Move the pointer over port 2 of the upper 3/2-way valve, normally closed. 8. Drag to port 1 of the single-acting cylinder. The circuit diagram should look similar to figure 3-6. figure 3-6

Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. 2. Press and hold CTRL on the keyboard. Industrial Pneumatics 3/2-Way Valve, Open and Closed 35 3. Move the pointer over the push button on the lower 3/2-way valve, normally closed, and then click to engage. See figure 3-7. Notice that the valve shifts from its initially closed position to an open position, which is indicated by the dark blue line showing air flow to the upper 3/2-way valve, normally closed. 3 4. On the upper 3/2-way valve, normally closed, click the push button. Notice that the valve shifts to an open position, allowing air to flow to the single-acting cylinder, which is indicated by the extension of the piston in the cylinder. 5. Release CTRL. Notice that both valves shift back to their initially closed positions and that the piston in the cylinder retracts. 6. On the toolbar, click Stop. figure 3-7

36 Industrial Pneumatics 3/2-Way Valve, Open and Closed Step 5. Change the valve used in the pneumatic circuit 1. Click the upper 3/2-way valve, normally closed, and then right-click the upper 3/2-way valve, normally closed. 2. On the submenu, click Delete. 3. On the Component Library pane, expand Directional Valves, and then expand Mechanically Operated. 3 4. Drag the 3/2-way valve with pushbutton, normally open to the drawing area, and then place it above the 3/2-way valve, normally closed. See figure 3-8. figure 3-8 5. Delete the connection line from the single-acting cylinder to the 3/2-way valve, normally open. Step 6. Apply connections 1. Move the pointer over port 2 of the 3/2-way valve, normally closed. 2. Drag to port 1 of the 3/2-way valve, normally open. 3. Move the pointer over port 2 of the 3/2-way valve, normally open.

4. Drag to port 1 of the single-acting cylinder. The circuit diagram should look similar to figure 3-9. Industrial Pneumatics 3/2-Way Valve, Open and Closed 37 3 figure 3-9 Step 7. Simulate the pneumatic circuit 1. On the toolbar, click Start. 2. Press and hold CTRL.

38 Industrial Pneumatics 3/2-Way Valve, Open and Closed 3. Move the pointer over the push button on the 3/2-way valve, normally closed, and then click to engage. Notice that the air flow travels to the single-acting cylinder and the piston extends. See figure 3-10. 3 4. On the 3/2-way valve, normally open, click the push button. Notice that the valve shifts to a closed position, stopping air flow to the single-acting cylinder, which is indicated by the retraction of the piston in the cylinder. 5. Release CTRL. 6. On the 3/2-way valve, normally closed, click the push button. Notice that the piston in the cylinder extends and immediately retracts due to the spring-return valve located in the cylinder. 7. On the toolbar, click Stop. figure 3-10

Step 8. Equipment and supplies Locate the following: 4 mm air hose (3) 3/2-way valve, normally closed #152860 (2) 3/2-way valve, normally open #152861 Safety glasses Industrial Pneumatics 3/2-Way Valve, Open and Closed 39 Single-acting cylinder #152887 3 Step 9. Place components on the trainer 1. On the start-up valve, turn the red shut-off valve to its horizontal, closed position. 2. Attach the single-acting cylinder two slots below the manifold in the middle portion of the profile plate. 3. Attach the first 3/2-way valve, normally closed, two slots below the single-acting cylinder. 4. Attach the remaining 3/2-way valve, normally closed, two slots below the first 3/2-valve, normally closed. 5. The components should be arranged on the profile plate similar to figure 3-11. figure 3-11

40 Industrial Pneumatics 3/2-Way Valve, Open and Closed Step 10. Connect the components on the trainer 1. Insert an air hose from a port on the manifold to port 1 of the lower 3/2-way valve, normally closed. 2. Insert an air hose from port 2 of the lower 3/2-way valve, normally closed, to port 1 of the upper 3/2-way valve, normally closed. 3. Insert an air hose from port 2 of the upper 3/2-way valve, normally closed, to port 1 of the single-acting cylinder. See figure 3-12. 3 figure 3-12 4. Carefully check all connection points to ensure that they are secure. Safety Glasses Note: The system should never be pressurized beyond 60 psi. 5. Put on the safety glasses. 6. Open the pressure regulator valve to supply air to the system. 7. On the lower 3/2-way valve, normally closed, push and hold the green button. 8. On the upper 3/2-way valve, normally closed, push and hold the green button. Notice that the piston in the single-acting cylinder extends. 9. Release the push buttons. 10. Continue to extend and retract the piston to gain a better understanding of how the system operates. 11. Close the shut-off valve by returning the red dial to its horizontal, closed position. 12. Remove the air hoses from the upper 3/2-way valve, normally closed by pressing the blue quick-release tabs at the top of the ports. 13. Remove the upper 3/2-way valve, normally closed, from the profile plate.

14. Attach the 3/2-way valve, normally open, in the spot vacated by the 3/2-way valve, normally closed. 15. Reconnect the air hoses between the components. See figure 3-13. Industrial Pneumatics 3/2-Way Valve, Open and Closed 41 3 figure 3-13 16. Carefully check all connection points to ensure that they are secure. 17. Open the pressure regulator valve to supply air to the system. 18. On the 3/2-way valve, normally closed, push and hold the green button. Notice that the piston in the single-acting cylinder extends. See figure 3-14. Note: The system should never be pressurized beyond 60 psi. figure 3-14

42 Industrial Pneumatics 3/2-Way Valve, Open and Closed 19. On the 3/2-way valve, normally open, push and hold the green button. Notice that the piston in the single-acting cylinder retracts. 20. Release the push buttons. 21. Continue to extend and retract the piston to gain a better understanding of how the system operates. 22. Close the shut-off valve by returning the red dial to its horizontal, closed position. 3 23. Remove the air hoses by pressing the blue quick-release tabs at the top of the ports. Note: Do not remove the 6 mm air hoses connected to the start-up valve. 24. Remove the components from the profile plate. Note: Do not remove the start-up valve or manifold. 25. Return all items to the proper storage location. Step 11. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. Summary In this lesson, you learned about directional control valves and used 3/2-way valves. You placed simulation components on the drawing area and applied connection lines to the drawing area components before simulating the circuit. You also created the circuit diagram on the trainer.

Lesson 3 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The first number in a valve description, such as 3/2-way DCV, describes which of the following? A. switching positions B. ports C. normally open D. normally closed Industrial Pneumatics 3/2-Way Valve, Open and Closed 43 2. The second number in the valve description, such as 5/3-way DCV, describes which of the following? A. switching positions B. ports C. normally open D. normally closed 3 3. A 3/2-way DCV that is normally closed will. A. let air pass with no signal applied B. stop air passage with no signal applied C. have a push button D. have a selector switch 4. The -way valve is becoming obsolete due to the increased versatility of the 5/2-way valve s double port exhausting features. A. 3/2 B. 2/4 C. 2/2 D. 4/2 5. The primary use for a 2/2-way DCV is. A. logic control for a DCV B. single-acting cylinder operations C. shut-off functions D. adjustable flow control

44 Industrial Pneumatics 3/2-Way Valve, Open and Closed DEPCO, LLC

Lesson 4 Double-Acting Cylinder Objectives After successfully completing Lesson 4, you will be able to: Explain the difference between absolute and air gauge pressure readings. Recite the value for atmospheric pressure at sea level. Explain the function of a barometer. Identify basic pneumatic principles. Explain how a double-acting cylinder operates. Build and operate a circuit that requires a double-acting cylinder. Apply connections and simulate a pneumatic circuit.

46 Industrial Pneumatics Double-Acting Cylinder Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using a double-acting cylinder. Compressed air at the front end of the cylinder causes the piston to extend while compressed air at the back end returns the piston to its initial position. The circuit will then be created using the Training Center. Terminology absolute pressure (psia) 4 atmospheric pressure barometer gauge pressure (psig) reference pressure Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. Step 2. Place components on the drawing area 1. On the Component Library pane, expand Supply Elements, and then drag the compressed air supply to the lower-left portion of the drawing area. Note: Collapse menus as needed. 2. Drag the Air service unit, simplified representation, to the right of the compressed air supply.

3. Expand Actuators, and then drag the double-acting cylinder to the upper-right portion of the drawing area. See figure 4-1. Industrial Pneumatics Double-Acting Cylinder 47 4 figure 4-1 4. Drag a single-acting cylinder to the upper-left portion of the drawing area. See figure 4-2. figure 4-2 5. Expand Direction Control Valves, and then expand Mechanically Operated. 6. Drag the 3/2-way valve with pushbutton, normally closed, to the drawing area, just below the single-acting cylinder.

48 Industrial Pneumatics Double-Acting Cylinder 7. Right-click the 3/2-way valve, normally closed. 8. On the submenu, click Copy. 9. Right-click the drawing area next to the 3/2-way valve, normally closed, and then on the submenu, click Paste. 10. Drag the new 3/2-way valve, normally closed, below the doubleacting cylinder. See figure 4-3. 4 figure 4-3 11. Press and hold CTRL. 12. Click each 3/2-way valve, normally closed. 13. Release CTRL. 14. On the toolbar, click the Align: Bottom button. See figure 4-4. Notice that the two components are now aligned. figure 4-4

Step 3. Apply pneumatic connections 1. Move the pointer over the compressed air supply port, and then drag to port 1 of the air service unit, simplified representation. 2. Move the pointer over port 1 of the right 3/2-way valve, normally closed, and then drag to the line connecting the left 3/2-way valve, normally closed and the air service unit, simplified representation. See figure 4-5. Industrial Pneumatics Double-Acting Cylinder 49 4 figure 4-5 3. Notice that you just created a T-connection. See figure 4-6. figure 4-6

50 Industrial Pneumatics Double-Acting Cylinder 4. Move the pointer over port 2 of the left 3/2-way valve, normally closed, and then drag to port 1 of the double-acting cylinder. 5. Move the pointer over port 2 of the right 3/2-way valve, normally closed, and then drag to port 2 of the double-acting cylinder. 6. Move the pointer over port 1 of the single-acting cylinder, and then drag to the line connecting the left 3/2-way valve, normally closed, and the double-acting cylinder. The circuit should look similar to figure 4-7. 4 figure 4-7

Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. 2. Move the pointer over the push button on the left 3/2-way valve, normally closed, and then click to engage the switch. See figure 4-8. Notice that the piston in the single-acting cylinder extends and then retracts while the double-acting cylinder extends and stays. The piston in the single-acting cylinder retracts automatically because the valve is configured with a spring-returned valve, which returns the piston to its initial position when the cylinder loses air supply. Industrial Pneumatics Double-Acting Cylinder 51 4 figure 4-8 3. Click the push button on the right 3/2-way valve, normally closed. Notice that the piston in the double-acting cylinder retracts. 4. Extend and retract the pistons a few times to gain a better understanding of how the system operates. 5. On the toolbar, click Stop.

52 Industrial Pneumatics Double-Acting Cylinder Step 5. Equipment and supplies 4 mm air hoses (6) 3/2-way valve, normally closed #152860 (2) Double-acting cylinder #152888 Safety glasses Single-acting cylinder #152887 T-connector #153128 4 Step 6. Place components on the trainer 1. Close the shutt-off valve. 2. Attach the single-acting cylinder two slots below the manifold. 3. Attach the double-acting cylinder to the right of the single-acting cylinder, allowing enough space between the components for the extension of the piston in the single-acting cylinder. 4. Attach the first 3/2-way valve, normally closed, two slots below the single-acting cylinder in the middle of the profile plate. 5. Attach the remaining 3/2-way valve, normally closed, to the right of the first 3/2-way valve, normally closed. 6. The components should be arranged on the profile plate similar to figure 4-9. figure 4-9

Step 7. Connect the components on the trainer 1. Insert an air hose from a port on the manifold to port 1 of the left 3/2-way valve, normally closed. 2. Insert an air hose from a port on the manifold to port 1 of the right 3/2-way valve, normally closed. 3. Insert an air hose from port 2 of the left 3/2-way valve, normally closed, to the bottom of the T-connector. See figure 4-10. Industrial Pneumatics Double-Acting Cylinder 53 4 figure 4-10 4. Insert an air hose from the left port of the T-connector to port 1 of the single-acting cylinder. See figure 4-11. figure 4-11

54 Industrial Pneumatics Double-Acting Cylinder 5. Insert an air hose from the right port of the T-connector to port 1 of the double-acting cylinder. See figure 4-12. 4 figure 4-12 6. Insert an air hose from port 2 of the right 3/2-way valve, normally closed, to port 2 of the double-acting cylinder. 7. Carefully check all connection points to ensure that they are secure. Safety Glasses Note: The system should never be pressurized beyond 60 psi. 8. Put on the safety glasses. 9. Open the shut-off valve. 10. On the left 3/2-way valve, normally closed, push the green button. Notice that the pistons in both cylinders extend and the piston in the single-acting cylinder retracts. 11. On the right 3/2-way valve, normally closed, push the green button. Notice that the piston in the double-acting cylinder retracts. 12. Continue to extend and retract the pistons to gain a better understanding of how the system operates. 13. Close the shut-off valve. 14. Remove the air hoses. 15. Remove the components from the profile plate. 16. Return all items to the proper storage location.

Step 8. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. Industrial Pneumatics Double-Acting Cylinder 55 Summary In this lesson, you learned about double-acting cylinders. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer. 4

56 Industrial Pneumatics Double-Acting Cylinder Lesson 4 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The atmospheric pressure at sea level is. A. 80 bars B. 14.7 psi C. 0 psi D. 7854 psi 4 2. The device that uses mercury to measure the weight of air is called a(n). A. barium balance B. barometer C. altimeter D. mercury air scale 3. A(n) is a vent used to discharge pressurized air when it is no longer needed. A. input B. exhaust port C. check valve D. pilot 4. Double-acting cylinders have a return spring. A. True B. False 5. A pneumatic system contains different elements. A. six B. four C. five D. three

Lesson 5 5/2-Way Valve, with Selection Switch Objectives After successfully completing Lesson 5, you will be able to: Explain the functions of a directional control valve. Explain the theory of air pressure generation. Describe the difference between a single and double-stage compressor. Explain how air supply reservoirs are used in pneumatics. Explain why reservoirs are used to store pressurized air. Explain why moisture control is important in pneumatic systems. Explain how a 5/2-way valve operates. Build and operate a circuit that requires a 5/2-way valve with selection switch. Apply connections and simulate a pneumatic circuit.

58 Industrial Pneumatics 5/2-Way Valve, with Selection Switch Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using the 5/2-way valve with selection switch. When the selection switch is engaged, the valve is opened, which allows air to flow through the valve and actuate other components. The circuit will then be created using the Training Center. Terminology check valve free air line lubricator silicon dioxide single-stage two-stage O-ring 5 Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. Step 2. Place components on the drawing area 1. On the Component Library pane, expand Supply Elements, and then drag the compressed air supply to the lower-left portion of the drawing area. Note: Collapse menus as needed. 2. Drag the Air service unit, simplified representation, to the right of the compressed air supply. 3. Expand Actuators, and then drag the double-acting cylinder to the upper-middle portion of the drawing area. 4. Expand Directional Valves, and then expand Mechanically Operated.

5. Drag the 5/2-way valve with selection switch to the drawing area below the double-acting cylinder. The circuit diagram should look similar to figure 5-1. Industrial Pneumatics 5/2-Way Valve, with Selection Switch 59 5 figure 5-1 Step 3. Apply pneumatic connections 1. Move the pointer over the compressed air supply port, and then drag to port 1 of the air service unit, simplified representation. 2. Move the pointer over port 2 of the air service unit, simplified representation, and then drag to port 1 of the 5/2-way valve with selection switch. 3. Move the pointer over port 4 of the 5/2-way valve with selection switch, and then drag to port 1 of the double-acting cylinder.

60 Industrial Pneumatics 5/2-Way Valve, with Selection Switch 4. Move the pointer over port 2 of the 5/2-way valve with selection switch, and then drag to port 2 of the double-acting cylinder. The circuit diagram should look similar to figure 5-2. 5 figure 5-2 Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. 2. Move the pointer over the selection switch on the 5/2-way valve with selection switch, and then click to engage the switch. Notice that the piston in the cylinder extends. 3. On the 5/2-way valve with selection switch, click the selection switch. Notice that the piston in the cylinder retracts. 4. Extend and retract the piston a few times to gain a better understanding of how the system operates. 5. On the toolbar, click Stop.

Step 5. Equipment and supplies Locate the following: 5/2-way valve with selector switch #152862 4 mm air hose (3) Double-acting cylinder #152888 Safety glasses Industrial Pneumatics 5/2-Way Valve, with Selection Switch 61 Step 6. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold in the middle portion of the profile plate. 3. Attach the 5/2-way valve with selection switch two slots below the double-acting cylinder. 4. The components should be arranged on the profile plate similar to figure 5-3. 5 figure 5-3

62 Industrial Pneumatics 5/2-Way Valve, with Selection Switch Step 7. Connect the components on the trainer 1. Insert an air hose from a port on the manifold to port 1 of the 5/2-way valve with selection switch. 2. Insert an air hose from port 4 of the 5/2-way valve with selection switch, to port 1 of the double-acting cylinder. 3. Insert an air hose from port 2 of the 5/2-way valve with selection switch, to port 2 of the double-acting cylinder. See figure 5-4. 5 4. Carefully check all connection points to ensure that they are secure. 5. Put on the safety glasses. figure 5-4 Safety Glasses Note: The system should never be pressurized beyond 60 psi. 6. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. 7. Open the shut-off valve.

8. On the 5/2-way valve with selection switch, turn the selection switch to the right. Notice that the piston in the cylinder extends. See figure 5-5. Industrial Pneumatics 5/2-Way Valve, with Selection Switch 63 figure 5-5 5 9. On the 5/2-way valve with selection switch, turn the selection switch to the left. Notice that the piston in the cylinder retracts. 10. Continue to engage the selection switch to view the pneumatic system. 11. Close the shut-off valve. 12. Remove the air hoses. 13. Remove the components from the profile plate. 14. Return all items to the proper storage location. Step 8. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen.

64 Industrial Pneumatics 5/2-Way Valve, with Selection Switch Summary In this lesson, you learned about air pressure generation and a 5/2-way valve with selection switch. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer. Lesson 5 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The untreated air that surrounds the earth is referred to as air. A. normal B. free C. conditional D. particulate 5 2. Devices that are affected by moisture need the conditioning services of a(n). A. water trap B. particulate filter C. air dryer D. percolator 3. Why is the length of an air supply pipe an issue in sizing a pneumatic system? A. cost B. speed of delivery C. pressure drop D. heat loss 4. Devices that are designed to provide oil mist to pneumatic systems are called. A. oil misters B. oil delivery valves C. line lubricators D. system oilers 5. A diameter pipe will allow a higher volume of air to be delivered. A. small B. medium C. large D. none of the answers are correct

Lesson 6 5/2-Way Valve, Pneumatically Operated Objectives After successfully completing Lesson 6, you will be able to: Explain the connection designations of pneumatic components. Describe the use of rotary actuators in industry. Name at least three types of pneumatic motors. List the advantages of using pneumatic motors. Explain how a pneumatically actuated 5/2-way valve operates. Build and operate a circuit that requires a 5/2-way valve, pneumatically operated. Apply connections and simulate a pneumatic circuit.

66 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using a 5/2-way valve, pneumatically operated. Airflow into pilot port 14 actuates the pneumatic valve and allows flow from position 1 to 2. A return spring and an opposite signal return the spring to its starting position. The circuit will then be created using the Training Center. Terminology axial pneumatic motor radial torque turbine vanes sliding vane Procedure 6 Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. Step 2. Place components on the drawing area 1. On the Component Library pane, expand Supply Elements, and then drag the compressed air supply to the lower-left portion of the drawing area. Note: Collapse menus as needed. 2. Drag the Air service unit, simplified representation, to the right of the compressed air supply. 3. Expand Actuators, and then drag the double-acting cylinder to the upper-middle portion of the drawing area. 4. Expand Directional Valves, and then expand Mechanically Operated.

5. Drag the 5/2-way valve, pneumatically operated to the drawing area below the double-acting cylinder. 6. Drag the 3/2-way valve, normally closed to the drawing area below and to the left of the 5/2-way valve, pneumatically operated. The circuit diagram should look similar to figure 6-1. Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 67 Step 3. Apply pneumatic connections figure 6-1 1. Move the pointer over the compressed air supply port, and then drag to port 1 of the air service unit, simplified representation. 6 2. Move the pointer over port 2 of the air service unit, simplified representation, and then drag to port 1 of the 3/2-way valve, normally closed. 3. Move the pointer over port 2 of the 3/2-way valve, normally closed, and then drag to port 14 of the 5/2-way valve, pneumatically operated. 4. Move the pointer over port 1 of the 5/2-way valve, pneumatically operated, and then drag to the connection line between the air service unit and the 3/2-way valve, normally closed. 5. Move the pointer over port 4 of the 5/2-way valve, pneumatically operated, and then drag to port 1 of the double-acting cylinder.

68 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 6. Move the pointer over port 2 of the 5/2-way valve, pneumatically operated, and then drag to port 2 of the double-acting cylinder. The circuit diagram should look similar to figure 6-2. 6 Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. figure 6-2 2. Move the pointer over the selection switch on the 5/2-way valve, pneumatically operated, and then click to engage the switch. Notice that the piston in the cylinder extends. 3. On the 5/2-way valve, pneumatically operated, click the selection switch. Notice that the piston in the cylinder retracts. 4. Extend and retract the piston a few times to gain a better understanding of how the system operates. 5. On the toolbar, click Stop. Step 5. Equipment and supplies Locate the following: 5/2-way valve, pneumatically operated #538694 4 mm air hose (5) 3/2-way valve, normally closed #152860 Double-acting cylinder #152888 Safety glasses

Step 6. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold in the middle portion of the profile plate. 3. Attach the 5/2-way valve, pneumatically operated, two slots below the double-acting cylinder. 4. Attach the 3/2-way valve, normally closed, two slots below the 5/2-way valve, pneumatically operated. 5. The components should be arranged on the profile plate similar to figure 6-3. Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 69 6 figure 6-3 Step 7. Connect the components on the trainer 1. Insert an air hose from the manifold to port 1 of the 5/2-way valve, pneumatically operated. 2. Insert an air hose from the manifold to port 1 of the 3/2-way valve, normally closed. 3. Insert an air hose from port 2 of the 3/2-way valve, normally closed, to port 14 of the 5/2-way valve, pneumatically operated. 4. Insert an air hose from port 2 of the 5/2-way valve, pneumatically operated, to port 2 of the double-acting cylinder.

70 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 5. Insert an air hose from port 4 of the 5/2-way valve, pneumatically operated, to port 1 of the double-acting cylinder. See figure 6-4. 6 Safety Glasses Note: The system should never be pressurized beyond 60 psi. 6. Carefully check all connection points to ensure that they are secure. 7. Put on the safety glasses. 8. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. 9. Open the shut-off valve. 10. On the 3/2-way valve, normally closed, push and release the green button. 11. Continue to engage the green button to view the pneumatic system. 12. Close the shut-off valve. 13. Remove the air hoses. 14. Remove the components from the profile plate. 15. Return all items to the proper storage location. figure 6-4 Step 8. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen.

Summary In this lesson, you learned about pneumatic motors and a 5/2-way valve, pneumatically operated. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer. Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 71 Lesson 6 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The name of the twisting force generated by a motor is called. A. shaft speed B. dynamic rotation C. circular interpolation D. torque 2. The spring-loaded fins that obstruct the free passage of air to produce rotary motion are called. A. force fins B. vanes C. paddles D. air interceptors 3. Pneumatic motors change pressure into rotary motion. A. True B. False 4. In a piston motor, air pressure is applied to the. A. motor shaft B. connecting rods C. piston D. none of the answers are correct 6 5. Gear type motors cannot be reversed. A. True B. False

72 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated DEPCO, LLC

Lesson 7 5/2-Way Impulse Valve, Pneumatically Operated Objectives After successfully completing Lesson 7, you will be able to: Explain the theory of Pascal s law. Use Pascal s law to calculate pressure, force, and area. Explain the force triangle. Explain how a pneumatically actuated 5/2-way impulse valve operates. Build and operate a circuit that requires a 5/2-way impulse valve, pneumatically operated. Apply connections and simulate a pneumatic circuit.

74 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using a 5/2-way impulse valve, pneumatically operated. The valve is controlled by receiving a signal through both piloted ports port 12, which allows airflow from ports 1 to 2; and port 14, which allows airflow from ports 1 to 4. The valve remains operative until an opposing signal is received. The circuit will then be created using the Training Center. Terminology force triangle Pascal s law spool Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 7 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics.

Step 2. Place components on the drawing area Place the following components on the drawing area as shown in figure 7-1: 5/2-way impulse valve, pneumatically operated 3/2-way valve with push button, normally closed (2) Air service unit, simplified representation Compressed air supply Double-acting cylinder Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 75 7 figure 7-1

76 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated Step 3. Apply pneumatic connections Connect the components as shown in figure 7-2. 7 figure 7-2

Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. 2. On the left 3/2-way valve, normally closed, click the push button. Notice that the piston in the cylinder extends. See figure 7-3. Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 77 figure 7-3 7

78 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 3. On the right 3/2-way valve, normally closed, click the push button. Notice that the piston in the cylinder retracts. See figure 7-4. 7 figure 7-4 4. Extend and retract the piston a few times to gain a better understanding of how the system operates. 5. On the toolbar, click Stop.

Step 5. Equipment and supplies Locate the following: 5/2-way impulse valve, pneumatically operated #539769 4 mm air hose (7) 3/2-way valve, normally closed #152860 (2) Double-acting cylinder #152888 Safety glasses Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 79 Step 6. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold in the middle portion of the profile plate. 3. Attach the 5/2-way impulse valve, pneumatically operated, two slots below the double-acting cylinder. 4. Attach the 3/2-way valve, normally closed, two slots below and to the left of the 5/2-way impulse valve, pneumatically operated. 5. Attach the remaining 3/2-way valve, normally closed, two slots below and to the right of the 5/2-way impulse valve, pneumatically operated. 6. The components should be arranged on the profile plate similar to figure 7-5. 7 figure 7-5

80 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated Step 7. Connect the components on the trainer 1. Insert an air hose from the manifold to port 1 of the 5/2-way impulse valve, pneumatically operated. 2. Insert an air hose from the manifold to port 1 of the left 3/2-way valve, normally closed. 3. Insert an air hose from the manifold to port 1 of the right 3/2-way valve, normally closed. 4. Insert an air hose from port 2 of the left 3/2-way, normally closed, to port 12 of the 5/2-way impulse valve, pneumatically operated. 5. Insert an air hose from port 2 of the right 3/2-way valve, normally closed, to port 14 of the 5/2-way impulse valve, pneumatically operated. 6. Insert an air hose from port 2 of the 5/2-way impulse valve, pneumatically operated, to port 2 of the double-acting cylinder. 7. Insert an air hose from port 4 of the 5/2-way impulse valve, pneumatically operated, to port 1 of the double-acting cylinder. See figure 7-6. 7 figure 7-6 8. Carefully check all connection points to make sure they are secure. Safety Glasses Note: The system should never be pressurized beyond 60 psi. 9. Put on the safety glasses. 10. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. 11. Open the shut-off valve. 12. On the left 3/2-way valve, normally closed, push and release the green button. Notice that the piston in the cylinder extends.

13. On the right 3/2-way valve, normally closed, push and release the green button. Notice that the piston in the cylinder retracts. 14. Continue to view the pneumatic circuit to gain a better understanding of how the system operates. 15. Close the shut-off valve. 16. Remove the air hoses. 17. Remove the components from the profile plate. 18. Return all items to the proper storage location. Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated 81 Step 8. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. Summary In this lesson, you learned about Pascal s law and a 5/2-way impulse valve, pneumatically operated. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer. 7

82 Industrial Pneumatics 5/2-Way Valve, Pneumatically Operated Lesson 7 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. Which of the following is possible to solve using Pascal s law? A. pressure B. area C. force D. all of the answers are correct 2. The formula for calculating force, using Pascal s law, is which of the following? A. F=P x A B. F=F/A C. F=P/A D. none of the answers are correct 3. A 5/2-way valve contains an internal shaft called a. A. cog B. spool C. cylinder D. none of the answers are correct 4. A manual override located at each end of a 5/2-way valve will allow the valve to be returned to its initial position. A. True B. False 5. A spool provides a memory function, because it will remain in the last position that was signaled. A. True B. False 7

Lesson 8 Roller Lever Valve Objectives After successfully completing Lesson 8, you will be able to: Calculate diameter by applying Pascal s law. Explain how friction and resistance affect the force of a cylinder. Explain how 3/2-way roller lever valves, normally closed, operate. Build and operate a circuit that requires a 3/2-way roller lever valve, normally closed. Apply a distance rule to a double-acting cylinder and link it to a 3/2-way roller lever valve. Apply connections and simulate a pneumatic circuit.

84 Industrial Pneumatics Roller Lever Valve Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using 3/2-way roller lever valves, normally closed. Roller lever valves are operated by means of an internal limit switch that, when actuated either by means of a switching cam in the cylinder or manually by pressing the roller levers, causes the valve to send a return signal. The valves are also spring-returned. You will apply a distance rule to link a double-acting cylinder to the roller lever valves, which causes the valves to automatically actuate by the switching cam signal. The circuit will then be created using the Training Center. Terminology annular area distance rule Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. 8

Step 2. Place components on the drawing area Place the following components on the drawing area as shown in figure 8-1: 5/2-way impulse valve, pneumatically operated 3/2-way roller lever valve, normally closed (2) Air service unit, simplified representation Compressed air supply Double-acting cylinder Industrial Pneumatics Roller Lever Valve 85 figure 8-1 8

86 Industrial Pneumatics Roller Lever Valve Step 3. Apply pneumatic connections Connect the components as shown in figure 8-2. figure 8-2 Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice that the piston in the cylinder extends and retracts rapidly. 8 2. View the pneumatic circuit to gain a better understanding of how the system operates. 3. On the toolbar, click Stop. Step 5. Equipment and supplies Locate the following: 5/2-way impulse valve, pneumatically operated #539769 4 mm air hose (7) 3/2-way roller lever valve, normally closed #152866 (2) Double-acting cylinder #152888 Safety glasses

Step 6. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold on the profile plate. 3. Attach the 5/2-way impulse valve, pneumatically operated, two slots below the double-acting cylinder. 4. Attach a 3/2-way roller lever valve, normally closed, two slots below and slightly to the right of the double-acting cylinder. The 3/2- way roller lever valve, normally closed, should be 1/2 in. from the double-acting cylinder with the piston resting on the roller lever valve. See figure 8-3. Industrial Pneumatics Roller Lever Valve 87 figure 8-3 5. Manually extend the piston in the double-acting cylinder. 8

88 Industrial Pneumatics Roller Lever Valve Note: The roller lever valve will be positioned upside down. 6. Attach the remaining 3/2-way roller lever valve, normally closed, two slots above the double-acting cylinder with the piston resting on the roller lever valve. See figure 8-4. 7. Manually retract the piston in the double-acting cylinder. figure 8-4 8. The components should be arranged on the profile plate similar to figure 8-5. 8 figure 8-5

Step 7. Connect the components on the trainer 1. Insert an air hose from the manifold to port 1 of the 5/2-way impulse valve, pneumatically operated. 2. Insert an air hose from the manifold to port 1 of the left 3/2-way roller lever valve, normally closed. 3. Insert an air hose from the manifold to port 1 of the right 3/2-way roller lever valve, normally closed. 4. Insert an air hose from port 2 of the left 3/2-way roller lever valve, normally closed, to port 12 of the 5/2-way impulse valve, pneumatically operated. 5. Insert an air hose from port 2 of the right 3/2-way roller lever valve, normally closed, to port 14 of the 5/2-way impulse valve, pneumatically operated. 6. Insert an air hose from port 2 of the 5/2-way impulse valve, pneumatically operated, to port 1 of the double-acting cylinder. 7. Insert an air hose from port 4 of the 5/2-way impulse valve, pneumatically operated, to port 2 of the double-acting cylinder. See figure 8-6. Industrial Pneumatics Roller Lever Valve Note: After the air hoses are connected to the components, it may be necessary to make slight adjustments to the position of the 3/2-way roller lever valves in order for them to work properly. Follow safety precautions when making the adjustments. 89 8 figure 8-6

90 Industrial Pneumatics Roller Lever Valve 8. Carefully check all connection points to make sure they are secure. 9. Put on the safety glasses. Safety Glasses Note: The system should never be pressurized beyond 60 psi. 10. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. 11. Open the shut-off valve. Notice the piston in the cylinder extends and retracts. The 3/2-way roller lever valves, normally closed, act as limit switches, which signal the piston to return to its starting position when actuated. The internal spring-return mechanism inside the 3/2-way roller lever valve returns the valve to its starting position. 12. Continue to view the pneumatic circuit to gain a better understanding of how the system operates. 13. Close the shut-off valve. 14. Remove the air hoses. 15. Remove the components from the profile plate. 16. Return all items to the proper storage location. Step 8. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. 8 Summary In this lesson, you learned about force and 3/2-way roller lever valves, normally closed. You placed simulation components on the drawing area, linked a distance rule to the 3/2-way roller lever valves, normally closed, and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer.

Lesson 8 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. The annular area refers to the. A. top of the piston B. coverage of pneumatic power in a building C. area of the piston not covered by the rod D. connection port seal 2. A rule is a device for attaching switches at the cylinder. A. yard B. distance C. switch D. mechanical 3. The labels at the distance rule define to the actual proximity or limit switch in the electrical circuit. A. distances B. links C. paths D. labels 4. When creating a distance rule, the field is used to define the exact position of the switches on the cylinder. A. label B. position C. placement D. measurement 5. To determine whether a cylinder has extended to a fully extended position, a(n) switch can be used. A. on-off B. visual C. delimiter D. limit Industrial Pneumatics Roller Lever Valve 91 8

92 Industrial Pneumatics Roller Lever Valve DEPCO, LLC

Lesson 9 Flow Control Valve Objectives After successfully completing Lesson 9, you will be able to: Identify industrial applications for flow control valves. Identify industrial applications for pressure control valves. Identify the different types of flow control valves. Place a flow control valve in a circuit to control cylinder extension speed. Build and operate a circuit that requires a flow control valve. Apply connections and simulate a pneumatic circuit.

94 Industrial Pneumatics Flow Control Valve Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using one-way flow control valves. The one-way flow control valve is configured from a throttle and check valve and allows the user to adjust by a regulator the amount of airflow the connected component, generally a cylinder, can receive. The circuit will then be created using the Training Center. Terminology bi-directional diaphragm flow control valve one-way flow control valve pressure control valve throttle valve needle valve Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. 9

Step 2. Place components on the drawing area Place the following components on the drawing area as shown in figure 9-1: 5/2-way impulse valve, pneumatically operated 3/2-way roller lever valve, normally closed (2) Air service unit, simplified representation Compressed air supply Double-acting cylinder Throttle check valve Industrial Pneumatics Flow Control Valve 95 Note: Rotate the throttle check valve 90 degrees. figure 9-1 9

96 Industrial Pneumatics Flow Control Valve Step 3. Apply pneumatic connections Connect the components as shown in figure 9-2. figure 9-2 Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice that the piston in the cylinder extends and retracts rapidly. 9 2. Move the pointer over the throttle check valve, and then click. See figure 9-3. figure 9-3

3. In the Throttle check valve box, in the Opening Level area, type 10. See figure 9-4. Notice that the extension and retraction of the piston in the cylinder slows. Industrial Pneumatics Flow Control Valve 97 4. Continue to adjust the air flow allowed by the throttle check valve and view the results on the pneumatic circuit to gain a better understanding of how the system operates. 5. On the toolbar, click Stop. figure 9-4 Step 5. Change the circuit diagram 1. Click the throttle check valve. 2. Right-click the throttle check valve, and then on the submenu, click Delete. 3. Delete the two pneumatic connection lines between the 5/2-way impulse valve, pneumatically operated, and the double-acting cylinder. 4. Delete the connection line between port 1 of the 5/2-way impulse valve, pneumatically operated, and the air supply unit. 5. On the Component Library pane, expand Shutoff Valves and Flow Control Valves. 9

98 Industrial Pneumatics Flow Control Valve 6. Drag the throttle check valve to the drawing area, and then place it above and to the left of the 5/2-way impulse valve, pneumatically operated. See figure 9-5. Note: Drag the 5/2-way impulse valve, pneumatically operated, to a lower position if needed. 7. Right-click the throttle check valve. 8. On the submenu, point to Rotate, and then click 90. figure 9-5 9 9. Drag another throttle check valve to the drawing area, and then place it above and to the right of the 5/2-way impulse valve, pneumatically operated. 10. Right-click the throttle check valve.

11. On the submenu, point to Rotate, and then click 90. The circuit diagram should look similar to figure 9-6. Industrial Pneumatics Flow Control Valve 99 figure 9-6 12. Create a pneumatic connection between port 1 of the 5/2-way impulse valve, pneumatically operated, and port 2 of the air service unit, simplified representation. 13. Create a pneumatic connection between port 4 of the 5/2-way impulse valve, pneumatically operated, and port 1 of the left throttle check valve. 14. Create a pneumatic connection between port 2 of the left throttle check valve and port 1 of the double-acting cylinder. 15. Create a pneumatic connection between port 2 of the 5/2-way impulse valve, pneumatically operated, and port 1 of the right throttle check valve. 9

100 Industrial Pneumatics Flow Control Valve 16. Create a pneumatic connection between port 2 of the throttle check valve and port 2 of the double-acting cylinder. The circuit diagram should look similar to figure 9-7. figure 9-7 Step 6. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice that the piston in the cylinder extends and retracts rapidly. 2. Move the pointer over the left throttle check valve, and then click. 9 3. In the Throttle Check valve box, in the Opening Level area, type 10. Notice that the extension of the piston in the cylinder slows, but the retraction remains the same. 4. Move the pointer over the right throttle check valve, and then click. 5. In the Throttle Check valve box, in the Opening Level area, type 10. Notice that the retraction of the piston in the cylinder matches the extension. 6. Continue to adjust the airflow allowed by the throttle check valves and view the results on the pneumatic circuit to gain a better understanding of how the system operates. 7. On the toolbar, click Stop.

Step 7. Equipment and supplies Locate the following: 5/2-way impulse valve, pneumatically operated #539769 4 mm air hose (10) 3/2-way roller lever valve, normally closed #152866 (2) 1-way flow control valve #539773 (2) Double acting cylinder #152888 Safety glasses Industrial Pneumatics Flow Control Valve 101 Step 8. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold on the profile plate. 3. Attach the 5/2-way impulse valve, pneumatically operated, two slots below the double-acting cylinder. 4. Attach the left 3/2-way roller lever valve, normally closed, two slots below and slightly to the right of the double-acting cylinder. The 3/2-way roller lever valve, normally closed, should be 1/2 in. from the double-acting cylinder with the piston resting on the roller lever valve. See figure 9-8. 9 figure 9-8 5. Manually extend the piston in the double-acting cylinder.

102 Industrial Pneumatics Flow Control Valve 6. Attach the right 3/2-way roller lever valve, normally closed, two slots above the double-acting cylinder with the piston resting on the roller lever valve. See figure 9-9. figure 9-9 7. Manually retract the piston in the double-acting cylinder. 8. The components should be arranged on the profile plate similar to figure 9-10. 9 figure 9-10

Step 9. Connect the components on the trainer 1. Insert an air hose from the manifold to port 1 of a 1-way flow control valve. See figure 9-11. Industrial Pneumatics Flow Control Valve 103 figure 9-11 2. Insert an air hose from port 2 of the same 1-way flow control valve to port 1 of the 5/2-way impulse valve, pneumatically operated. 3. Insert an air hose from the manifold to port 1 of the left 3/2-way roller lever valve, normally closed. 4. Insert an air hose from the manifold to port 1 of the right 3/2-way roller lever valve, normally closed. 5. Insert an air hose from port 2 of the left 3/2-way roller lever valve, normally closed, to port 12 of the 5/2-way impulse valve, pneumatically operated. 6. Insert an air hose from port 2 of the right 3/2-way roller lever valve, normally closed, to port 14 of the 5/2-way impulse valve, pneumatically operated. 7. Insert an air hose from port 2 of the 5/2-way impulse valve, pneumatically operated, to port 1 of the double-acting cylinder. 9

104 Industrial Pneumatics Flow Control Valve 8. Insert an air hose from port 4 of the 5/2-way impulse valve, pneumatically operated, to port 2 of the double-acting cylinder. See figure 9-12. figure 9-12 9. Twist the blue regulator on the 1-way flow control valve counterclockwise to open the valve. See figure 9-13. 9 figure 9-13 10. Carefully check all connection points to ensure that they are secure. Safety Glasses Note: The system should never be pressurized beyond 60 psi. 11. Put on the safety glasses. 12. Check the pressure regulator gauge on the start-up valve to see how much air pressure is in the system. 13. Open the shut-off valve.

14. Twist the blue regulator at the end of the 1-way flow control valve clockwise to adjust the air supply to the system. The air flow level will control how fast the piston in the cylinder extends and retracts. 15. Continue to adjust the air flow allowed by the 1-way flow control valve and view the pneumatic circuit to gain a better understanding of how the system operates. 16. Close the shut-off valve. 17. Remove the 1-way flow control valve and connected air hoses. 18. Insert an air hose from the manifold to port 1 of the 5/2-way impulse valve, pneumatically operated. 19. Remove the air hoses from both ports on the double-acting cylinder. 20. Insert an air hose from port 4 of the 5/2-way impulse valve, pneumatically operated, to port 1 of the 1-way flow control valve. 21. Insert an air hose from port 2 of the 1-way flow control valve to port 2 of the double-acting cylinder. 22. Insert an air hose from port 2 of the 5/2-way impulse valve, pneumatically operated, to port 1 of the 1-way flow control valve. 23. Insert an air hose from port 1 of the double-acting cylinder to port 2 of the 1-way flow control valve. See figure 9-14. Industrial Pneumatics Flow Control Valve 105 9 figure 9-14 24. On the 1-way flow control valve, twist the blue regulators counterclockwise to open the valves. 25. On the start-up valve, open the red shut-off valve to its vertical, open position.

106 Industrial Pneumatics Flow Control Valve 26. Twist the blue regulator at the end of the left 1-way flow control valve to adjust the air supply to the system. Notice that the extension of the cylinder slows. 27. Twist the blue regulator at the end of the right 1-way flow control valve to adjust the air supply to the system. Notice that the retraction of the cylinder slows. 28. Continue to adjust the air flow allowed by the 1-way flow control valves and view the pneumatic circuit to gain a better understanding of how the system operates. 29. Close the shut-off valve. 30. On the 1-way flow control valves, twist the blue regulators clockwise. 31. Remove the air hoses. 32. Remove the components from the profile plate. 33. Return all items to the proper storage location. Step 10. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. Summary 9 In this lesson, you learned about flow control valves and how they are used in industrial pneumatics. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer.

Lesson 9 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. Which type of pneumatic motor is typically found in small hand tools? A. sliding vane B. piston C. gear D. turbine 2. A typical application for a flow control valve is? A. direction control of a cylinder B. flow reversal C. linear actuator speed control D. increasing cylinder force 3. A common application for a pressure limiting valve is? A. cylinder operations B. safety C. valve sequencing D. check valve applications 4. A valve that contains an adjustable spring-loaded diaphragm to perform its function is a valve. A. flow control B. bi-directional C. pressure regulating D. pressure limit 5. When air pressure demand the set tension on the spring, the diaphragm will open. A. releases B. exceeds C. reduces D. expands Industrial Pneumatics Flow Control Valve 107 9

108 Industrial Pneumatics Flow Control Valve DEPCO, LLC

Lesson 10 Two-Pressure Valve Objectives After successfully completing Lesson 10, you will be able to: Explain the basic principles of Boolean logic. Differentiate between AND, OR, and NOT logic. Explain how devices that act as safety switches are useful in industrial applications. Build and operate a circuit that requires a two-pressure valve. Apply connections and simulate a pneumatic circuit.

110 Industrial Pneumatics Two-Pressure Valve Average Lesson Time = 60 Minutes In this lesson, you will use the FluidSIM program to create and simulate a working pneumatic circuit using a two-pressure valve. The two-pressure valve is actuated by air entering the valve at two input positions. Because the valve acts as a safety switch, both ports must receive air pressure for the valve to actuate before being expressed through port 2. The port receiving the lowest pressure takes precedence, which is a display of AND logic. The circuit will then be created using the Training Center. Terminology AND Boolean junction element OR pressure signal two-pressure valve NOT Procedure Step 1. Start the program 1. On the taskbar, click Start. 2. On the Start menu, point to Programs. 3. On the submenu, click Festo Didactic, and then click FluidSIM 5. 4. On the submenu, click FluidSIM 5 Pneumatics. 10

Step 2. Place components on the drawing area Place the following components on the drawing area as shown in figure 10-1: 5/2-way valve, pneumatically operated 5/2-way valve with selection switch 3/2-way valve with push button, normally closed (2) Air service unit, simplified representation Compressed air supply Double-acting cylinder Pressure gauge Two pressure valve Industrial Pneumatics Two-Pressure Valve 111 figure 10-1 10

112 Industrial Pneumatics Two-Pressure Valve Step 3. Apply pneumatic connections Connect the components as shown in figure 10-2. figure 10-2 Step 4. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice the pressure reading on the pressure gauge. 2. On the 5/2-way valve with selection switch, click the selection switch. Notice that the valve shifts, which cuts off flow to the pressure gauge and redirects the air flow to the two 3/2-way valves, normally closed, and the 5/2-way valve, pneumatically operated. 3. Press and hold CTRL. 4. On the left 3/2-way valve, normally closed, click the push button. 5. On the right 3/2-way valve, normally closed, click the push button. Notice that the piston in the cylinder extends. Both 3/2-way valves must be actuated in order for the two pressure valve to release pressure from both ports, thereby allowing the circuit to run. 10 6. On the right 3/2-way valve, normally closed, click the push button. Notice that the piston in the cylinder retracts. 7. Continue to actuate the valves to gain a better understanding of how the system operates. 8. On the toolbar, click Stop.

Step 5. Change the circuit diagram 1. Click the throttle check valve. 2. Right-click the throttle check valve, and then on the submenu, click Delete. 3. Delete the two pneumatic connection lines between the 5/2-way impulse valve, pneumatically operated, and the double-acting cylinder. 4. Delete the connection line between port 1 of the 5/2-way impulse valve, pneumatically operated, and the air supply unit. 5. On the Component Library pane, expand Shutoff Valves and Flow Control Valves. 6. Drag the throttle check valve to the drawing area, and then place it above and to the left of the 5/2-way impulse valve, pneumatically operated. Note: Drag the 5/2-way impulse valve, pneumatically operated, to a lower position if needed. 7. Right-click the throttle check valve. 8. On the submenu, point to Rotate, and then click 90. 9. Drag another throttle check valve to the drawing area, and then place it above and to the right of the 5/2-way impulse valve, pneumatically operated. 10. Right-click the throttle check valve. 11. On the submenu, point to Rotate, and then click 90. 12. Create a pneumatic connection between port 1 of the 5/2-way impulse valve, pneumatically operated, and port 2 of the air service unit, simplified representation. 13. Create a pneumatic connection between port 4 of the 5/2-way impulse valve, pneumatically operated, and port 1 of the left throttle check valve. Industrial Pneumatics Two-Pressure Valve 113 14. Create a pneumatic connection between port 2 of the left throttle check valve and port 1 of the double-acting cylinder. 15. Create a pneumatic connection between port 2 of the 5/2-way impulse valve, pneumatically operated, and port 1 of the right throttle check valve. 10

114 Industrial Pneumatics Two-Pressure Valve 16. Create a pneumatic connection between port 2 of the throttle check valve and port 2 of the double-acting cylinder. Step 6. Simulate the pneumatic circuit 1. On the toolbar, click Start. Notice that the piston in the cylinder extends and retracts rapidly. 2. Move the pointer over the left throttle check valve, and then click. 3. In the Throttle Check valve box, in the Opening Level area, type 10. Notice that the extension of the piston in the cylinder slows, but the retraction remains the same. 4. Move the pointer over the right throttle check valve, and then click. 5. In the Throttle Check valve box, in the Opening Level area, type 10. Notice that the retraction of the piston in the cylinder matches the extension. 6. Continue to adjust the airflow allowed by the throttle check valves and view the results on the pneumatic circuit to gain a better understanding of how the system operates. 7. On the toolbar, click Stop. Step 7. Equipment and supplies Locate the following: 5/2-way valve, pneumatically operated #538694 5/2-way valve, with selection switch #152862 4 mm air hose (12) 3/2-way valve, normally closed #152860 (2) 2-pressure valve #539770 Double-acting cylinder #152888 10 Manometer #152865 Safety glasses T-connector #000399 (2)

Step 8. Place the components on the trainer 1. Close the shut-off valve. 2. Attach the double-acting cylinder two slots below the manifold in the middle portion of the profile plate. 3. Attach the 5/2-way valve, pneumatically operated, three slots below the double-acting cylinder. 4. Attach the 5/2-way valve, with selection switch, three slots below the 5/2-way valve, pneumatically operated. 5. Attach the manometer one slot below and to the right of the 5/2- way valve, with selection switch. 6. Attach the 2-pressure valve one slot above and to the right of the 5/2-way valve, with selection switch. 7. Attach a 3/2-way valve, normally closed, in the same slot and to the right of the 2-pressure valve. 8. Attach the remaining 3/2-way valve, normally closed, two slots above the first 3/2-way valve, normally closed. 9. The components should be arranged on the profile plate similar to figure 10-3. Industrial Pneumatics Two-Pressure Valve 115 Step 9. Connect the components on the trainer figure 10-3 10 1. Insert an air hose from the manifold to port 1 of the 5/2-way valve, with selection switch. 2. Insert an air hose from port 2 of the 5/2-way valve, with selection switch, to port 1 of the manometer.

116 Industrial Pneumatics Two-Pressure Valve 3. Insert an air hose from port 4 of the 5/2-way valve, with selection switch, to a T-connector. 4. Insert an air hose from the same T-connector to port 1 of the 5/2-way valve, pneumatically operated. 5. Insert an air hose from the same T-connector to another T-connector. 6. Insert an air hose from the second T-connector to port 1 of the upper 3/2-way valve, normally closed. 7. Insert an air hose from the second T-connector to port 1 of the lower 3/2-way valve, normally closed. 8. Insert an air hose from port 2 of the 5/2-way valve, pneumatically operated, to port 2 of the double-acting cylinder. 9. Insert an air hose from port 4 of the 5/2-way valve, pneumatically operated, to port 1 of the double-acting cylinder. 10. Insert an air hose from port 14 of the 5/2-way valve, pneumatically operated, to port 2 of the 2-pressure valve. See figure 10-4. figure 10-4 10 11. Insert an air hose from port 12 of the 2-pressure valve to port 2 of the upper 3/2-way valve, normally closed.

12. Insert an air hose from port 14 of the 2-pressure valve to port 2 of the lower 3/2-way valve, normally closed. See figure 10-5. Industrial Pneumatics Two-Pressure Valve 117 13. Ensure that all connections are secure, and then put on the safety glasses. 14. Open the shut-off valve. 15. On the 5/2-way valve, with selection switch, turn the selection switch to the right. 16. On the lower 3/2-way valve, normally closed, push and hold the green button. 17. On the upper 3/2-way valve, normally closed, push and hold the green button. Notice that the piston in the cylinder extends. 18. On the upper 3/2-way valve, normally closed, release the green button. Notice that the piston in the cylinder retracts. 19. Continue to run the circuit to gain a better understanding of how the system operates. 20. Close the shut-off valve. figure 10-5 Safety Glasses 21. Remove the air hoses. 22. Remove the components from the profile plate. 23. Return all items to the proper storage location. 10

118 Industrial Pneumatics Two-Pressure Valve Step 10. Exit the program and return to the media 1. On the File menu, click Exit. 2. If asked to save changes, click No. 3. Click the Next button on the media screen. Summary In this lesson, you learned about Boolean, AND, OR, and NOT logic, as well as how 2-pressure valves are useful as safety switches in industrial applications. You placed simulation components on the drawing area and applied connection lines to drawing area components before simulating the circuit. You also created the circuit diagram on the trainer. Lesson 10 Review Answer the following questions in the classroom management system or on a piece of notebook paper. 1. Which of the following components provide a 3-way connection in pneumatic circuitry, which does not allow the return of any signal, but directs the path of signal air? A. tertiary distributors B. tri-connector valves C. junction elements D. T-connectors 2. The dual pressure valve only allows airflow out of port 2 if. A. both input ports 12 and 14 have a pressure signal B. input port 12 has a pressure signal C. input port 14 has a pressure signal D. neither input ports 12 or 14 have a pressure signal 3. The component that provides the Boolean logic function of AND is the. A. 3/2-way DCV B. shuttle valve C. 2-pressure valve D. AND gate valve 10 4. The premise of Boolean logic is that simple choices create solutions for complicated problems. A. True B. False 5. Incorporating safety devices is common practice when designing pneumatic systems where some functions are performed by an operator. A. True B. False

Reference Glossary...120 Reference Materials...124

120 Industrial Pneumatics Glossary 5/2-way: A directional control valve that has five ports for the inflow or outflow of air, and two switch positions, open or closed. 3/2-way: A directional control valve that has three ports for the inflow or outflow of air, and two switch positions, open or closed. absolute pressure: Air pressure referenced from a perfect vacuum. actuator: Any device that converts air pressure to linear or rotary motion in a pneumatic system. component: A part in an assembly or grouping of devices. Component Library: Contains pneumatic and electrical components for the creation of new circuit diagrams. compressor: A machine designed to produce pressurized air. device label: An identification method used in fluid power and electro-fluid power simulation programs to categorize or physically link device relationships in a circuit. AND: A Boolean operation that requires two positive inputs to produce an output. diagram: A line drawing that provides details of pneumatic connection points and components. annular area: The area of the piston not covered by the rod. diaphragm: A disk or cone used to close off a large area of air passage inside of a pressure regulator. atmospheric pressure: Pressure caused by the weight of the atmosphere. Also referred to as reference pressure. axial: The condition where principle components are aligned along a common axis. bar: A unit of metric measurement equal to one atmosphere of air pressure. directional control valve (DCV): A device used to switch the pathways used in a fluid power circuit. distance rule: A device for attaching switches at the cylinder. double-pilot valve: A pneumatically actuated device that negotiates between two input signals to cause switching and output to occur. barometer: A measuring instrument that uses a scaled glass tube of mercury to indicate the equalization point of the mercury with the weight of the surrounding atmosphere. bi-directional: An indication that a device allows the passage of air in two directions. Boolean: A type of logic that interprets true or false inputs to discover whether an output will occur. check valve: A device that permits flow in only one direction. embossing: A process where a die and pressure is used to imprint a raised image on soft material. exhaust port: A vent used to discharge pressurized air when it is no longer needed. flow control valve: A component used to adjust the volume of air that is allowed to flow in a pneumatic circuit. force triangle: A partitioned line drawing used to indicate any one of three algebraic expressions of Pascal s Law.

Reference 121 Glossary free air: The untreated air that surrounds the earth. gauge pressure (psig): Pressure connected to atmostpheric pressure. Gauge pressure readings are reduced by one atmosphere of pressure per inch. newtons: A unit of metric measurement used to designate force. normal position: The position of the moving parts of a valve when not connected to a pressurized system. hose whip: The unsafe condition where one end of a hose is released from one end of a pressurized system. normally closed: No passage of air is allowed without receiving a signal. indirect control: A valve control method that allows the use of small directional control valves to pneumatically signal higher volume valves. initial position: The switching position assumed by the moving parts of an installed valve when the system is pressurized. input: The data flow in a controller or control function. normally open: Allows the passage of air to a device with no signal applied. NOT: A Boolean operation used to reverse the status of the input. one-way flow control valve: A device that restricts the passage of air in one direction by using a needle valve and free flow in the opposite direction. interlock: A safety function designed to require additional inputs to ensure an operation can be initiated. OR: A Boolean operation that requires one of two possible inputs to trigger an output. junction element: A type of non-return valve that has two input connections and one output port that uses logic functions to control the passage of input air. kilopascals (kpa): A unit of metric measurement used to designate one thousand pascals. limit switch: A device that is used to indicate the physical location of an actuator-controlled action. line lubricator: A device used to inject an oil mist into pressurized air systems to provide lubrication for pneumatic tools and equipment. linear: A straight line or relationship. O-ring: A round, supple sealing component used to prevent air leakage around a shaft fitted inside of a bore. output: The data flow out of a controller or control function. P abs: The metric indication that the gauge pressure reading is referenced from zero pressure. P amb: The metric indication that the gauge pressure reading is compensated to eliminate one atmosphere of pressure. pascals: The metric measurement used to quantify pressure. manometer: A device that is used to display the pressure at its connection. needle valve: A device that uses a tapered pin to restrict the free passage of air. Pascal s law: A principle that states that pressure added to a confined fluid is transmitted undiminished through the fluid. The pressure acts on all surfaces in a direction at right angles to those surfaces.

122 Industrial Pneumatics Glossary pneumatically actuated: A DCV that is switched using a pressure signal. pneumatic motor: A device that changes pneumatic pressure into mechanical rotary motion on a continuous basis. pneumatics: The engineering science pertaining to pressurized gas. port: An opening for the passage of a fluid. pressure: The stress of compacted air molecules in an air system that causes flow. pressure control valve: A device used to control the amount of pressure in a pneumatic system. pressure signal: The causal action meant to instruct a pneumatically actuated DCV to switch from one side to another. profile plate: The mounting board used to attach and align Festo pneumatic training components to a pneumatic circuit. pounds per square inch (psi): One psi is equal to the pressure from a one pound force evenly applied over a one square inch area. quick-exhaust valve: A venting device with a check valve that directs the flow in one direction to the atmosphere with very low restriction. quick-release connector: A small receptacle for pneumatic tubing that seals around inserted tubes and allows them to be removed without using tools. radial: A type of motor design where the cylinders are arranged like equally spaced spokes in a wheel. International System of units (S.I.): A universal system of physical units. schematic: A line drawing that adheres to specific drawing conventions that specify the devices and the required connections to assemble a pneumatic circuit. shuttle valve: A junction element device with two input ports and one output port that provides OR logic in a pneumatic circuit. silicon dioxide: A granular compound with the propensity to absorb moisture. single-stage: An air compression method where air is compressed once inside a piston chamber before being released to the storage reservoir. sliding vane: A type of pneumatic motor that uses fins captured radically around the motor shaft to impart torque from passing air. spool: The sliding shaft used inside of a DCV that can move to specific locations to open different output ports. square meters: The unit of measurement used to define area in the metric system. throttle valve: A pneumatic device used to control the speed of a cylinder by restricting the free flow of air through a passage containing a needle valve. time-delay valve: A combination of various components that, when used in a pneumatic circuit, provide an interval of time where an existing pressure signal is not allowed to pass. T-junction: Joins three pneumatic lines, thus having a single-pressure potential. torque: The power and twisting force generated by motors that is usually measured in foot or inch pounds. turbine: A machine in which the kinetic energy of a moving fluid is converted to mechanical power.

Reference 123 Glossary two-pressure valve: A junction element device that provides AND logic to a pneumatic circuit. two-stage: An air compression method where air is progressively compressed twice to attain a higher pressure than is possible with single-stage compression. vanes: Spring-loaded fins that obstruct the free passage of air to produce rotary motion. vertical stack magazine: A gravity fed multiple parts holder.

124 Industrial Pneumatics Reference Materials Valves 3/2-way valve, normally closed #152860 3/2-way valve, normally open #152861 5/2-way valve, with selection switch #152862 5/2-way vale, pneumatically operated #576307 5/2-way impulse valve, pneumatically operated #576303 Time-delay valve, normally closed #540694 3/2-way roller lever valve, normally closed #152866

Reference 125 Reference Materials Pressure-sequence valve #152884 Two-pressure valve (AND) #539770 Shuttle valve (OR) #539771 Quick-exhaust valve with silencer #539772 Start-up Valve One-way flow control valve #193967 Start-up valve with filter control valve #540691

126 Industrial Pneumatics Reference Materials Gauges Pressure regulator valve with gauge #539756 Actuators Manometer #152865 Single-acting cylinder #152887 Double-acting cylinder #152888 T-connector Manifold T-connector - 4 mm Manifold #152896

Reference 127 Reference Materials 3/2-way valve, normally closed #152860 3/2-way valve, normally open #152861 5/2-way valve, with selection switch #152862 5/2-way valve, pneumatically operated #576307 5/2-way impulse valve, pneumatically operated 576303 Time-delay valve, normally closed #540694

128 Industrial Pneumatics Reference Materials 3/2-way roller lever valve, normally closed #152866 (2) Pressure-sequence valve #152884 Two-pressure valve (AND) #539770 Shuttle valve (OR) #539771 Quick-exhaust valve with silencer #539772 One-way flow control valve #193967

Reference 129 Reference Materials Start-up valve with filter control valve #540691 Pressure regulator valve with gauge #539756 Manometer #152865 Single-acting cylinder #152887 Double-acting cylinder #152888 Manifold #152896