Hydraulic Training Courses

Basic level training:
 Design, function and most important characteristics of a hydraulic power unit

 Design and function of pressure-relief valves, cylinders and directional control valves
 Design and function of the non-return valve, one-way flow control valve and piloted
non-return valve
 Design and function of flow control valves
Measurements and calculations:
 Recording and interpreting the characteristic curve of a hydraulic pump

 Measuring the volume flow of a hydraulic control system
 Recording the characteristic curve of a pressure-relief valve
 Identifying and calculating times, pressures and forces during advancing and
retracting of a cylinder
 Recording the characteristic curve of a flow control valve
 Calculating performance ratios when using 4/3-way valves with different mid-
positions
Hydraulic circuits:
 Commissioning hydraulic circuits safely

 Using the flow control valve in the inflow and outflow and adjusting the drive speed
 Difference between a flow control valve and one-way flow control valve in hydraulic
control systems
 Design and mode of operation of a differential circuit
 Effect of the piston surfaces on pressures, forces, speeds and travel times
 Proper use of piloted non-return valves
 Circuits with different types of counter pressure
 Operating cylinders with varying loads
Advanced level training: troubleshooting
Systematic troubleshooting and professional error elimination are an essential part of

everyday operating life in many jobs in the fields of mechanics, mechatronics and electrical
engineering. In order to acquire a skills in this area via a structured procedure that takes into
account safety aspects, it is important that systematic troubleshooting is both learned and
practiced. Key to this are:
 Understanding circuits and discerning any non-conformities

 Delimiting/precluding any error areas
 Locating and rectifying errors
This procedure assumes specialist knowledge such as modes of operation of individual

components and their system limits.
Pressure relief valve with broken spring

One example of a defective component is a pressure relief valve with a broken spring. This
defect may be due to a continuous load or a material flaw. The defect results in the spring
length being shortened and hence in a reduction in the maximum pressure that can be set. The
conspicuous symptoms result in a lower cylinder force. Pressure sensors or force sensors may
not switch, which can lead to interruptions to operation cycles or process safety being put at
risk.
Flow control valve with damaged pressure compensator

Another example of a defect is a two-way flow control valve with a damaged pressure
compensator. While intact, the valve ensures a constant volumetric flow rate, regardless of
the load pressure. The pressure compensator is not working in this case however. The
differential pressure is no longer being regulated via the throttle valve. Here, the flow control
valve behaves like an unregulated throttle valve. A fault like this occurs if dirt has entered the
system and the pressure compensator's piston has seized up in open position as a result.
Requirements
Building on from Basic Level Hydraulics, the Advanced Level contains eight components
appropriate for equipment set TP 501. Possible troubleshooting tasks are aimed at all job
areas involving maintenance and repair activities. Special measuring equipment is not
assumed since all symptoms can be observed and are therefore visible. Error patterns can also
be quantified using measuring equipment such as a flowmeter or pressure gauge however.
The most important components at a glance
 Shut-off valve, defective

 One-way flow control valve, defective
 Pressure relief valve, defective
 2-way flow control valve, defective
 4/3-way hand lever valve, H-center position, detenting (PTAB)
 Flow control valve
 Differential cylinder 16/10/200, defective
 Tubing line with quick connection coupling, clogged
Closed loop hydraulics: basic training:
Hydraulic closed-loop control circuits are normally operated with continuous valves. A
control valve with integrated electronics, linear characteristic curve (volumetric flow to
control piston position) and zero overlap makes commissioning easy and provides good
results in the closed-loop control circuit.
Training content
Position control circuits:
 Characteristic curve of a displacement sensor

 Flow rate characteristics of a continuous directional control valve
 Linear unit as a controlled system for position control
 Designing and commissioning a position control circuit
 Lag errors in the position control circuit
 Position control with a changed controlled system
 Commissioning a position control circuit with disturbances
 Characteristics and transition functions of a status controller
 Parameterising a status controller
Pressure control circuits:
 Characteristic curve of a pressure sensor

 Controlled system for pressure control
 Characteristics of a PID controller board
 Transition function of a P controller
 Control performance of a pressure control circuit with P controller
 Transition functions of I and PI controllers
 Transition functions of D, PD and PID controllers
 Empirical parameterisation of a PID controller
 Parameterising using the Ziegler-Nichols method
 Changed controlled system with disturbances
Controllers in hydraulics:
 Controlled systems with and without compensation

 Low-delay hydraulic controlled systems
 First, second and third order hydraulic controlled systems
 Classifying controlled systems according to their step response
 Operating point and controller amplification
 Discontinuous controllers
 Block diagrams for discontinuous and continuous controllers
 P, I, D, PI, PD and PID controllers
 Status controllers
 Selecting the controller structure
 Disturbance reaction and control factor
 Designing control circuits
 Hydraulic, mechanical and electrical controllers
 Analogue and digital controllers
 Selection criteria for controllers
Valves and measuring systems:
 Designation, circuit symbols and function of continuous directional control valves

 Stationary characteristics and dynamic behaviour of continuous directional control
valves
 Function, design and mode of operation of a pressure regulating valve
 Pressure control with a directional control valve
 Mode of operation and interface of a measuring system
Recommendations for accessories, media and extensions
 Hose line with quick release couplings

 Pressure relief unit
 Function generator
 Cable BNC – 4 mm
 Cable BNC – BNC
 T-piece BNC
 4 mm Safety laboratory cables, 106 pieces, red, blue, and black
 Aluminum profile plate
 Hydraulic power pack with two constant-displacement pumps and one motor
 Power supply unit for mounting frame
 Closed-loop hydraulics: Workbook
 PID controller
 Status controller
 Pressure sensor
 Pressure gauge
 Hydraulic motor
 Flow sensor
 Pressure filter, 5 μm
 Flow control valve
 Shut-off valve
 4-way distributor with pressure gauge
 T-distributor
 4/3-way regulating valve
 Linear drive
 Weight, 5 kg, for linear drive
Advanced training electrohydraulic:
Training content
Power packs and components:
 Design and mode of operation of different proximity sensors

 Function and possible applications of a time relay with switch-on and switch-off delay
 Design and use of an electrical predetermining counter
Learning objectives for hydraulic circuits:
 Selecting proximity sensors according to the technical control requirements

 Expanding electrohydraulic control systems and adjusting the documentation
 Designing and arranging path- and pressure-dependent sequence controls
 Identifying signal overlaps in a sequence control and taking the appropriate action
 Designing and arranging sequence control as a standing sequencer
 Using memory to implement an emergency operation
 Implementing control systems with the operating modes single cycle and continuous
cycle
 Querying time in electrohydraulic control systems
 Getting to know and using further logical connections
 Designing and arranging pressure sequence control
 Knowing safety-related conditions that could be needed for a drive
 Designing and arranging safety functions with a predefined motion sequence for a
control system
 Implementing control systems with the operating modes inching and aligning
 Systematically identifying and eliminating errors in complex electrohydraulic control
systems
 Creating sequence control as a displacement-step diagram
 Representing procedure descriptions with GRAFCET
 Time relay, two-fold

 Relay, three-fold
 Preset counter, electronic
 Diaphragm accumulator with shut-off block
 Hydraulic motor
 4/3-way solenoid valve, relieving mid-position (AB −> T)
 Proximity sensor, inductive, M12
 Emergency stop pushbutton, electrical
 T-distributor
 Non-return valve, delockable (Order no. 544339)
 Pressure relief valve, compensated (Order no. 567237)

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Basic level training:

 Design, function and most important characteristics of a hydraulic power unit

Measurements and calculations:

 Recording and interpreting the characteristic curve of a hydraulic pump

 Commissioning hydraulic circuits safely

Advanced level training: troubleshooting

Systematic troubleshooting and professional error elimination are an essential part of

 Understanding circuits and discerning any non-conformities

This procedure assumes specialist knowledge such as modes of operation of individual

Pressure relief valve with broken spring

Flow control valve with damaged pressure compensator

The most important components at a glance

 Shut-off valve, defective

Closed loop hydraulics: basic training:

Position control circuits:

 Characteristic curve of a displacement sensor

Pressure control circuits:

 Characteristic curve of a pressure sensor

 Controlled systems with and without compensation

Valves and measuring systems:

 Designation, circuit symbols and function of continuous directional control valves

Recommendations for accessories, media and extensions

 Hose line with quick release couplings

The most important components at a glance

Advanced training electrohydraulic:

Power packs and components:

 Design and mode of operation of different proximity sensors

Learning objectives for hydraulic circuits:

 Selecting proximity sensors according to the technical control requirements

The most important components at a glance

 Time relay, two-fold

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