LAB-VOLT SYSTEMS, INC.

LAB-VOLT (QUBEC) LTE

FARMINGDALE, NJ 07727 USA CHARLESBOURG, QUEBEC
G2N, 2K7 CANADA
Phone: (732) 938-2000
Fax: (732) 774-8573 Phone: (418) 849-1000
Email: us@labvolt.com Fax: (418) 849-1666
Email: ca@labvolt.com

www.labvolt.com

1-800-LAB-VOLT
(in the USA and Canada)

HANDS-ON INDUSTRIAL TRAINING

Copyright 2005, Lab-Volt Systems, Inc. All rights reserved. All products featured in this guide are
94068-00 Rev. C
subject to change without notice. Lab-Volt recognizes all product names used herein as trademarks or FLUID SENSORS
registered trademarks of their respective holders. Lab-Volt is not responsible for typographical errors.

SIMULATION SOFTWARE
E-LEARNING
CERTIFICATION PREPARATION
 Innovative Design Offers Exceptional Options
L ab-Volt offers the most comprehensive and
flexible course in fluid power available. Lab-Volts
premier training system for fluid power
technology consists of two programs: the
Hydraulics Training System, Model 6080, and the
Pneumatics Training System, Model 6081.
Both are innovative, modular systems that
use state-of-the-ar t hardware and
courseware to deliver job training in fluid
power.
2
The entire fluid power series has been designed for
educational growth. Using either the Hydraulics or
the Pneumatics Training System, students gain a
solid foundation in, and hands-on experience with,
fluid power components and circuits, the principles
and concepts underlying fluid power systems and
applications, and methods of troubleshooting and
testing fluid systems. Each lesson builds upon
previous lessons, making this an ideal job-training
program.
Engineered for extreme ease of use, the core system
begins with a work surface assembly consisting of a
solid metal, universal drip-tray hinged to a
perforated, tiltable work surface that serves as a
panel onto which hydraulics or pneumatics com-
ponents are mounted. By adding optional
expansion panels, the work surface can be
configured to accommodate a wide variety
of space and teaching needs. Mounting
and dismounting components is easy
with push-lock fasteners that snap
easily into the perforations on the
work surface. The tilting work
surface facilitates instructor
demonstration to an entire
class.

Table-top work surface and Hydraulics Fundamentals components
(Model 6080-1)
Table-top work surface and Pneumatics Fundamentals components
(Model 6081-1)
Ideal for Training Centers Tight
on Budget and Space
The basic Lab-Volt Hydraulics Training System consists of
a power unit, work surface assembly, industrial-grade
components, hoses, a hose rack, metering instruments and
related courseware. The basic Pneumatics Training System
consists of a work surface assembly, pneumatic
components, measuring instruments and necessary
pneumatic accessories to perform experiments. All
components in both systems exceed industrial safety
standards. Hydraulic connections are made through
double-check valve quick-disconnect fittings. Optional
equipment includes a mobile support bench with
expandable storage shelves, lockable dress panels and
additional expansion panels.
Operating on a standard electrical supply, the Hydraulics
system requires no special wiring. The power unit is
designed to match components with training needs. The
pump (3.0 l/min, 0.8 U.S. gal/min) delivers flow to
components at a rate that allows for observation and is
powerful enough to provide pressures in excess of 6200
kPa or 900 psi.
The scope of the entire Lab-Volt Fluid Power product line
addresses the diverse needs of secondary and post-
secondary technology programs. The interfacing of
electronics, sensors, robots and controls makes the
Lab-Volt program an ideal cornerstone of any job-training
program in Mechatronics, Electromechanical Systems or
Automation.
3
 Models 6080-1, 6080-A and 6080-B
The Lab-Volt Hydraulics Training System begins with Hydraulics Fundamentals, the first in a series of five subsystems
that take students from basic to advanced training in industry-standard hydraulic applications.

The standard modular system consists of a perforated work surface, components for the Hydraulics Fundamentals
course, a drip tray attached at the bottom of the work surface, a hose rack with hydraulic hoses, and a power supply unit
in a mobile frame.

The work surface and components (Model 6080-1) can be placed on a table, on an optional workbench containing
sliding channels for storing additional work surfaces (Model 6080-A), or a lockable, paneled bench (Model 6080-B).

FEATURES

Engineered for extreme ease of use

Workstation can be configured to accommodate a wide
variety of space and teaching needs
Components mount/dismount with push-lock fasteners
Optional support bench and dressing panels are available
Components exceed industrial safety standards

TOPIC COVERAGE

Introduction to Hydraulics Functional Circuits

Fundamentals
- Pressure Limitation
- Pressure and Force
- Flow Rate and Velocity
- Work and Power
Basic Circuits
- Cylinder Control
- Cylinders in Series
- Cylinders in Parallel
- Regenerative Circuits
- Accumulators
- Hydraulic Motor Circuits
- Pressure Reducing Valves
- Remotely Controlled
Pressure Relief Valves
Troubleshooting
Typical Hydraulics Fundamentals setup features
Model 6080-B, consisting of a lockable storage bench,
along with standard Hydraulics Fundamentals
equipment (hose rack not shown). Additional work
surfaces and components are optional.
See Page 10 for additional work bench options.

Model 6080-2
Electrical Control of Hydraulic Systems introduces students FEATURES
to electrical concepts and electrically controlled hydraulic
systems. Through hands-on experimentation, students gain Seamless integration with Hydraulics
familiarity with functional and industrial electrically con- Fundamentals System
trolled hydraulic systems while learning systematic methods Prepares students for jobs and advanced
of troubleshooting and testing electrically controlled education in state-of-the-art fluid power
hydraulic systems. applications

This module requires the same perforated work surface, drip Provides add-on capabilities for PLC
tray, hose rack and hoses, and power supply unit that are operations, Servo/Proportional Control and
used with the Hydraulics Fundamentals system. Sensors

Integrates with Electrical Control of

Pneumatics Systems

4
ELECTRICAL CONTROL OF HYDRAULIC SYSTEMS
Model 6080-2 (continued)
TOPIC COVERAGE

Introduction to Electrical Control of Hydraulic

Systems

Electrical Concepts
- Basic Electricity
- Ladder Diagrams
- Basic Electrically Controlled Hydraulic Systems

Functional Systems Model 6080-2: Table-top work surface provides ample space for storing most
- Hydraulic Sequencing of Cylinders components of Electrical Control of Hydraulic Systems (Table not induded)
- Electrical Sequencing of Cylinders
- Speed Regulation and Braking of Hydraulic
Motors Troubleshooting
- Continuous Reciprocation with Dwell Period - Troubleshooting Electrical Control Circuits
- Troubleshooting Electrically Controlled
Industrial Applications Hydraulic Systems
- Drilling System
- Safety Circuits
- Counting of Actuator Cycles
- Multiple Pressure Systems
- Rapid-Traverse-Slow Feed System

Virtual Laboratory Equipment for Hydraulics

To provide training centers and students with a fast and
effective instructional tool, Lab-Volt has created a series of
Windows-based simulation software programs (LVSIM)
that cover the same material and produce the same results
as actual laboratory equipment. The Lab-Volt Hydraulics
training systems, Models 6080-1/2, also are available as an
LVSIM program.
Computer-screen images represent the standard laboratory
equipment and fully simulate the mechanical characteristics
of the actual hydraulic module. Using the mouse, students
can select and set up virtual equipment for a given exercise,
make the necessary connections between the simulated
modules and obtain the same results as with the real equip-
ment.
Used either as a complement to the actual laboratory equip-
ment or as a stand-alone product, LVSIM is a cost-effective
tool that enables students to safely and accurately perform
experiments and become familiar with the equipment con-
figuration and laboratory setup before entering the lab. As a
result, their time spent in duplicating hands-on tasks in the
actual laboratory may be reduced by as much as 50%, result-
ing in the need for less physical hardware per student. In
addition, students can install a limited version of the
LVSIM software into their own computers, and practice Sample screens from the LVSIM-HYD show simulations of the Hydraulics
and prepare in advance for their lab exercises. Training System. Using virtual components, meters, gauges and hoses, students
can perform the same experiments and derive the same results as they would with
actual laboratory equipment.
5
 Model 6080-4
The Servo/Proportional Control module is an add-
on to the Electrical Control system for the
Hydraulics Training System. Through hands-on
operation of signal conditioners; pressure, speed,
and position transducers; P.I.D. controllers; propor-
tional control valves; and corresponding interface
hardware and courseware, students are trained in the
precise controls used in industrial applications such
as robotics, aviation, CNC machines, marine, mobile
equipment and material handling.

All exercises require Basic and Electrical Control of

Hydraulics (Models 6080-1 and 6080-2).
Model 6080-4: Components of Hydraulic Servo/Proportional Set (Add-on)

FEATURES
Modular construction to better understand
P.I.D. control
Incorporates both Servo and Proportional
Valve Control studies
Motor Speed Control
Cylinder Rod Position Control
Open- and Closed-Loop Control
Illustrated student manuals
TOPIC COVERAGE
Design and Operation of Proportional Valves
Control of Hydraulic Actuator
Acceleration and Deceleration
Control of the Speed of a Hydraulic
Motor in the:
Open-Loop Mode
Closed-Loop Proportional (P) Mode
Proportional-Plus-Integral (PI) Mode
Proportional-Plus-Integral-Plus-Derivative
(PID) Mode
Control of the Position of a Cylinder Rod
in the Open-and Closed-Loop Modes
Control of the Pressure Applied to a
Cylinder Position in the Closed-Loop Mode
COMPUTER-BASED LEARNING FOR
HYDRAULICS & PNEUMATICS
Models 6386, 6486
FEATURES
Graphics, animations, simulation and interactivity
enhance learning speed and retention
Internet Link resource provides links to related
websites to broaden trainees' knowledge
Instructor-enabled narration assists trainees who
learn more effectively through auditory means
GradePoint 2020 electronic classroom manager
enables instructors to automatically compute and
record grades, generate competency reports, and
provide instruction via remote control to trainees'
computers
Powerful delivery systems allows instructors to
easily integrate and launch software applications;
edit tests, competencies, and rubrics; and add
video and audio enhancements

Sold as a site license in

addition to Fluid Power
trainers.

6
Models 6081-1 and 6081-2
The Pneumatics Training System follows the same
structure and uses the same work bench and many elec-
trical components as the Hydraulics Training System,
Model 6080, providing a convenient interconnection
between both systems.

The Pneumatics Fundamentals system provides stu-

dents with an introduction to the basic principles and
components of pneumatic systems. Electrical Control
of Pneumatic Systems introduces students to electrical
control of pneumatic systems using ladder diagrams.
Fluid Control Applications add-ons consist of the same
PLC, Servo/Proportional Control and Sensors mod-
ules found in the Hydraulics Training System.
Model 6081-1: Consisting of the Pneumatics Fundamentals courseware,
and work surface components; configurable on a table top or on the work
bench described with the Hydraulics Fundamentals Training System
Model 6081-2: Components of Electrical Control of Pneumatic
Systems

Learning material, in both the manual and simulation

formats, is divided into units consisting of exercises
within a specific field of pneumatics. Each exercise
provides a clearly stated objective, a discussion, refer-
ences, a summary of the exercise procedure, a conclu-
sion, a set of review questions and a 10-question test at
the end of the unit.

FEATURES Functional Systems

Designed for economy, flexibility and compatibility
with the Lab-Volt Hydraulics Training System
Develops basic through advanced skills in
industry-standard pneumatic applications
Available in manual and simulation formats to
provide maximum program flexibility
TOPIC COVERAGE
Pneumatic Fundamentals
Introduction to Basic Pneumatics
Basic Physical Concepts
- Pressure vs. Force Relationship
- Pressure vs. Volume Relationship
- Pressure Drop vs. Flow Relationship
- Vacuum Generation
Electrical Control of Pneumatic Systems
Introduction to Intermediate Pneumatics
Basic Concepts of Electropneumatics
- Basic Electricity
- Ladder Diagrams
- Basic Electrically Controlled Pneumatic Circuits
- Basic and/or Logic Function Circuits
Basic Controls of Cylinders
- Directional Control Valves
- Directional and Speed Control of Cylinders
- Cylinders in Series
- Cylinders in Parallel
Basic Controls of Pneumatic Motors
- Indirect Control using Pilot-Operated Valves
- Pneumatic Motor Circuits
- Pneumatic Motor Performance
- Basic Memory and Priority Electropneumatic
Circuits
- Multi-Pressure Systems
- Sequencing Pneumatic Circuits
- Time-Delay Electropneumatic Applications
Industrial Applications
- Pneumatic Actuator Deceleration Circuits
- Counting of Actuator Cycles
- Industrial Drilling System and Safety Circuits
- Garbage Compactor Simulation Circuit
Troubleshooting
- Troubleshooting Electrical Control Circuits
- Troubleshooting Electrically Controlled
Pneumatic Systems

7
 Virtual Laboratory Equipment for Pneumatics
Similar to LVSIM-HYD, this simulation software program
provides fast and effective training. By gaining familiarity
with equipment prior to entering the actual laboratory, either
in the classroom or on their own computers at home,
students may spend significantly less time (a reduction of up
to 50%) using the actual equipment. In addition, each student
would require less physical hardware, so the training system
is cost-effective, as well. The Lab-Volt Pneumatics training
system, Models 6081-1/2, also are available as an LVSIM
program.

LVSIM-PNEU can be used as a

stand-alone product or as a The sample screens from LVSIM-
complement to the actual labora- PNEU show simulations of the
tory equipment. In addition, it Pneumatics Training System. Using
can be loaded together with virtual components, meters, gauges,
and hoses, students can perform the
LVSIM-HYD. T h i s a l l o w s same experiments and derive the same
students to view and work with results as they would with actual labo-
virtual components for both ratory equipment.
hydraulics and pneumatics at the
same time.

Model 6081-4
The Servo-Proportional Control module supplements
training in Electrical Control of Pneumatic Systems.
Students gain hands-on experience in operating a
complete range of pneumatic equipment, including:

Signal conditioners
Pressure, speed and position transducers
P.I.D. controllers
Proportional control valves
Corresponding interface hardware and courseware

This training enables students to operate precise

controls in a broad range of industrial applications,
including robotics, aviation, CNC machines, marine,
mobile equipment and material handling.
Model 6081-4: Components of pneumatic servo-proportional control
All exercises require Basic and Electrical Control of
Pneumatics (Models 6081-1 and 6081-2).
8
Models 6082 and 6085
PROGRAMMABLE LOGIC CONTROLLER
(PLC)
Model 6082-X
Using a PLC with either the Hydraulics or Pneumatics
Training System, students learn how to send instructions
from the PLC and download ladder programs in order to
operate fluid power circuits by means of switches, sensors
and solenoid-operated directional valves. The P L C also
allows students to make comparisons with relay operated
control circuits and design time-delay circuits, up and down
counting circuits, latch and unlatch circuits, and more.

The system consists of a PLC equipped with input/output

2-mm banana sockets, allowing quick interconnection to Allen-Bradley PLC with PC interface & Software
components, along with a basic hand-held programmer or
advanced PC interface software, an expansion work surface
and curriculum.

The PLC is available in basic and advanced models: the

Allen Bradley Model 6082-1 (basic) and 6082-5 (advanced);
the OMRON Model 6082-2 (basic) and 6082-5 (advanced),
and the Siemens Model 6082-3 (basic) and 6082-7
(advanced).

ELECTRONIC SENSORS

Model 6085-A Model 6085-A

The Lab-Volt Sensors Training System, Model 6085-A, is

designed to familiarize students with the operation of
various sensor types. This training system is available as an
add-on to the Electrical Control of Hydraulic Systems,
Model 6080-2, and Electrical Control of Pneumatic
Systems, Model 6081-2. It is also available as a stand-alone
system. The Sensors Training System contains a selection of
photoelectric, inductive and capacitive sensors representa-
tive of what can be found in industry.

Each sensor is mounted on a flexible support attached to a

metallic base, which can be snapped into the perforations of
the Hydraulics and Pneumatics Trainer work surfaces. The
sensors are protected against reverse polarity and can be
used in conjunction with a Programmable Logic Controller
Model 5901, Flexible Manufacturing System
to achieve advance fluid control applications.
Models from the Pneumatics product line can be added to the
As a stand-alone system, the Sensors Training System also Flexible Manufacturing System to simulate a production line and
implement more sophisitcated applications.
includes a power supply, pilot lamps, leads and a work
surface.
9
 Models 6302, 6301, 6302-1 expansion panels provide a multitude of
configurations when stacked and locked together.
Model 6309 reinforced panel can be used to store students circuits.
For advanced circuit layouts, an inside bench enclosure can be used or Work surface with A frame on optional bench with dressing
panels can be linked together on a table top. panels and lockable doors (6303-DO).

Work surface on optional bench (6303-10)

with dress panels and door (6303-AO).

Work surface on optional bench (6303-10)
without dress panels.

Models 3509 and 6085: The conveyor systems provide a true applica-
tion of fluid power control and flexibility. Speed control, stamping,
drilling and positioning can make a unique and practical testing
platform for advanced students.

10
With the production speed and efficiency of todays work-
force, companies are increasingly seeking better-qualified
employees. Workers are more decentralized than ever
before, and government- and corporate-mandated training
is on the rise. The integration of Industrial Training Zones
e-learning programs enables Lab-Volt to meet these chal-
lenges by delivering fast, localized, updated training at an
affordable price.

FEATURES

Premier training interface organizes curriculum in

a logical sequence
Interactive learning programs build content mastery
and troubleshooting expertise
Pre-testing and post-test certification ensures mastery
of industrial skills
3D animations illustrate in real time how equipment
works
Self-paced learning increases retention and job skills
Video narrations guide training step by step

TOPIC COVERAGE

INDUSTRIAL HYDRAULICS INDUSTRIAL PNEUMATICS

Model 47901 Model 47902
Basic Hydraulics Physics Basic Physics
Pumps and Actuators Compressors
Pressure Control Air Dryers
Directional Control Air Preparation
Flow Control Valves Air Distribution
Modular Control Valves Directional Control Valves
Fluid Conditioning
Actuators
Check Valves
Miscellaneous Valves
Accessory Components
Fluid Conductors Airline Conductors
Understanding Schematics Vacuum
Basic System Design Understanding Schematics

PNEUMATIC SPECIALIST COURSE MOBILE HYDRAULICS

Model 47909 Model 47906
Developed in conjunction with the Fluid Power Society,
Pumps and Actuators in Mobile Equipment
this course prepares trainees to become certified
Pneumatic Specialists. Topic coverage includes: Hydrostatic Transmissions
Pressure Control
Load and Motion Control Directional Control Valves
System Analysis and Troubleshooting Flow Control Valves
System Design Modular Control Valves
Component Application Fluid Conditioning
Air Compression and Preparation Check Valves
Certification Study Guide Fluid Conductors 11
 LAB-VOLT SYSTEMS, INC. LAB-VOLT (QUBEC) LTE
FARMINGDALE, NJ 07727 USA CHARLESBOURG, QUEBEC
G2N, 2K7 CANADA
Phone: (732) 938-2000
Fax: (732) 774-8573 Phone: (418) 849-1000
Email: us@labvolt.com Fax: (418) 849-1666
Email: ca@labvolt.com

www.labvolt.com

1-800-LAB-VOLT
(in the USA and Canada)

HANDS-ON INDUSTRIAL TRAINING

Copyright 2005, Lab-Volt Systems, Inc. All rights reserved. All products featured in this guide are
94068-00 Rev. C
subject to change without notice. Lab-Volt recognizes all product names used herein as trademarks or FLUID SENSORS
registered trademarks of their respective holders. Lab-Volt is not responsible for typographical errors.

SIMULATION SOFTWARE
E-LEARNING
CERTIFICATION PREPARATION