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Qualification solutions

for process automation


Process automation

Professional, industry-focused qualification solutions


for process automation

MPS® PA
The new learning system for
process automation
Filtering, mixing, tempering and
filling as in industry

Networked system
With 3 or 4 stations
Measurement and control of level,
flow rate, pressure and temperature

Compact Workstation
Measurement and control of level,
flow rate, pressure and temperature

2 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com


Process automation

Challenging – The process industry

Few industries have as many fac- Even though the end products may
ets or are as interesting as the proc- differ, automation is making huge
ess industry, which produces a wide leaps forward in each of these ar-
range of products for the most di- eas. International competition and
verse areas of daily life. the resultant pressure to continu-
ally increase productivity as well as
On the one hand, the chemical indus- a continuously expanding range of
try produces preliminary products variants and strict requirements for
for other industries. This group in- process and quality assurance de-
cludes base chemicals, petrochemi- mand automation solutions.
cals, polymers as well as refined and
special chemicals. Key consumers in-
clude the automotive, packaging and
building industries.

On the other hand, chemical prod-


ucts are used in the areas of health,
the environment and nutrition. As
well as the chemical and pharmaceu-
tical industry, the process industry
includes other sectors such as the
biotechnology, paper and food in-
dustries.

www.festo-didactic.com 3
Process automation

Filtering, mixing, tempering and filling


as in industry

Modular Training for many areas of


application and careers
The modularity of the learning sys-
tem enables you to realise a diverse – Electronic engineers
range of configurations for typical – Mechatronics engineers
production processes from very dif- – Systems engineers
ferent industries in a safe learning – Microtechnologists
environment. – Process technicians for plastic and
rubber technology, glass and coat-
ing technology
– Experts in food, confectionery and
fruit juice technology
– Experts in water supply, sewage
technology, pipe, canal and indus-
trial services
– Chemical engineers
– Pharmaceutical engineers
– Biotechnicians
– Paper technicians
– Systems engineers for sanitary,
heating and air conditioning tech-
nology

4 www.festo-didactic.com
Process automation

Train efficiently

Festo – The partner to the


process industry

Festo is fast becoming a key part-


ner to the process industry. It is only
logical that the process automation
learning system benefits from this
know-how and is tailored to the re-
quirements of different industries
through its consistent modularisa-
tion:

– Water supply and disposal industry


– Food industry
– Bulk goods industry
– Chemical and petrochemical indus-
tries
– Biotechnology/pharmaceutical
industries
– Paper industry

Why stop production to facilitate


training?

It is prohibitively expensive to shut


down an industrial system to facili-
tate training. Comprehensive train-
ing in the individual areas of process
automation requires industry-ori-
ented model systems or training in-
stallations. „Learning by doing“ and
„process orientation“ are two princi-
ples that are central to the success-
ful imparting of the many detailed
training aims in process technology.
Simulation of a process engineering
system on a PC provides the oppor-
tunity of using a simulation as an ac-
tual training system.

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 5


Process automation

Understanding process automation –


By means of seminars and workshops

Open seminar on measurment and Specific customer training course


The goal of Festo Didactic is to control fundamentals of control
offer further training that not technology Customer-specific training course for
only supports personnel in com- those employed in the areas of main-
panies with current problems, The participants will acquire basic tenance, servicing and operational
but that also provides new ap- knowledge and skills in the areas support.
proaches to future tasks. of electrical engineering as well as
measurement and control technol- The following training aims are con-
Festo is fast becoming a key ogy. They will learn about the basic veyed to the participants using the
partner to the process industry. structure, mode of operation and professional training equipment of
Close coordination with our par- application of process engineer- Festo Didactic through „learning by
ent company, Festo AG & Co. ing systems and be able to use this doing“:
KG., ensures the use of the most equipment. The procedure for the – Cross section of all controller types
modern equipment and systems identification of control systems, se- (P, I, D, PI, PD, PID)
in our learning systems and a lection of a suitable controller and – Controller technologies (Fluid Lab®-
source of first-hand expertise for definition and setting of control pa- PA, industrial controllers and mod-
our trainers. rameters will also be explained. ern PLCs)

However our focus and meth- Target group Looking for something more?
odology also set us apart. Our The seminar is recommended for an- Workshop offering more complex ex-
trainers and consultants are yone seeking training in the funda- ercises on practical operational sup-
practicians. They are familiar mentals of control technology. port and maintenance, for example:
with the requirements of the – Replacement and reuse of sensors
participants attending their Training aims and their incorporation into a con-
courses, including those re- – Project planning, standards, flow trol process
quirements that go beyond the charts – Error localisation through diagno-
purely technical. – Analysis of the sensors, actuators, sis of the controller characteristics
components and control systems in – Control process with inactive time
We set ourselves a high stand- a system on request
ard. You will immediately no- – Measurement transformation of
tice the difference between our physical measurement variables On request
seminars and those offered by – Analogue value processing with
other providers. We provide new Siemens S7
answers to old questions – an- – Analysis, recording and evaluation
swers that will help you to take of various control processes such
that critical step in your opera- as level, flow rate, pressure and
tional projects. temperature
– Commissioning of a test system
– Basic principles of control technol-
ogy, P, I, PI and PID controllers in
theory and practice
– Definition: Y – W – Z – X – etc., am-
plification, rate time, reset time,
dwell time, balance time, inactive
time
– Setting of the control parameters
for different control processes
– Practical utilisation of applications
in the process industry:
· use of an industrial controller as
control equipment
· use of a Siemens SPS (S7-300) as
control equipment

On request

6 www.festo-didactic.com
Process automation

Fluid Lab®-PA

Fluid Lab®-PA can be used to teach „Process Sequence“ menu item


and demonstrate the fundamentals The process sequence of each sta-
of control technology. The main com- tion can be easily started from Fluid
ponents required for actuating the Lab®-PA. All of the process steps are
MPS® PA stations using a PC are the visualised and can be monitored on
„EasyPort D/A“ and the Fluid Lab®- the flow chart.
PA software.
„Measuring and Control“ menu item
Fluid Lab®-PA can be easily installed All the functions of the MPS® PA
on any Microsoft Windows operat- station can be clearly and directly
ing system. controlled. The states of the proc-
ess valves, pumps and sensors are
Key features graphically recorded, which means
Three main functions are integrated they can be directly evaluated. The
in Fluid Lab®-PA in combination with following functions are provided for
the EasyPort D/A: recording the sensor characteristics
Measurement and determining the step response:
For detection and evaluation of – Selection of measuring channels
measured variables from 8 digital/ – Factor for physical scale
4 analogue input signals. – Adaptation of the time scale
Open-loop control – Display of the input signals
For binary or continuous control of 8 – Setting of output signals, switching
digital/2 analogue outputs. on/off of the manipulated variable
Closed-loop control – Printing of the measured value dis-
For freely selectable closed-loop con- play or saving as a .jpg file
trol functions such as 2-point, P, I, PI
and PID. „Analysis“ menu item
Analyses of a wide range of proc-
Actual process or simulation ess components can be directly per-
All exercises and experiments can be formed using predefined exercises,
performed online on the actual proc- for example:
ess in conjunction with the station – Recording of sensor characteristics
or offline using the pre-integrated – Recording of pump characteristics
simulation. – Recording of heating characteris-
tics
„Settings“ menu item This permits a fast and thorough un-
The following parameters can be derstanding of the typical process
set here for the four analogue input components.
channels and the sensors connected
to them: „2-Point Controller“ and
– Factor „Continuous Controller“ menu item
– Offset For easy parameterisation of the re-
– Filter quired controller with an immedi-
– Inversion ate effect on the process. One click
The analogue and binary output sig- of the mouse starts various control-
nals can also be switched and the ler functions for the selected control
signal states of the inputs read off. system. Documentation of the con-
General PC system settings can also troller parameters is also straight-
be made here. forward. The measured values and
characteristic curve profiles can be
easily printed out.

DE/EN/ES/FR 544304

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 7


MPS® PA – The new learning system for process automation

MPS® PA – The new learning system for process automation

Teaching today using the


technology of tomorrow

MPS® PA, an innovative learning sys-


tem equipped with the most modern
technical features and products from
market leaders.

Practical training Sensors

The exclusive use of industrial components underlines the necessary practi- Typical process engineering sensors assume control of temperature, level, flow
cality and ensures a speedy transfer of knowledge from a training scenario to rate and pressure in the MPS® PA.
practical application.

8 24-month Festo Didactic warranty


MPS® PA – The new learning system for process automation

Investment protection Boundless variety

A well thought-out modular design with clear-cut interfaces facilitates adapta- It is only logical that the MPS® PA stations can be combined with stations from
tion to future developments in components as well as open-loop and closed- the greater MPS® family. After all, it is this possibility of combination with
loop control systems. This means that the system can be adapted to new re- MPS® stations that makes the MPS® PA an interesting proposition for basic and
quirements. further training in many industries which are dominated by process automa-
tion but still require elements from production automation.

www.festo-didactic.com 9
MPS® PA – The new learning system for process automation

Measuring and controlling as in industry

The closest thing to reality Components Operation and configuration Advantages


The MPS® PA learning system is
based on industrial standards. The
MPS® PA concept is based on a
market leaders‘ automation solu-
tions and trends and can be control-
led in a number of ways:

Simulation box – Simple commissioning of an


MPS® PA station
– Testing and commissioning of
process components or system
components of a station

Fluid Lab®-PA – Commissioning and testing of an


MPS® PA station
– Analysis of process components
and control processes of an MPS®
PA station
– Monitoring and analysis of the
process sequences of a station
– Testing, configuration and opti-
misation of control processes
(2-point, P, PI or PID controllers)
– Analysis of the control response

PLC – Programming of process se-


quences and recipe controllers
– Analogue signal processing
– Operation and monitoring using
the touch panel
– Programming of PID controllers
– Configuration and parameterisa-
tion of P, PI or PID controllers

PLC with external industrial Same as PLC, plus:


controller – Operation of an industrial con-
troller (manual operation, auto-
matic operation)
– Parameterisation of industrial
controllers (P, PI or PID control
algorithm)
– Configuration of measuring rang-
es, setpoint value limits and
alarm limits
– Self-optimisation with oscillation
or step response method

10 www.festo-didactic.com
MPS® PA – The new learning system for process automation

Combining stations

The new interface concept offers MPS® PA stations can be Stations Possible direct downstream station
many possibilities for direct combina- combined as follows:
tion of individual MPS® PA stations. Filtration Mixing Reactor Bottling
Various aspects determine the deci-
sion as to which combination is re- Filtration
quired:
– Training aims Mixing
– Supplementation of existing
stations Reactor
– Budget

The MPS® 204 complete system sec-


tion shows a fully configured system.

24-month Festo Didactic warranty 11


MPS® PA 204 Complete system

MPS® PA 204 Complete system

Control technology is clearly and Using a constant flow rate, the three Pressure control ensures constant- The filling level of the dosing tank is
practically explained using the P, PI raw materials are mixed to a recipe ly high filter quality during flushing. detected in the bottling station using
or PID control algorithm. The temper- in the mixing station. The flow rate is The pressure sensor with LCD dis- an analogue filling level sensor. The
ature sensor – the reactor station us- recorded by means of an electronic play, analogue output and switching controller regulates the filling level
es a PT100 resistance thermometer – flow sensor with impeller and addi- output always supplies the correct to the required setpoint value via
supplies a unit signal of 0 – 10 V via tionally displayed using a variable- measurement variable. The control- the continuously controllable pump.
the measuring transducer. The con- area flowmeter. The controller ad- ler ensures constantly high filter The filling level in the dosing tank is
troller approaches the setpoint tem- justs the necessary flow rate via the quality during rinsing via the propor- kept constant during filling, which
perature via the continuously control- pump with analogue control. tional pressure regulator. optimises the quality of the filling
lable heater and keeps it constant. process.

12 24-month Festo Didactic warranty


MPS® PA 204 Complete system

Function Special training aims


The system is made up of the filtra- – Construction, wiring and commis-
tion, mixing, reactor and bottling sta- sioning of a system for process
tions. The filtration station filters a technology
liquid. The filtrate is pumped from – Measurement of electrical and
the first tank into the second tank process-related variables such as
through the filter using various proc- level, flow rate, pressure and tem-
ess valves. The filtered liquid is then perature
fed into the first tank in the mixing – Design and commissioning of con-
station. The mixing station mixes trol circuits
different recipes from three reser- – Evaluation of the control response
voir tanks. The finished mixture is – Networking of process engineering
pumped to the reactor station, where systems
it is tempered. Depending on the – Process operation and monitoring,
recipe selected, different tempera- system management
ture profiles with different stirring – Selection, application and actua-
times are activated. The bottling sta- tion of process valves
tion fills the liquid into bottles. These – Analysis of control processes and Included in the scope of delivery:
bottles are transported to the filling control circuits
position via conveyors. A pneumatic – Parameterisation and optimisation Various measurement and control options
separator separates the bottles. The of P, PI or PID controllers – Simple commissioning, simulation and display using the
bottles are filled with different filling – Drafting of open-loop and closed- simulation box
quantities from the dosing tank in loop control programs – Multimedia measurement, open and closed-loop control, op-
accordance with the recipe selected. – Process operation and monitoring eration, monitoring and commissioning using Fluid Lab®-PA
– Inspection, maintenance and serv- – Starting process sequences in the PLC or monitoring them
icing using the touch panel
– The PLC or the industrial controller likewise included for
each station can assume the control function. Parameteri-
sation of the controller is performed at the touch panel or
directly at the industrial controller. All the process vari-
ables are shown clearly – and also as a trend – both on the
touch panel and on the industrial controller.
The MPS® PA complete system offers everything required
for an efficient start with measurement and closed-loop con-
trol technology.

MPS PA 204 with SIMATIC S7-300 control package 544248


MPS PA 204 with Festo CPX control package 544249
MPS PA 204 with Allen Bradley ML 1500 control package 544250
MPS PA 204 with Mitsubishi MELSEC control package 544251

The complete system is made up of the filtration, mixing, reactor and bottling stations with
trolleys, colour touch panels, mounting frames and power supply units and includes:
– 4x PLC board
(either with SIMATIC S7-313C, Festo CPX, Allen Bradley ML 1500 or
Mitsubishi MELSEC FX1N)
– 4x Fluid Lab®-PA software with digital/analogue EasyPort PC interface
– 4x digital/analogue simulation box
– 4x industrial controller
Supplied complete with all the necessary connecting cables.

Successful project work thanks to modular structure


Learning by doing – the MPS® PA system offers process
technology that you can really get to grips with. This allows
you to implement your own project ideas quickly and with-
out risk.

www.festo-didactic.com 13
MPS® PA Stations

Filtration station

Function

The filtration station filters liquids.


The filtrate is pumped from the first
tank into the second tank through
the filter using a knife gate. The fil-
tered liquid reaches the second tank
via a butterfly valve with pneumatic
semi-rotary drive. The filtered liquid
can be pumped onwards to the next
station using a separate pump. The
filter can be rinsed using a rinse pro-
gram. Regulated compressed air is
additionally blown through the filter
to loosen deposits.

Measurement and control Sensors detect the filling level of the output always supplies the correct
container in the filtering station. This measured variable. The controller
permits lessons on simple control with P, PI or PID control algorithm
exercises for monitoring the pumps ensures constantly high filter qual-
right up to complete control projects ity during rinsing via the proportional
involving complex processes. pressure regulator. Control technolo-
gy is clearly and practically explained
Pressure control ensures constant- in this way.
ly high filter quality during flushing.
The pressure sensor with LCD dis-
play, analogue output and switching

14 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com


MPS® PA Stations

Shutting off, opening, closing

The right selection of process valve,


drive, drive accessories and control
valve plays an important role in com-
plex process sequences. The filtering
station uses an extremely wide range
of process components. All the valve
actuators are actuated via a directly
connected NAMUR valve.

Knife gate with COPAC linear actua- Butterfly valve with sturdy rack and Three-way ball valve with SYPAR
tor. pinion COPAR rotary actuator and scotch yoke rotary actuator and large
large visual display. visual display.

Complete Filtration station 544253


(with trolley, colour touch panel, mounting frame and power supply unit)

Also order
Open-loop and closed-loop control with PLC:
PLC board with SIMATIC S7-313C 533526
SIMATIC S7 connecting cable set 544296
PLC board with Festo CPX 541187
Festo CPX connecting cable set 544297
PLC board with Allen Bradley ML 1500 544300
Allen Bradley ML 1500 connecting cable set 544298 Training aims for project work Recommended training media
PLC board with Mitsubishi MELSEC 544301 – Construction, wiring and commis- – Fluid Lab®-PA
Mitsubishi MELSEC connecting cable set 544299 sioning of a system for process – Web-based training program,
Or alternative: technology Fundamentals of open and closed-
SIMATIC S7 EduTrainer Compact 313C 533018 – Selection, application and actua- loop control
SIMATIC S7 connecting cable set 544296 tion of process valves – Design and simulation program
For working with Fluid Lab®-PA: – Measurement of electrical and FluidSIM® Pneumatics
Fluid Lab-PA 544304 process-related variables such as
Digital/analogue EasyPort PC interface 193930 level and pressure
RS232 PC data cable 162305 – Design and commissioning of
RS232 USB adapter 540699 control circuits
SysLink cable 034031 – Analysis of control processes and
Analogue cable 529141 control circuits
For simple commissioning, simulation and display using the simulation box: – Parameterisation and optimisation
Digital/analogue simulation box 526863 of P, PI or PID controllers
SysLink cable 034031 – Drafting of open-loop and closed-
Analogue cable 529141 loop control programs
For professional control using industrial controllers: – Process operation and monitoring
Industrial controller 544293 – Inspection, maintenance and serv-
icing
Recommended accessories
Replacement filter cartridge 544303
Mains cable for tabletop power supply unit On request

24-month Festo Didactic warranty 15


MPS® PA Stations

Mixing station

Function

The mixing station mixes different


recipes from three reservoir tanks.
The liquid from one of the three
reservoir tanks is pumped into the
main tank in a controlled manner by
opening the respective two-way ball
valve. The finished mixture can be
pumped to the next station via a sec-
ond pump – or pumped back to the
reservoir tank.

Measurement and control Using a constant flow rate, the three adjusts the necessary flow rate via
raw materials are mixed to a recipe the pump with analogue control –
in the mixing station. The flow rate is using a simple two-point controller
recorded by means of an electronic or various dynamic controllers such
flow sensor with impeller and addi- as P, PI or PID. This permits a clear
tionally displayed using a variable- explanation of control technology on
area flowmeter. The output signal various levels.
from the flow sensor is converted to
a standard signal from 0 – 10 V. The
mixing station can also be actuated
through binary means using the in-
tegrated comparator. The controller

16 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com


MPS® PA Stations

Always the right mixture

The component mix of the mixing


station offers a wide selection of typ-
ical components from process engi-
neering. Pumps and process valves,
various sensors for signal detection
as well as electronic modules for
signal conversion permit the right
„training mix“.

Sensors for detecting the filling lev- Signal converters convert all ana- Two-way ball valve with SYPAR
el of containers. With overflow pro- logue signals from the station to scotch yoke rotary actuator, large
tection thanks to additional sensors standard signals from 0 – 10 V. Prac- optical display and directly connect-
on each container, thereby virtually tical for the purpose of experimen- ed NAMUR valve.
eliminating the possibility of over- tation: integrated comparators also
flow. supply purely binary signals.

Complete Mixing station 544254


(with trolley, colour touch panel, mounting frame and power supply unit)

Also order
Open-loop and closed-loop control with PLC:
PLC board with SIMATIC S7-313C 533526
SIMATIC S7 connecting cable set 544296
PLC board with Festo CPX 541187
Festo CPX connecting cable set 544297
PLC board with Allen Bradley ML 1500 544300
Allen Bradley ML 1500 connecting cable set 544298 Training aims for project work Recommended training media
PLC board with Mitsubishi MELSEC 544301 – Construction, wiring and commis- – Fluid Lab®-PA
Mitsubishi MELSEC connecting cable set 544299 sioning of a system for process – Web-based training program,
Or alternative: technology Fundamentals of open and closed-
SIMATIC S7 EduTrainer Compact 313C 533018 – Selection, application and connec- loop control
SIMATIC S7 connecting cable set 544296 tion of various flow sensors – Design and simulation program
For working with Fluid Lab®-PA: – Measurement of electrical and FluidSIM® Pneumatics
Fluid Lab-PA 544304 process-related variables such as
Digital/analogue EasyPort PC interface 193930 level and flow rate
RS232 PC data cable 162305 – Design and commissioning of con-
RS232 USB adapter 540699 trol circuits
SysLink cable 034031 – Analysis of control processes and
Analogue cable 529141 control circuits
For simple commissioning, simulation and display using the simulation box: – Parameterisation and optimisation
Digital/analogue simulation box 526863 of P, PI or PID controllers
SysLink cable 034031 – Drafting of open-loop and closed-
Analogue cable 529141 loop control programs
For professional control using industrial controllers: – Process operation and monitoring
Industrial controller 544293 – Inspection, maintenance and serv-
icing
Recommended accessories
Mains cable for tabletop power supply unit On request

www.festo-didactic.com 17
MPS® PA Stations

Reactor station

Function

The reactor station tempers a liquid.


Depending on the recipe selected,
different temperature profiles with
different stirring times are activated.
A cooling pump is activated to cool
the liquid. The tempered liquid can
be pumped onwards to the next sta-
tion using a separate pump.

Measurement and control Sensors detect the filling level of the 0 – 10 V via the measuring transduc-
reservoir in the reactor station. This er. The controller with P, PI or PID
facilitates lessons on simple control control algorithm can approach the
exercises for monitoring the pumps setpoint temperature values via the
right up to complete control projects dynamically controlled heating unit
involving complex processes. and keep the values constant. Sim-
ple control exercises, for example
Exact adherence to the various tem- control using the two-point control-
perature profiles when activating ler, can be realised using the reactor
the recipes is achieved by means of station. Control technology is clearly
temperature control. The tempera- and practically explained in this way.
ture sensor (PT100 resistance ther-
mometer) supplies a unit signal of

18 24-month Festo Didactic warranty


MPS® PA Stations

Heating and stirring

Key basic operations in many proc-


ess engineering systems involve
heating and stirring. The compo-
nents of the reactor station are de-
signed to permit a wide range of ex-
periments in this area.

Infinitely adjustable heating with Stirrer with DC motor. Signal converters convert all ana-
control signal from 0 – 10 V. A safe logue signals from the station to
experimental environment permits standard signals from 0 – 10 V. Prac-
integrated linking of the heater with tical for the purpose of experimen-
the integrated temperature switch tation: integrated comparators also
– thus ruling out the possibility of supply purely binary signals.
„running dry“ in a practical way.

Complete Reactor station 544255


(with trolley, colour touch panel, mounting frame and power supply unit)

Also order
Open-loop and closed-loop control with PLC:
PLC board with SIMATIC S7-313C 533526
SIMATIC S7 connecting cable set 544296
PLC board with Festo CPX 541187
Festo CPX connecting cable set 544297
PLC board with Allen Bradley ML 1500 544300
Allen Bradley ML 1500 connecting cable set 544298 Training aims for project work Recommended training media
PLC board with Mitsubishi MELSEC 544301 – Construction, wiring and commis- – Fluid Lab®-PA
Mitsubishi MELSEC connecting cable set 544299 sioning of a system for process – Web-based training program,
Or alternative: technology Fundamentals of open and closed-
SIMATIC S7 EduTrainer Compact 313C 533018 – Selection, application and connec- loop control
SIMATIC S7 connecting cable set 544296 tion of temperature sensors
For working with Fluid Lab®-PA: – Measurement of electrical and
Fluid Lab-PA 544304 process-related variables such as
Digital/analogue EasyPort PC interface 193930 level and temperature
RS232 PC data cable 162305 – Use and connection of measuring
RS232 USB adapter 540699 transducers
SysLink cable 034031 – Design and commissioning of con-
Analogue cable 529141 trol circuits
For simple commissioning, simulation and display using the simulation box: – Analysis of control processes and
Digital/analogue simulation box 526863 control circuits
SysLink cable 034031 – Parameterisation and optimisation
Analogue cable 529141 of P, PI or PID controllers
For professional control using industrial controllers: – Drafting of open-loop and closed-
Industrial controller 544293 loop control programs
– Process operation and monitoring
Recommended accessories – Inspection, maintenance and serv-
Mains cable for tabletop power supply unit On request icing

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 19


MPS® PA Stations

Bottling station

Function

The bottling station fills bottles with


liquid. The liquid is pumped into the
dosing tank from the reservoir. The
bottles are transported to the filling
position via conveyors. A pneumatic
separator separates the bottles. The
bottles are filled with different filling
quantities from the dosing tank in
accordance with the recipe selected.

Measurement and control The filling level of the dosing tank The characteristics of the control
is detected in the filling station us- process can be modified using hand
ing an analogue filling level sensor. valves already integrated. Control
The controller regulates the filling technology is clearly and practically
level to the required setpoint value explained in this way.
via the dynamically controlled pump
(0 – 10 V).

The filling level in the dosing tank is


kept constant during filling, which
optimises the quality of the filling
process. Various control algorithms
such as P, PI or PID can be applied
and optimised during experiments.

20 www.festo-didactic.com
MPS® PA Stations

Transporting, separating, filling

Few segments of the diversified


process industry are associated with
such a wide range of end products
as the food industry. All foodstuffs,
whether dairy products, baked
goods, juice, beer or wine have their
own requirements with regard to the
handling and production of the cor-
responding end products. Transport-
ing, separating, dosing and bottling
play an important role here.
Optical sensors, adjustable using The pneumatic separator ensures The filling quantity can be easily ad-
background suppression, monitor that there is never more than one justed by selecting different recipes.
transportation on the conveyors of bottle at the filling position.
the filling station.

Complete Bottling station 544256


(with trolley, colour touch panel, mounting frame and power supply unit)

Also order
Open-loop and closed-loop control with PLC:
PLC board with SIMATIC S7-313C 533526
SIMATIC S7 connecting cable set 544296
PLC board with Festo CPX 541187
Festo CPX connecting cable set 544297
PLC board with Allen Bradley ML 1500 544300
Allen Bradley ML 1500 connecting cable set 544298 Training aims for project work Recommended training media
PLC board with Mitsubishi MELSEC 544301 – Construction, wiring and commis- – Fluid Lab®-PA
Mitsubishi MELSEC connecting cable set 544299 sioning of a system for process – Web-based training program,
Or alternative: technology Fundamentals of open and closed-
SIMATIC S7 EduTrainer Compact 313C 533018 – Selection and application of filling loop control
SIMATIC S7 connecting cable set 544296 level sensors – Design and simulation program
For working with Fluid Lab®-PA: – Measurement of electrical and FluidSIM® Pneumatics
Fluid Lab-PA 544304 process-related variables such as
Digital/analogue EasyPort PC interface 193930 level
RS232 PC data cable 162305 – Design and commissioning of con-
RS232 USB adapter 540699 trol circuits
SysLink cable 034031 – Analysis of control processes and
Analogue cable 529141 control circuits
For simple commissioning, simulation and display using the simulation box: – Parameterisation and optimisation
Digital/analogue simulation box 526863 of P, PI or PID controllers
SysLink cable 034031 – Drafting of open-loop and closed-
Analogue cable 529141 loop control programs
For professional control using industrial controllers: – Process operation and monitoring
Industrial controller 544293 – Inspection, maintenance and serv-
icing
Recommended accessories
Set of 20 x 100 ml bottles 544302
Mains cable for tabletop power supply unit On request

24-month Festo Didactic warranty 21


Process automation – Networked system

Networked system with 3 or 4 stations

Adjustable centrifugal pump to en- Sipart DR19 controller from A standard connecting station with An alternative connecting station
sure the right flow for every station. Siemens – now fitted in all stations. 2/2-way solenoid valve and S7-300 with pneumatic process actuators
controller controls the interaction of from Festo, Namur valves and CPX
the individual stations. valve terminal actuation is also
available.

22 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com


Process automation – Networked system

Function Training aims


A networked system enables level This system complements the train-
control, flow rate control, pressure ing aims of the Compact Worksta-
control and temperature control sys- tion.
tems to be operated simultaneously. – Commissioning and maintenance
Each station is equipped with a Sie- personnel:
mens DR19 and can therefore also Realizing bus networks. From plan-
be operated individually. The sta- ning, design and configuration
tions are connected to the host com- through to realisation.
puter (PC) via Profibus DP. Access – Operators:
to the process variables of all sta- Process operation, monitoring and
tions is provided by the operation performance training as part of
and visualisation software InTouch system management.
or WinCC.
The networked system can be sup-
Step by step to greater complexity plied as a version with 4 stations
Training starts with individual groups (level control, flow rate control, pres-
of students at the individual stations sure control and temperature con-
tackling tasks of similar complexity. trol) or as a version with 3 stations
The complexity can be gradually in- (no pressure control). Integrated systems: SIMATIC WinCC is a PC-based con-
creased later by merging the stations from the control station to the field trol and monitoring system designed
into one system. In both cases, a connecting station Modern communication technology for visualising and controlling proc-
comprising a pump and 8 x 2/2-way enables you to „see“ the sensor from esses, sequences and machines.
solenoid valves controls the flow of the control room. The critical ques-
water between the stations. Six or tion remains as to which signals are InTouch is an interactive system
eight capacitive sensors (depend- relevant for display or which inter- for visualising, monitoring and con-
ing on whether there are 3 stations vention options should be made trolling industrial processes on IBM
or 4 stations respectively) monitor accessible to individual groups of compatible computers.
the level of the containers. Supplied people. The system provides a quick
with a SIPART DR19 controller and insight into complex relationships
S7-313-2DP. and points to trends in the latest
technologies and methods through
the use of hardware and software
from market leaders.

System with 3 stations On request System with 4 stations On request Also order

Comprising: Comprising: For simple commissioning, simulation and display using the simulation box:
level, flow rate and temperature control level, flow rate, pressure and temperature Simulation box, digital/analogue 526863
as well as a standard connecting control as well as a standard connecting SysLink cable 034031
station station Analogue cable 529141

– 3x industrial controller DR19 in the – 4x industrial controller DR19 in the Control variants
ER mounting frame ER mounting frame See Compact Workstation
– 1x EduTrainer® with S7-313C-2DP – 1x EduTrainer® with S7-313C-2DP
– 4x mobile trolley – 5x mobile trolley Recommended training media
– 4x power supply unit in the mounting – 5x power supply unit in the mounting – Fluid Lab®-PA, including EasyPort, digital/analogue
frame frame – Web-based training program, Fundamentals of open and closed-loop control
– 1x individual licence STEP 7 – 1x individual licence STEP 7
– 1x licence for WinCC or InTouch – 1x licence for WinCC or InTouch
– 1x licence for SIMATIC PDM – 1x licence for SIMATIC PDM
– 1x Profibus card CP 5611 – 1x Profibus card CP 5611
– 1x set of Profibus cables – 1x set of Profibus cables
– Technical documentation – Technical documentation
– Initial start-up at Festo Didactic – Initial start-up at Festo Didactic

Commissioning and training on-site upon request.

Information on customer projects: www.festo-didactic.com 23


Process automation – Compact Workstation

Compact Workstation with level, flow rate,


pressure and temperature closed-loop control systems

Optimisation relative
to your space requirement

Maybe you‘re restricted in the


amount of space you have available
but you want each of your training
workstations to offer a high level of
complexity. If so then the Compact
Workstation with four integrated
closed-loop control systems is the
solution for you. As shown in the
flow chart, the individual control sys-
tems can be activated by simply re-
positioning the ball valves. The flex-
ible piping system enables you to
change the flow scheme or integrate
other components quickly and easily.

Function

The four control systems in the Com-


pact Workstation can be operated
individually. The level and flow rate
control systems can be structured as
a cascade control system through the
addition of an appropriate controller.

The layout of the sensors and servo


drives permits experimentation with
both continuous (e.g. P, I, PI, PID) and
discontinuous action controller types
(e.g. 2-point controllers). The pump
can either be controlled directly or
operated in controlled speed mode.

The manipulated variable of the con-


troller in the flow rate and pressure
control systems can alternatively act
upon a proportional directional con-
trol valve. A ball valve with pneu-
matic drive is built into the return
between the high-level container
and the lower reservoir. The pneu-
matic drive can be used to simulate a
“load” for switching on a disturbance
in the level control system or as an
on-off valve for emergency switch-off.

Scope of delivery of the Mechanical components, Actuation components Compact Workstation On request
Compact Workstation fully assembled – Pump Commissioning and training on-site upon
(Basic version including manual – 2 containers – Proportional directional control request.
without actuation components) – Reservoir valve
– Plug-in piping system – Ball valve with pneumatic drive
– Aluminium profile benches – Heater
– Mounting frame
– Profile plate 700 x 700 x 32 mm Electrical components
– I/O connection board with
Sensors measuring transducer
– 2 capacitive sensors – Motor controller with relay
– 2 float switches – I/O terminal, SysLink, 8 I/8 O
– 1 process drive signal box – Analogue terminal, SysLink, 15-pin
– Ultrasound sensor
– Flow sensor
– Pressure sensor
– PT100 temperature sensor

24 www.festo-didactic.com
Process automation – Compact Workstation

Piping and instrument flow chart Mounting frame Pneumatic drive Intelligent in the field –
An important part of project work Can be equipped with accessories With ball valve and signal box. Train- closedloop control with the CPX/
in process engineering is develop- for controllers, control unit and/or ing aims: Design and application ar- FEC valve terminal and the FED 120
ing a piping and instrument flow touchpanel. It can also be converted eas of various metering and shut-off touchpanel
chart. A piping and instrument flow from the ER format to DIN A4 format devices when controlling the flow of The Festo Front End Controller with
chart explains the electrical, meas- at any time by the user. The activa- liquids. integrated web server and Ethernet
uring and control technology func- tion and/or control devices can be interface is ideally suited to current
tions using measuring points and replaced in just seconds. communication tasks.
final control elements. The measure-
ment variable or another input vari-
able, its processing, its direction of
action and directional specifications
and positions should follow from
the chart.

Control variants

Control kit S1: Control kit F2: Control kit PC2: Visualisation with WinCC or InTouch
Siemens SIMATIC EduTrainer® Festo CPX/FEC® valve terminal Fluid Lab®-PA software licence with on request.
Compact with S7-313C – 1 x Festo CPX/FEC® EasyPort
– 1 x EduTrainer Compact S7-313C – 1 x control unit – 1 x Fluid Lab®-PA, individual licence Accessories for the
– 1 x control unit – 1 x Ethernet cable, crossover – 1 x EasyPort D/A Compact Workstation
– 2 x I/O data cable – 2 x I/O data cable – 1 x RS232 data cable – Trolley
– 1 x analogue cable – 1 x analogue cable – 1 x mains cable – Tabletop power supply or power
Note: STEP 7 software and MPI Note: FST software and programming – 1 x I/O data cable supply unit for the mounting frame
cable must be ordered separately cable must be ordered separately – 1 x analogue cable – Control kit
if required. if required.
Control kit S1-DP On request Recommended training media
Control kit S1 On request Control kit F2 On request Control kit PC2 On request – Fluid Lab®-PA, including EasyPort,
digital/analogue
– Web-based training program,
Control kit S2: Control kit F3: I/O simulation box, Fundamentals of open and closed-
Siemens SIPART DR19 controller Festo CPX/FEC® with FED digital/analogue loop control
– 1 x SIPART DR19 with serial inter- – 1 x Festo CPX/FEC® – 1 x simulation box incl. mains cable
face integrated in ER frame – 1 x Ethernet cable, crossover – 1 x I/O data cable, crossover
– 1 x PDM software for parameterisa- – 1 x FED-120 touchpanel – 1 x analogue cable, crossover
tion and configuration of the DR19 – 1 x I/O data cable
controller – 1 x analogue cable
– 1 x serial data cable Note: FST software and programming
– 1 x I/O data cable cable must be ordered separately
– 1 x analogue cable if required.
Control kit S2 On request Control kit F3 On request I/O simulation box On request

24-month Festo Didactic warranty 25


Hybrid processes

Hybrid processes

Boundless variety

Qualification solutions and training


factories for production and process
automation.

Tell us what you need – we‘ll design


your ideal learning environment and
establish the required dependencies
at process level. We look forward to
designing solutions with you for spe-
cial topics such as:
– Water treatment
– Cooling and refrigeration
technology
– pH value measurement
– Conductivity measurement
– Pneumatics in process engineer-
ing, for example slide valve actua-
tors with positioners, specifically
for the paper industry. MPS® PA, It is only logical that the MPS® PA
combined with MPS® stations (process automation) stations can
be combined with stations from the
greater MPS® family. This makes
MPS® an interesting proposition for
basic and further training in many
industries which are dominated by
process automation but still require
elements from production automa-
tion.

The well thought-out modular de-


sign with clear-cut interfaces pro-
tects your investment and facilitates
adaptation to future developments
in components as well as open-loop
and closed-loop control systems.
This means that the system can be
adapted to new requirements.

26 www.festo-didactic.com
Hybrid processes

Production automation and process automation

AFB – The learning system for all processes Customer-specific solutions You have specific requirements?
The modular concept factory for all associated with production automa- Numerous installations across the
hybrid production tasks tion and process automation. globe have given rise to a range of
solutions with a particular focus on
– Production hybrid automation.
– Handling of seals
– Packaging An example of this is provided by
– Filling Siemens AG Professional Education
– Transportation and routing Berlin, whose mixing and filling sta-
– Storage tion demonstrates how a continu-
– Input/output ous flow process is brought into line
with a gradual container filling proc-
The ideal solution for hybrid pro- ess. The students experience an op-
duction process requirements in erational process showing the entire
the food sector. The platform con- sequence of an automated customer
nects stations and elements from order processing system.
the MPS® Modular Production Sys-
tem with stations from the MPS® PA Detailed information on this and
learning system and the Compact other projects can be found on the
Workstation. website:
www.festo-didactic.com
The system is therefore complete- under Services ➔ References.
ly modular and new processes and
training content can be added grad-
ually. Project work with hands-on
training can take place at individual
stations, on partially integrated pro-
duction lines and in a fully integrated
learning factory.

Information on customer projects: www.festo-didactic.com 27


Festo Didactic GmbH & Co. KG

Rechbergstraße 3
73770 Denkendorf/Germany
Tel. ++49 (0)711/3467-0
56943 en

Fax ++49 (0)711/34754-88500


www.festo-didactic.com
did@festo.com