Process Automation Festo Didactic

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 facets or are as interesting as the process industry, which produces a wide range of products for the most diverse areas of daily life. On the one hand, the chemical industry produces preliminary products for other industries. This group includes base chemicals, petrochemicals, polymers as well as refined and special chemicals. Key consumers include the automotive, packaging and building industries.

Even though the end products may differ, automation is making huge leaps forward in each of these areas. International competition and the resultant pressure to continually increase productivity as well as a continuously expanding range of variants and strict requirements for process and quality assurance demand automation solutions.

On the other hand, chemical products are used in the areas of health, the environment and nutrition. As well as the chemical and pharmaceutical industry, the process industry includes other sectors such as the biotechnology, paper and food industries.

www.festo-didactic.com

3

Process automation

Filtering, mixing, tempering and filling as in industry

Modular The modularity of the learning system enables you to realise a diverse range of configurations for typical production processes from very different industries in a safe learning environment.

4

www.festo-didactic.com

Training for many areas of application and careers – Electronic engineers – Mechatronics engineers – Systems engineers – Microtechnologists – Process technicians for plastic and rubber technology, glass and coating technology – Experts in food, confectionery and fruit juice technology – Experts in water supply, sewage technology, pipe, canal and industrial services – Chemical engineers – Pharmaceutical engineers – Biotechnicians – Paper technicians – Systems engineers for sanitary, heating and air conditioning technology

Process automation

Train efficiently

Festo – The partner to the process industry Festo is fast becoming a key partner to the process industry. It is only logical that the process automation learning system benefits from this know-how and is tailored to the requirements of different industries through its consistent modularisation: – Water supply and disposal industry – Food industry – Bulk goods industry – Chemical and petrochemical industries – Biotechnology/pharmaceutical industries – Paper industry

Why stop production to facilitate training? It is prohibitively expensive to shut down an industrial system to facilitate training. Comprehensive training in the individual areas of process automation requires industry-oriented model systems or training installations. „Learning by doing“ and „process orientation“ are two principles that are central to the successful imparting of the many detailed training aims in process technology. Simulation of a process engineering system on a PC provides the opportunity of using a simulation as an actual 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

The goal of Festo Didactic is to offer further training that not only supports personnel in companies with current problems, but that also provides new approaches to future tasks. Festo is fast becoming a key partner to the process industry. Close coordination with our parent company, Festo AG & Co. KG., ensures the use of the most modern equipment and systems in our learning systems and a source of first-hand expertise for our trainers. However our focus and methodology also set us apart. Our trainers and consultants are practicians. They are familiar with the requirements of the participants attending their courses, including those requirements that go beyond the purely technical. We set ourselves a high standard. You will immediately notice the difference between our seminars and those offered by other providers. We provide new answers to old questions – answers that will help you to take that critical step in your operational projects.

Open seminar on measurment and control fundamentals of control technology The participants will acquire basic knowledge and skills in the areas of electrical engineering as well as measurement and control technology. They will learn about the basic structure, mode of operation and application of process engineering systems and be able to use this equipment. The procedure for the identification of control systems, selection of a suitable controller and definition and setting of control parameters will also be explained. Target group The seminar is recommended for anyone seeking training in the fundamentals of control technology. Training aims – Project planning, standards, flow charts – Analysis of the sensors, actuators, components and control systems in a system – Measurement transformation of physical measurement variables – Analogue value processing with Siemens S7 – Analysis, recording and evaluation of various control processes such as level, flow rate, pressure and temperature – Commissioning of a test system – Basic principles of control technology, P, I, PI and PID controllers in theory and practice – Definition: Y – W – Z – X – etc., amplification, 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

Specific customer training course Customer-specific training course for those employed in the areas of maintenance, servicing and operational support. The following training aims are conveyed to the participants using the professional training equipment of Festo Didactic through „learning by doing“: – Cross section of all controller types (P, I, D, PI, PD, PID) – Controller technologies (Fluid Lab®PA, industrial controllers and modern PLCs) Looking for something more? Workshop offering more complex exercises on practical operational support and maintenance, for example: – Replacement and reuse of sensors and their incorporation into a control process – Error localisation through diagnosis of the controller characteristics – Control process with inactive time on request On request

Process automation

Fluid Lab®-PA

Fluid Lab®-PA can be used to teach and demonstrate the fundamentals of control technology. The main components required for actuating the MPS® PA stations using a PC are the „EasyPort D/A“ and the Fluid Lab®PA software. Fluid Lab®-PA can be easily installed on any Microsoft Windows operating system. Key features Three main functions are integrated in Fluid Lab®-PA in combination with the EasyPort D/A: Measurement For detection and evaluation of measured variables from 8 digital/ 4 analogue input signals. Open-loop control For binary or continuous control of 8 digital/2 analogue outputs. Closed-loop control For freely selectable closed-loop control functions such as 2-point, P, I, PI and PID. Actual process or simulation All exercises and experiments can be performed online on the actual process in conjunction with the station or offline using the pre-integrated simulation. „Settings“ menu item The following parameters can be set here for the four analogue input channels and the sensors connected to them: – Factor – Offset – Filter – Inversion The analogue and binary output signals can also be switched and the signal states of the inputs read off. General PC system settings can also be made here.

„Process Sequence“ menu item The process sequence of each station can be easily started from Fluid Lab®-PA. All of the process steps are visualised and can be monitored on the flow chart. „Measuring and Control“ menu item All the functions of the MPS® PA station can be clearly and directly controlled. The states of the process valves, pumps and sensors are graphically recorded, which means they can be directly evaluated. The following functions are provided for recording the sensor characteristics and determining the step response: – Selection of measuring channels – Factor for physical scale – Adaptation of the time scale – Display of the input signals – Setting of output signals, switching on/off of the manipulated variable – Printing of the measured value display or saving as a .jpg file „Analysis“ menu item Analyses of a wide range of process components can be directly performed using predefined exercises, for example: – Recording of sensor characteristics – Recording of pump characteristics – Recording of heating characteristics This permits a fast and thorough understanding of the typical process components. „2-Point Controller“ and „Continuous Controller“ menu item For easy parameterisation of the required controller with an immediate effect on the process. One click of the mouse starts various controller functions for the selected control system. Documentation of the controller parameters is also straightforward. 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 system equipped with the most modern technical features and products from market leaders.

8

Practical training

Sensors

The exclusive use of industrial components underlines the necessary practicality and ensures a speedy transfer of knowledge from a training scenario to practical application.

Typical process engineering sensors assume control of temperature, level, flow rate and pressure in the MPS® PA.

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 adaptation to future developments in components as well as open-loop and closedloop control systems. This means that the system can be adapted to new requirements.

It is only logical that the MPS® PA stations can be combined with stations from the greater MPS® family. After all, it is this possibility of combination with MPS® stations that makes the MPS® PA an interesting proposition for basic and further training in many industries which are dominated by process automation 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 The MPS® PA learning system is based on industrial standards. The MPS® PA concept is based on a market leaders‘ automation solutions and trends and can be controlled in a number of ways:

10

Components

Operation and configuration

Advantages

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 optimisation of control processes (2-point, P, PI or PID controllers) – Analysis of the control response

PLC

– Programming of process sequences and recipe controllers – Analogue signal processing – Operation and monitoring using the touch panel – Programming of PID controllers – Configuration and parameterisation of P, PI or PID controllers

PLC with external industrial controller

Same as PLC, plus: – Operation of an industrial controller (manual operation, automatic operation) – Parameterisation of industrial controllers (P, PI or PID control algorithm) – Configuration of measuring ranges, setpoint value limits and alarm limits – Self-optimisation with oscillation or step response method

www.festo-didactic.com

MPS® PA – The new learning system for process automation

Combining stations

The new interface concept offers many possibilities for direct combination of individual MPS® PA stations. Various aspects determine the decision as to which combination is required: – Training aims – Supplementation of existing stations – Budget

MPS® PA stations can be combined as follows:

Stations

Possible direct downstream station Filtration

Mixing

Reactor

Bottling

Filtration Mixing Reactor

The MPS® 204 complete system section 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 practically explained using the P, PI or PID control algorithm. The temperature sensor – the reactor station uses a PT100 resistance thermometer – supplies a unit signal of 0 – 10 V via the measuring transducer. The controller approaches the setpoint temperature via the continuously controllable heater and keeps it constant.

12

24-month Festo Didactic warranty

Using a constant flow rate, the three raw materials are mixed to a recipe in the mixing station. The flow rate is recorded by means of an electronic flow sensor with impeller and additionally displayed using a variablearea flowmeter. The controller adjusts the necessary flow rate via the pump with analogue control.

Pressure control ensures constantly high filter quality during flushing. The pressure sensor with LCD display, analogue output and switching output always supplies the correct measurement variable. The controller ensures constantly high filter quality during rinsing via the proportional pressure regulator.

The filling level of the dosing tank is detected in the bottling station using an analogue filling level sensor. The controller regulates the filling level to the required setpoint value via the continuously controllable pump. The filling level in the dosing tank is kept constant during filling, which optimises the quality of the filling process.

MPS® PA 204 Complete system

Function The system is made up of the filtration, mixing, reactor and bottling stations. The filtration station filters a liquid. The filtrate is pumped from the first tank into the second tank through the filter using various process valves. The filtered liquid is then fed into the first tank in the mixing station. The mixing station mixes different recipes from three reservoir tanks. The finished mixture is pumped to the reactor station, where it is tempered. Depending on the recipe selected, different temperature profiles with different stirring times are activated. The bottling station fills the liquid into bottles. These 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.

Special training aims – Construction, wiring and commissioning of a system for process technology – Measurement of electrical and process-related variables such as level, flow rate, pressure and temperature – Design and commissioning of control circuits – Evaluation of the control response – Networking of process engineering systems – Process operation and monitoring, system management – Selection, application and actuation of process valves – Analysis of control processes and control circuits – Parameterisation and optimisation of P, PI or PID controllers – Drafting of open-loop and closedloop control programs – Process operation and monitoring – Inspection, maintenance and servicing

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

Included in the scope of delivery: Various measurement and control options – Simple commissioning, simulation and display using the simulation box – Multimedia measurement, open and closed-loop control, operation, monitoring and commissioning using Fluid Lab®-PA – Starting process sequences in the PLC or monitoring them using the touch panel – The PLC or the industrial controller likewise included for each station can assume the control function. Parameterisation of the controller is performed at the touch panel or directly at the industrial controller. All the process variables 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 control technology.

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 without 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 filtered 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 program. Regulated compressed air is additionally blown through the filter to loosen deposits.

Measurement and control

Sensors detect the filling level of the container in the filtering station. This permits lessons on simple control exercises for monitoring the pumps right up to complete control projects involving complex processes. Pressure control ensures constantly high filter quality during flushing. The pressure sensor with LCD display, analogue output and switching

14

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

output always supplies the correct measured variable. The controller with P, PI or PID control algorithm ensures constantly high filter quality during rinsing via the proportional pressure regulator. Control technology is clearly and practically explained in this way.

MPS® PA Stations

Shutting off, opening, closing The right selection of process valve, drive, drive accessories and control valve plays an important role in complex 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 actuator.

Complete Filtration station

Butterfly valve with sturdy rack and pinion COPAR rotary actuator and large visual display.

Three-way ball valve with SYPAR scotch yoke rotary actuator and large visual display.

Training aims for project work – Construction, wiring and commissioning of a system for process technology – Selection, application and actuation of process valves – Measurement of electrical and process-related variables such as level and pressure – Design and commissioning of control circuits – Analysis of control processes and control circuits – Parameterisation and optimisation of P, PI or PID controllers – Drafting of open-loop and closedloop control programs – Process operation and monitoring – Inspection, maintenance and servicing

Recommended training media – Fluid Lab®-PA – Web-based training program, Fundamentals of open and closedloop control – Design and simulation program FluidSIM® Pneumatics

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

PLC board with Mitsubishi MELSEC

544301

Mitsubishi MELSEC connecting cable set

544299

Or alternative: SIMATIC S7 EduTrainer Compact 313C

533018

SIMATIC S7 connecting cable set

544296

For working with Fluid Lab®-PA: Fluid Lab-PA

544304

Digital/analogue EasyPort PC interface

193930

RS232 PC data cable

162305

RS232 USB adapter

540699

SysLink cable

034031

Analogue cable

529141

For simple commissioning, simulation and display using the simulation box: Digital/analogue simulation box

526863

SysLink cable

034031

Analogue cable

529141

For professional control using industrial controllers: Industrial controller

544293

Recommended accessories Replacement filter cartridge Mains cable for tabletop power supply unit

544303 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 second pump – or pumped back to the reservoir tank.

Measurement and control

16

Using a constant flow rate, the three raw materials are mixed to a recipe in the mixing station. The flow rate is recorded by means of an electronic flow sensor with impeller and additionally displayed using a variablearea flowmeter. The output signal 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 integrated comparator. The controller

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

adjusts the necessary flow rate via the pump with analogue control – using a simple two-point controller or various dynamic controllers such as P, PI or PID. This permits a clear explanation of control technology on various levels.

MPS® PA Stations

Always the right mixture The component mix of the mixing station offers a wide selection of typical components from process engineering. 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 level of containers. With overflow protection thanks to additional sensors on each container, thereby virtually eliminating the possibility of overflow.

Complete Mixing station

Signal converters convert all analogue signals from the station to standard signals from 0 – 10 V. Practical for the purpose of experimentation: integrated comparators also supply purely binary signals.

Two-way ball valve with SYPAR scotch yoke rotary actuator, large optical display and directly connected NAMUR valve.

Training aims for project work – Construction, wiring and commissioning of a system for process technology – Selection, application and connection of various flow sensors – Measurement of electrical and process-related variables such as level and flow rate – Design and commissioning of control circuits – Analysis of control processes and control circuits – Parameterisation and optimisation of P, PI or PID controllers – Drafting of open-loop and closedloop control programs – Process operation and monitoring – Inspection, maintenance and servicing

Recommended training media – Fluid Lab®-PA – Web-based training program, Fundamentals of open and closedloop control – Design and simulation program FluidSIM® Pneumatics

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

PLC board with Mitsubishi MELSEC

544301

Mitsubishi MELSEC connecting cable set

544299

Or alternative: SIMATIC S7 EduTrainer Compact 313C

533018

SIMATIC S7 connecting cable set

544296

For working with Fluid Lab®-PA: Fluid Lab-PA

544304

Digital/analogue EasyPort PC interface

193930

RS232 PC data cable

162305

RS232 USB adapter

540699

SysLink cable

034031

Analogue cable

529141

For simple commissioning, simulation and display using the simulation box: Digital/analogue simulation box

526863

SysLink cable

034031

Analogue cable

529141

For professional control using industrial controllers: Industrial controller

544293

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 station using a separate pump.

Measurement and control

Sensors detect the filling level of the reservoir in the reactor station. This facilitates lessons on simple control exercises for monitoring the pumps right up to complete control projects involving complex processes. Exact adherence to the various temperature profiles when activating the recipes is achieved by means of temperature control. The temperature sensor (PT100 resistance thermometer) supplies a unit signal of

18

24-month Festo Didactic warranty

0 – 10 V via the measuring transducer. The controller with P, PI or PID control algorithm can approach the setpoint temperature values via the dynamically controlled heating unit and keep the values constant. Simple control exercises, for example control using the two-point controller, can be realised using the reactor station. Control technology is clearly and practically explained in this way.

MPS® PA Stations

Heating and stirring Key basic operations in many process engineering systems involve heating and stirring. The components of the reactor station are designed to permit a wide range of experiments in this area.

Infinitely adjustable heating with control signal from 0 – 10 V. A safe experimental environment permits integrated linking of the heater with the integrated temperature switch – thus ruling out the possibility of „running dry“ in a practical way.

Complete Reactor station

Stirrer with DC motor.

Signal converters convert all analogue signals from the station to standard signals from 0 – 10 V. Practical for the purpose of experimentation: integrated comparators also supply purely binary signals.

Training aims for project work – Construction, wiring and commissioning of a system for process technology – Selection, application and connection of temperature sensors – Measurement of electrical and process-related variables such as level and temperature – Use and connection of measuring transducers – Design and commissioning of control circuits – Analysis of control processes and control circuits – Parameterisation and optimisation of P, PI or PID controllers – Drafting of open-loop and closedloop control programs – Process operation and monitoring – Inspection, maintenance and servicing

Recommended training media – Fluid Lab®-PA – Web-based training program, Fundamentals of open and closedloop control

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

PLC board with Mitsubishi MELSEC

544301

Mitsubishi MELSEC connecting cable set

544299

Or alternative: SIMATIC S7 EduTrainer Compact 313C

533018

SIMATIC S7 connecting cable set

544296

For working with Fluid Lab®-PA: Fluid Lab-PA

544304

Digital/analogue EasyPort PC interface

193930

RS232 PC data cable

162305

RS232 USB adapter

540699

SysLink cable

034031

Analogue cable

529141

For simple commissioning, simulation and display using the simulation box: Digital/analogue simulation box

526863

SysLink cable

034031

Analogue cable

529141

For professional control using industrial controllers: Industrial controller

544293

Recommended accessories Mains cable for tabletop power supply unit

On request

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 is detected in the filling station using an analogue filling level sensor. The controller regulates the filling level to the required setpoint value 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

The characteristics of the control process can be modified using hand valves already integrated. Control technology is clearly and practically explained in this way.

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 corresponding end products. Transporting, separating, dosing and bottling play an important role here. Optical sensors, adjustable using background suppression, monitor transportation on the conveyors of the filling station.

Complete Bottling station

The pneumatic separator ensures that there is never more than one bottle at the filling position.

The filling quantity can be easily adjusted by selecting different recipes.

Training aims for project work – Construction, wiring and commissioning of a system for process technology – Selection and application of filling level sensors – Measurement of electrical and process-related variables such as level – Design and commissioning of control circuits – Analysis of control processes and control circuits – Parameterisation and optimisation of P, PI or PID controllers – Drafting of open-loop and closedloop control programs – Process operation and monitoring – Inspection, maintenance and servicing

Recommended training media – Fluid Lab®-PA – Web-based training program, Fundamentals of open and closedloop control – Design and simulation program FluidSIM® Pneumatics

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

PLC board with Mitsubishi MELSEC

544301

Mitsubishi MELSEC connecting cable set

544299

Or alternative: SIMATIC S7 EduTrainer Compact 313C

533018

SIMATIC S7 connecting cable set

544296

For working with Fluid Lab®-PA: Fluid Lab-PA

544304

Digital/analogue EasyPort PC interface

193930

RS232 PC data cable

162305

RS232 USB adapter

540699

SysLink cable

034031

Analogue cable

529141

For simple commissioning, simulation and display using the simulation box: Digital/analogue simulation box

526863

SysLink cable

034031

Analogue cable

529141

For professional control using industrial controllers: Industrial controller

544293

Recommended accessories Set of 20 x 100 ml bottles Mains cable for tabletop power supply unit

544302 On request

24-month Festo Didactic warranty

21

Process automation – Networked system

Networked system with 3 or 4 stations

Adjustable centrifugal pump to ensure the right flow for every station.

22

Sipart DR19 controller from Siemens – now fitted in all stations.

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

A standard connecting station with 2/2-way solenoid valve and S7-300 controller controls the interaction of the individual stations.

An alternative connecting station with pneumatic process actuators from Festo, Namur valves and CPX valve terminal actuation is also available.

Process automation – Networked system

Function A networked system enables level control, flow rate control, pressure control and temperature control systems to be operated simultaneously. Each station is equipped with a Siemens DR19 and can therefore also be operated individually. The stations are connected to the host computer (PC) via Profibus DP. Access to the process variables of all stations is provided by the operation and visualisation software InTouch or WinCC. Step by step to greater complexity Training starts with individual groups of students at the individual stations tackling tasks of similar complexity. The complexity can be gradually increased later by merging the stations into one system.

System with 3 stations

On request

Training aims This system complements the training aims of the Compact Workstation. – Commissioning and maintenance personnel: Realizing bus networks. From planning, design and configuration through to realisation. – Operators: Process operation, monitoring and performance training as part of system management. The networked system can be supplied as a version with 4 stations (level control, flow rate control, pressure control and temperature control) or as a version with 3 stations (no pressure control). In both cases, a connecting station comprising a pump and 8 x 2/2-way solenoid valves controls the flow of water between the stations. Six or eight capacitive sensors (depending on whether there are 3 stations or 4 stations respectively) monitor the level of the containers. Supplied with a SIPART DR19 controller and S7-313-2DP.

System with 4 stations

On request

Integrated systems: from the control station to the field Modern communication technology enables you to „see“ the sensor from the control room. The critical question remains as to which signals are relevant for display or which intervention options should be made accessible to individual groups of people. The system provides a quick insight into complex relationships and points to trends in the latest technologies and methods through the use of hardware and software from market leaders.

SIMATIC WinCC is a PC-based control and monitoring system designed for visualising and controlling processes, sequences and machines. InTouch is an interactive system for visualising, monitoring and controlling industrial processes on IBM compatible computers.

Also order

Comprising:

Comprising:

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

ER mounting frame

ER mounting frame

– 1x EduTrainer® with S7-313C-2DP

– 1x EduTrainer® with S7-313C-2DP

– 4x mobile trolley

– 5x mobile trolley

– 4x power supply unit in the mounting

– 5x power supply unit in the mounting

frame

frame

– 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

For simple commissioning, simulation and display using the simulation box:

Control variants See Compact Workstation Recommended training media – Fluid Lab®-PA, including EasyPort, digital/analogue – Web-based training program, Fundamentals of open and closed-loop control

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 systems can be activated by simply repositioning the ball valves. The flexible piping system enables you to change the flow scheme or integrate other components quickly and easily. Function The four control systems in the Compact 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 controller in the flow rate and pressure control systems can alternatively act upon a proportional directional control valve. A ball valve with pneumatic drive is built into the return between the high-level container and the lower reservoir. The pneumatic 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 Compact Workstation (Basic version including manual without actuation components)

Mechanical components, fully assembled – 2 containers – Reservoir – Plug-in piping system – Aluminium profile benches – Mounting frame – Profile plate 700 x 700 x 32 mm Sensors – 2 capacitive sensors – 2 float switches – 1 process drive signal box – Ultrasound sensor – Flow sensor – Pressure sensor – PT100 temperature sensor

24

www.festo-didactic.com

Actuation components – Pump – Proportional directional control valve – Ball valve with pneumatic drive – Heater Electrical components – I/O connection board with measuring transducer – Motor controller with relay – I/O terminal, SysLink, 8 I/8 O – Analogue terminal, SysLink, 15-pin

Compact Workstation

On request

Commissioning and training on-site upon request.

Process automation – Compact Workstation

Piping and instrument flow chart An important part of project work in process engineering is developing a piping and instrument flow chart. A piping and instrument flow chart explains the electrical, measuring and control technology functions using measuring points and final control elements. The measurement variable or another input variable, its processing, its direction of action and directional specifications and positions should follow from the chart.

Mounting frame Can be equipped with accessories for controllers, control unit and/or touchpanel. It can also be converted from the ER format to DIN A4 format at any time by the user. The activation and/or control devices can be replaced in just seconds.

Pneumatic drive With ball valve and signal box. Training aims: Design and application areas of various metering and shut-off devices when controlling the flow of liquids.

Intelligent in the field – closedloop control with the CPX/ FEC valve terminal and the FED 120 touchpanel The Festo Front End Controller with integrated web server and Ethernet interface is ideally suited to current communication tasks.

Control kit F2: Festo CPX/FEC® valve terminal – 1 x Festo CPX/FEC® – 1 x control unit – 1 x Ethernet cable, crossover – 2 x I/O data cable – 1 x analogue cable Note: FST software and programming cable must be ordered separately if required.

Control kit PC2: Fluid Lab®-PA software licence with EasyPort – 1 x Fluid Lab®-PA, individual licence – 1 x EasyPort D/A – 1 x RS232 data cable – 1 x mains cable – 1 x I/O data cable – 1 x analogue cable

Visualisation with WinCC or InTouch on request.

Control variants Control kit S1: Siemens SIMATIC EduTrainer® Compact with S7-313C – 1 x EduTrainer Compact S7-313C – 1 x control unit – 2 x I/O data cable – 1 x analogue cable Note: STEP 7 software and MPI cable must be ordered separately if required. Control kit S1-DP

On request

Control kit S1

On request

Control kit S2: Siemens SIPART DR19 controller – 1 x SIPART DR19 with serial interface integrated in ER frame – 1 x PDM software for parameterisation and configuration of the DR19 controller – 1 x serial data cable – 1 x I/O data cable – 1 x analogue cable Control kit S2

On request

Control kit F2

On request

Control kit F3: Festo CPX/FEC® with FED – 1 x Festo CPX/FEC® – 1 x Ethernet cable, crossover – 1 x FED-120 touchpanel – 1 x I/O data cable – 1 x analogue cable Note: FST software and programming cable must be ordered separately if required. Control kit F3

On request

Control kit PC2

On request

I/O simulation box, digital/analogue – 1 x simulation box incl. mains cable – 1 x I/O data cable, crossover – 1 x analogue cable, crossover

I/O simulation box

Accessories for the Compact Workstation – Trolley – Tabletop power supply or power supply unit for the mounting frame – Control kit Recommended training media – Fluid Lab®-PA, including EasyPort, digital/analogue – Web-based training program, Fundamentals of open and closedloop control

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 special topics such as: – Water treatment – Cooling and refrigeration technology – pH value measurement – Conductivity measurement – Pneumatics in process engineering, for example slide valve actuators with positioners, specifically for the paper industry.

MPS® PA, combined with MPS® stations

It is only logical that the MPS® PA (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 automation. The well thought-out modular design with clear-cut interfaces protects 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 modular concept factory for all hybrid production tasks

The learning system for all processes associated with production automation and process automation. – Production – Handling of seals – Packaging – Filling – Transportation and routing – Storage – Input/output The ideal solution for hybrid production process requirements in the food sector. The platform connects stations and elements from the MPS® Modular Production System with stations from the MPS® PA learning system and the Compact Workstation. The system is therefore completely modular and new processes and training content can be added gradually. Project work with hands-on training can take place at individual stations, on partially integrated production lines and in a fully integrated learning factory.

Customer-specific solutions

You have specific requirements? Numerous installations across the globe have given rise to a range of solutions with a particular focus on hybrid automation. An example of this is provided by Siemens AG Professional Education Berlin, whose mixing and filling station demonstrates how a continuous flow process is brought into line with a gradual container filling process. The students experience an operational process showing the entire sequence of an automated customer order processing system. Detailed information on this and other projects can be found on the website: www.festo-didactic.com under Services ➔ References.

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

27

Rechbergstraße 3 73770 Denkendorf/Germany Tel. ++49 (0)711/3467-0 Fax ++49 (0)711/34754-88500 www.festo-didactic.com [email protected]

56943 en

Festo Didactic GmbH & Co. KG