Process Automation and Closed-Loop Control Technology Process Automation and Closed-Loop Control Technology

Process automation and closed-loop control technology Process automation and closed-loop control technology

Media...... 4

MPS® PA – The Modular Production System...... 10

System description...... 11 MPS® EduKit PA/Project kits...... 16 MPS® PA Compact Workstation...... 20 MPS® PA Stations and MPS® PA 200 Complete systems...... 24 Accessories and optional components...... 38

Hybrid training factories...... 40

Media Software Digital training programmes/WBTs

Actuators – DC motor Open- and closed-loop control

Using the everyday example of a From the contents: The training program uses practical From the contents: car park access control system, the – The function of actuators in me- examples to show the difference be- – Differences between open- and trainee learns the basics of a me- chatronic systems tween open- and closed-loop control closed-loop control (characteris- chatronic system. – Electric motors in automation. Easy-to-understand tics of controllers, characteristics – DC motor tasks are used first to examine the of regulators Building on this, the training pro- – Torque and current overall process of a simple function- – DIN 19226 gram determines what function the – Behaviour of DC motors ing system. Later sections then look – Signal types actuators have in the controller. A DC – Induced voltage and speed control at different types of controllers, the – Differences between types of con- motor is then studied in more detail – Characteristic torque/speed curve different ways in which signals are trol as an example of a typical actuator, – Working with data sheets represented and processed and the – Signal processing (synchronous e.g. its structure and the laws which – Determining the transmission ratio ways in which programs are imple- control, controlling links, asynchro- govern its operation. Further chap- mented. nous control, process control) ters cover speed control and the use Training time: approx. 2 hours – Types of control (regulating to of data sheets as well as the trans- fixed values, tracking values) mission ratios which can be achieved E.g. single licence on CD-ROM – Regulators (P, I and D controllers, by using a gearbox. with online activation DE/EN/ES/FR combined controllers such as PI or Order no. 540953 PID controllers) with network licence connector DE/EN/ ES/FR Training time: approx. 2 hours Order no. 540955 E.g. single licence on CD-ROM with online activation DE/EN/ES/FR Order no. 540947 with network licence connector DE/EN/ ES/FR Order no. 540949

All training programs on CD-ROM or as a WBT version, also for installation on networks and learning management systems – with as many licences as you need. Media Software Digital training programmes/WBTs

Process automation The fascination of technology New!

Basic principles of process – Handling substances This exciting journey through the his- Fundamentals of automation automation Product manufacturing is, for the tory of technology shows how in- technology The training programme deals with most part, subject to defined phys- ventions have changed the world. This training module goes more the broad spectrum of technical ical and chemical characteristics. New forms of work have been creat- deeply into practical examples. A process automation in a concise Students‘ awareness should be ed: from the hunter to the engineer. manufacturing process previously way. The characteristics and special heightened so that they can assess „The fascination of technology“ is an carried out manually is automated: features of process automation are production conditions and are able interactive journey through the world you learn about the parts (sensors, conveyed in a simple manner via im- to deal with them correctly. of automation. The program contains actuators) and processes (material ages from actual real-life situations, – System planning many different multimedia compo- flow, energy flow, signal flow) in- graphic representations of physical- This guides students through a nents to help you on your journey. volved in an automated process. technical processes and animated planning office, providing an in- Experience the excitement of dis- processes which you yourself can sight into the planning and devel- covery and learning – this is pure Technology and ... manage and control. opment of a system. Students can edutainment! The programme con- Technology and society have always examine all the fundamental activi- sists of 4 modules: been closely interwoven. This train- Content topics: ties of the planning phase, from ing module uses easy-to-understand The three chapters „Handling sub- the basic principles of project man- Technology and automation examples to show how technology stances“, „System planning“ and agement to drawing a circuit dia- Every day we come across technolo- and society influence each other. The „Practical processes for process en- gram, until the system can finally gy and automated processes. This in- module also covers the limitations of gineering“, guide you step-by-step be built. troduction illustrates, with practical technology – and possible negative to a complete on-screen system. The – Practical processes for process examples, just how much life is af- impacts on society. content of these chapters is reflected engineering fected by technology, in earlier times in the MPS® PA stations, which you The vast number of engineering too but particularly today. Training time: approx. 6 hours will use during the practical part of processes can be reduced to four the training. typical ones: filtration, tempering, The history of automation E.g. single licence on CD-ROM mixing and filling. Design and func- technology with online activation DE/EN/ES/FR tion are analysed using the four Mankind has always tried to make Order no. 540899 MPS® PA stations and the modu- work easier through mechanisation with network licence connector DE/EN/ lar product systems from Festo Di- and automation. Fascinating exam- ES/FR dactic and any questions that arise ples show how hard this develop- Order no. 540901 while learning about process engi- ment has sometimes been and how Further languages on request. neering are answered. impressive the results can be.

Training time: about 4 hours

E.g. single licence on CD-ROM with online activation DE/EN/ES/FR Order no. 567705 with network licence connector DE/EN/ ES/FR Order no. 567706

www.festo-didactic.com Media Software Interface EasyPort

EasyPort USB – An interface for measuring, open-loop control, closed-loop control. New!

Connection of software/simulation Technical data with actual training equipment/all – 24 V power supply via separate PLCs screw terminals or via SysLink connectors The principle is simple: the USB in- – Interface to PC (galvanically iso terface is connected to the PC. The lated): USB 2.0, RS 232. Up to connection to the automation equip- 4 modules can be connected via ment is via standard SysLink connec- a USB hub. Transmission speed: tors. Input and output signals can 115 kbaud thus be read into and output from a – Analogue interface: sub-D 15-pin PC. So that EasyPort can adapt to dif- socket, 12 bit resolution, 4 ana- ferent situations, we have developed logue inputs, 2 analogue outputs, software for the device drivers with sample frequency 0.5 kHz a graphical user interface, via which – Digital interface: 16 digital inputs, connections can be made. 16 digital outputs on 2 x 24-pin Centronics sockets with 8 digital in- Control of numerous practical puts each (24 V), 8 digital outputs process model (24 V). 24 V power supply. Digital signals represented by LEDs Numerous practical process models – Large LCD display, display of chan- can be controlled using any PLC us- nel, unit, trend and measured val- ing EasyPort and the EasyVeep® sim- ue (4 digits). Selection of the chan- ulation software included in scope nel to be displayed and the units of delivery. The models are docu- via keys. mented and meet a broad range of – Controllable via Activ-X control requirements. from Labview, C++ or Visual Basic

The topics covered include the following: – Level crossings – Multi-storey car parks – Sorting systems – Sluice chambers – Lifts – Washing machines – 7-segment display – Garage doors

EasyPort USB 548687

Also order: For EasyPort with a real process or SimuBox: I/O data cable with IEEE 488 SysLink connectors at both ends 4031 Analogue cable, parallel 529141 For EasyPort with a real PLC: I/O data cable with IEEE 488 SysLink connectors at both ends 167106 For EasyPort, freely wirable, with any PLC: I/O data cable with one IEEE 488 SysLink connector and open cable end sleeves 167122 For EasyPort with a PLC board: I/O data crossover cable, with terminal socket 167197 For EasyPort with a real PLC or SimuBox: Analogue crossover cable 533039

PLC starter kit 543081 Universal connection unit, digital (SysLink) 162231 EasyPort adapter for slotted profile plate 549806

www.festo-didactic.com Media Software Interface EasyPort

Connects the simulation to the real world

Example applications Measuring Control (open loop) Closed-loop control Controlling a simulation

PC: – Fluid Lab®-PA – FluidSIM® (only digital) – Fluid Lab®-PA – EasyVeep® Software and simulations – Fluid Lab®-P – S7-PLCSIM – Fluid Lab®-P – FluidSIM® – Fluid Lab®-H – CoDeSys Soft-SPS from version 2.0 – CIROS® – Labview – Labview – Labview – Labview – C++ – C++ – C++ – C++ – Visual Basic – Visual Basic – Visual Basic – Visual Basic

Interface: USB Interface: USB Interface: USB Interface: USB

Interface: EasyPort USB

Interface: digital/analogue Interface: digital/analogue Interface: digital/analogue Interface: digital

Real training equipment – Simulation box, – Simulation box, – Simulation box, – Any PLC digital/analogue digital/analogue digital/analogue – Simulation box, – MPS® PA – MPS® PA – MPS® PA digital – TP 210 – MPS® – TP 210 – EduTrainer® – TP 610 – TP 301 – TP 610 – PLC Board

EasyPort USB is the PC in- EasyPort USB is the PC in- EasyPort USB is the PC in- Recommendation: terface for receiving ana- terface to control actual terface to control an actu- the PLC starter kit contains logue measurements and processes or simulations al closed-loop controlled everything that is needed digital signals. on a PC via an actual PLC. system. to start on the subject of control. See Training pack- Measurement data logged Actual process, controlled Closed-loop controlled ages Electronics/PLCs. via: via: system, controlled via: – Fluid Lab®-PA – S7-PLCSIM – Fluid Lab®-PA Simulated process, – Fluid Lab®-P – FluidSIM® – Fluid Lab®-P displayed via: – Fluid Lab®-H – CoDeSys from version 2.0 – CIROS® – FluidSIM® – EasyVeep®

Scope of delivery – EasyPort USB – 24 V connecting cable on 4 mm safety plugs – USB cable – CD-ROM: EasyVeep®, EasyOPC driver, datasheet, Activ-X control, examples of control using Labview

www.festo-didactic.com Media Software Fluid Lab®-PA

Fluid Lab®-PA

Fluid Lab®-PA can be used to teach Actual process or simulation „Measuring and Control“ „Analysis“ menu item and demonstrate the fundamentals All exercises and experiments can menu item Analyses of a wide range of process of control technology. The main be performed online on the actual All the functions of the MPS® PA components can be directly per- components required for actuating process in conjunction with the station can be clearly and directly formed using predefined exercises, the MPS® PA stations using a PC are station or offline using the pre- controlled. The states of the proc- for example: the EasyPort and the Fluid Lab®-PA integrated simulation. ess valves, pumps and sensors are – Recording of sensor characteristics software. graphically recorded, which means – Recording of pump characteristics „Settings“ menu item they can be directly evaluated. The – Recording of heating character- Fluid Lab®-PA can be easily installed The following parameters can be following functions are provided for istics on any Microsoft Windows operating set here for the four analogue input recording the sensor characteristics system. channels and the sensors connected and determining the step response: This permits a fast and thorough to them: – Selection of measuring channels understanding of the typical process Key features – Factor – Factor for physical scale components. Three main functions are integrated – Offset – Adaptation of the time scale in Fluid Lab®-PA in combination with – Filter – Display of the input signals „2-Point Controller“ and the EasyPort: – Inversion – Setting of output signals, switching „Continuous Controller“ menu item on/off of the manipulated variable For easy parameterisation of M as in measurement The analogue and binary output – Printing of the measured value dis- the required controller with an For detection and evaluation of signals can also be switched and the play or saving as a .jpg file immediate effect on the process. measured variables from 8 digital/ signal states of the inputs read off. One click of the mouse starts various 4 analogue input signals. General PC system settings can also controller functions for the selected be made here. control system. Documentation of C as in open-loop control the controller parameters is also For binary or continuous control of „Process Sequence“ menu item straightforward. The measured 8 digital/2 analogue outputs. The process sequence of each values and characteristic curve station can be easily started from profiles can be easily printed out. R as in closed-loop (regulated) Fluid Lab®-PA. All of the process control steps are visualised and can be DE/EN/ES/FR 544304 For freely selectable closed-loop monitored on the flow chart. control functions such as 2-point, P, I, PI and PID.

www.festo-didactic.com Media Courseware Mechatronics/Handling technology/Process automation

Mechatronics/Handling technology/Process automation

® ® Kommunikations- MPS MPS PA Arbeitsbuch EduKit PA orientiertes Prozessoptimierung Arbeitsbuch Projektbaukasten Handeln bei Prozessautomation Störungen in Ausbildungsunterlage Anlagen Mit CD-ROM

Leitfaden für die Ausbildung

Festo Didactic 543068 DE 539934 DE 548590 DE 563969 DE

Communication-oriented approach Training document MPS® PA workbook Workbook for EduKit PA to system malfunctions Process optimisation Workbook including solutions, for New! The importance of maintenance and With the basics of training in process automation. Workbook with solutions for training servicing, in particular with respect – Analysis of existing systems in closed-loop control/process tech- to malfunction management, cannot – Project plan This workbook includes tables that nology with EduKit PA. be underestimated in production. – Planning and optimisation of allocate training aims with exercis- automated systems es and components with exercises, This workbook explains the basic The purpose of this textbook is to – Value creation and wastage together with the fundamentals of principles of process technology and teach students how to reduce down- – KANBAN closed-loop control technology, exer- provides an introduction to the sub- times. Identifying failure modes, di- – SMED cises with all necessary worksheets ject. It covers manual and automated agnosing malfunctions and fixing – TPM and didactic instructions about an- measurement, open and closed-loop faults requires both specialist knowl- – Poka-Yoke alysing and inspecting a system, control and system design topics edge and interpersonal communica- – FMEA measuring, open and closed-loop such as planning, installation, com- tion skills. This practical textbook ad- control, as well as the solutions for missioning, marketing and sales. You dresses the situation using the case The detailed project task, with seven the instructors. The workbook pro- will be provided with exercises in- example of a medium-sized drinks subsidiary tasks based on the ex- vides detailed descriptions of the cluding all necessary worksheets as bottling company: training scenarios ample of the MPS Distribution, In- problem definition and parameters. well as didactic information and so- portray realistic situations, that pro- spection, Processing, Handling and The worksheets support the stu- lutions as support for trainers. The vide instruction in a range of faults Sorting stations, enables practical dents through the required steps workbook contains detailed descrip- from the simple to the cross-linked. optimisation of a production proc- of planning, execution and function tions of the problems and parame- ess, with material flow analysis, de- testing. ters. The worksheets guide students Includes a CD-ROM with presenta- vising and appraising suggestions through the required steps of plan- tions on the topic of communica- for improvement, procurement and The exercises refer to the filtering, ning, execution and function testing. tion and troubleshooting, circuit di- production of components, program- mixing, temperature maintenance agrams and function charts for the ming and commissioning the opti- and bottling processes. The train- The measurement/open and closed- MPS® distributing and sorting sta- mised system. ees acquire the ability to inspect sys- loop control exercises relate to flow, tions plus the textbook. tems, to describe components and level and pressure technology. Includes a CD-ROM with circuit dia- functions as well as the operation of Walter E. Theuerkauf, Sarah Funke, grams, symbols and sample pro- systems. The workbook includes a CD-ROM Gabriele Graube grams for the Siemens PLC S7-300. with the worksheets, data sheets Edition 2006, 144 pages, in binder incl. The workbook includes a CD-ROM and solutions. CD-ROM M. Bellenberg, T. Mehwald, H. Regber, with the worksheets and the solu- DE 543068 G. Schmidt tions. J. Helmich, H. Kaufmann Edition 2006, 310 pages, in binder incl. Edition 2009, workbook 270 pages, with CD-ROM J. Helmich, H. Kaufmann CD-ROM, in folder, solutions 160 pages, DE 539934 Edition 2007, workbook 270 pages, with bound CD-ROM, in folder, solutions 160 pages, DE 563969 bound EN 563971 DE 548590 ES 563973 EN 548591 FR 563975 ES 548592 FR 548593

Order online at: www.festo-didactic.com MPS® PA – The Modular Production System

With MPS® PA, you determine the degree of complexity: – Task-based projects with the EduKit PA project kit – Complex problem definitions with MPS® PA stations or the MPS® PA Compact Workstation – Multi-layered projects with the PA 204 complete MPS® system or the hybrid AFB training factory

10 Process automation and closed-loop control technology MPS® PA System description

Filtering, mixing, tempering Train efficiently and bottling as in industry

Modular Training for many areas of Festo – The partner to the Why stop production to application and careers process industry facilitate training? The modularity of the learning system enables you to realise a – Electronic engineers Festo is fast becoming a key partner It is prohibitively expensive to diverse range of configurations – Mechatronics engineers to the process industry. It is only shut down an industrial system to for typical production processes – Systems engineers logical that the process automation facilitate training. Comprehensive from very different industries in a – Microtechnologists learning system benefits from training in the individual areas safe learning environment. – Process technicians for plastic this know-how and is tailored of process automation requires and rubber technology, glass to the requirements of different industry-oriented model systems or and coating technology industries through its consistent training installations. „Learning by – Experts in food, confectionery modularisation: doing“ and „process orientation“ and fruit juice technology – Water supply and disposal industry are two principles that are central to – Experts in water supply, sewage – Food industry the successful imparting of the many technology, pipe, canal and – Bulk goods industry detailed training aims in process industrial services – Chemical and petrochemical technology. Simulation of a process – Chemical engineers industries engineering system on a PC provides – Pharmaceutical engineers – Biotechnology/pharmaceutical the opportunity of using a simulation – Biotechnicians industries as an actual training system. – Paper technicians – Paper industry – Systems engineers for sanitary, heating and air conditioning technology

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 11 Process automation and closed-loop control technology MPS® PA System description

From the kit to the training factory Application and process-oriented learning systems

Industry-oriented basic and further training

As practical training on actual production and industrial systems is seldom possible, project kits, stations, systems and training factories from Festo Didactic prepare trainees for the demands of their profession in the best possible way.

12 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Process automation and closed-loop control technology MPS® PA System description

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 solutions and trends.

SimuBox – 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 Same as PLC, plus: controller – 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 13 Process automation and closed-loop control technology MPS® PA System description

Understanding process automation – Through seminars and workshops

Valves and fittings – Specific customer training, e.g. Process control valves the basic principles of control This course provides detailed in- engineering sights into valve and fitting techno- Customised training for employees logy and shows how they are used from the areas of maintenance, in the process industry. Participants service and operational support. gain basic knowledge of the indivi- With the professional training dual valve and fitting types and equipment from Festo Didactic, the components. In addition, selecting following course topics are covered materials and operating conditions/ by the training systems on the basis limitations are described in detail. of „learning by doing“: The various types of actuators are – Cross section of all controller types also explained with regard to the (P, I, D, PI, PD, PID) individual fitting and valve types and – Control technologies all relevant standards are discussed. (Fluid Lab®-PA, industrial controllers and modern PLCs) Basic principles and mode of operation of industrial measuring Do you need anything else? technology and instrumentation Workshop with more complex tasks This course provides detailed for practical operational support and and sound insights into process maintenance. For example: engineering. The various measuring – Exchange and new use of sensors types, as well as the different and their integration in a controlled principles, such as pressure, system flow rate, temperature and filling – Troubleshooting with control level control are treated in detail. characteristic diagnostics Furthermore, control engineering is – Controlled system with reaction taught in-depth based on P, I and time (on request) PID controllers, along with their advantages and disadvantages.

Further training, with the objective We have high standards. In our cour- Closed-loop control circuits of supporting people in companies ses you will realise the difference Participants gain detailed and to deal with current as well as future between us and other providers: sound insights into process control problems and provide them with we provide new answers to old technology based on P, I and PID new answers – that is the purpose of questions – answers that help you controllers and their advantages and Festo Didactic. get that critical step ahead with your disadvantages. Practical exercises operational plans. with the PA EduKit and the Fluid Festo is developing itself to become Lab®-PA software ensure that the an important partner to the process Give us a call; we‘ll be happy to help. knowledge acquired is transferred industry. The close coordination with into practice. our parent company, Festo AG & Co. KG, ensures that state-of-the-art devices and systems are used in our learning systems. And our trainers have first-hand expert knowledge.

Our orientation and methods set us apart. Our trainers and consultants are practicians. They are familiar with the tasks of their participants, even those that go beyond technical requirements.

14 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA System description

Fluid Lab®-PA

www.festo-didactic.com 15 Project kits for task-based training

The significance of control technology is increasing constantly in all areas as energy and resources can be saved using this technology. To achieve efficient production, individual steps must be planned, sequences understood and double- checked.

With the EduKit PA project kit, the introduction to process and control technology is easy and safe.

16 Process automation and closed-loop control technology MPS® PA MPS® EduKit PA/Project kits

EduKit PA The new project kits for process and control technology New!

The inexpensive introduction to process and control technology

The project kits are modular, can be expanded flexibly and are therefore ideally suited for exciting and practical lessons in technology. Links can be made with industrial project work, filling level control, flow rate control and pressure control.

The didactic concept of EduKit PA both supports experimental learning as well as a structured procedure, thanks to extensive optional training materials with project exercises and a lot of additional documentation on CD ROM. EduKit PA is therefore the inexpensive way to become familiar with process and control technology, both in vocation-oriented lessons as well as for use at colleges and universities.

www.festo-didactic.com 17 Process automation and closed-loop control technology MPS® PA MPS® EduKit PA/Project kits

EduKit PA Unpack and away you go New!

EduKit PA Basic

Teaches the basic principles of Learning content for project work Presentation and documentation: The EduKit PA Basic and EduKit PA project work and the fundamen- – Creating assembly instructions Advanced modular product systems tals of closed-loop control – manual Planning a project: – Documenting measured values are each supplied in a Systainer. measurement, open and closed-loop – Allocating tasks in teams – Graphical analysis control – without a PC and without – Creating a project plan with – Presenting project process sophisticated control technology. different steps

The benefits to you Construction, assembly, connection: V101 – Handy, easy to transport and sim- – Creating sketches for the pipe B102 ple to set up connection system V103 V102 – Step by step construction of a func- – Producing an assembly diagram tional system: start with a small – Mechanical assembly

setup – a tank – and finish the – Electrical connection of pump to FI 101 project with a level control system 24 V supply PI B101 – Training documents available – Checking activities 103 – Easy to use and expandable for use – Creating test logs P101 with other topic areas V105 – Water acts as a non-hazardous Commissioning and measured data M teaching medium ideally suited for acquisition: closed-loop control – System start-up As well as electrical pneumatic dia- – Consistent with existing Festo – Recording measured values with grams, you will also learn how to un- Didactic systems changed valve position, changed derstand and describe a PI diagram. voltage on the pump or different fill heights – Observation of level, pressure and flow, as well as time response

18 24-month Festo Didactic warranty Process automation and closed-loop control technology MPS® PA MPS® EduKit PA/Project kits

EduKit PA Basic in the Systainer 549822 Recommended learning media

The most important components at a glance: Workbook with project tasks and Arbeitsbuch EduKit PA Projektbaukasten Prozessautomation

1x Pump 170712 solutions for EduKit PA Basic and Mit CD-ROM 2x Tank, round On request Advanced on: 1x Flow meter 548604 – Technological issues – Mathematics Accessories, also order: – Open-loop control Tabletop power supply unit ➔ Internet – Closed-loop control Tubing cutter 7658 – Work scheduling

Festo Didactic Includes CD-ROM containing: 563969 DE – Parts lists and data sheets – RI flowcharts and circuit diagrams DE 563969 – Assembly instructions for mechani- EN 563971 cal construction ES 563973 – Checklists for commissioning FR 563975 – Acceptance logs – Worksheets for recording characteristic curves – Process automation WBT

EduKit PA Advanced

Supplements the EduKit PA Basic modular product system with the topics of 1 2 3 automated measurement, open and closed-loop control, sensors and electrical interfaces. The EduKit PA Basic is required when using the components of the EduKit PA Advanced.

EduKit PA Advanced in the Systainer 564631

The most important components at a glance: 4 5 6 1 1x I/O board for EduKit PA 549823 2 2x Sensor, capacitive 549824 3 1x Sensor, ultrasound 548689 4 1x Flow sensor for EduKit PA incl. transducer 549825 5 1x Pressure sensor 0 – 400 mbar 549826 6 1x 2/2-way solenoid valve 549827

Recommended accessories for control EasyPort USB 548687 Fluid Lab-PA DE/EN/ES/FR 544304 I/O data cable with SysLink connectors (IEEE 488) at both ends, 2.5 m 34031 Analogue cable, parallel, 2 m 529141 The open interface provides various actuation options, e.g. controllers from Siemens, Festo, Allen Bradley and Mitsubishi.

Extension options: – Two-way ball valve for EduKit PA with quarter-turn actuator DAPS, double acting (order no. 549828) – Float switch sensor, top (order no. 548597)

Additional components ➔ Internet

www.festo-didactic.com 19 Compact Workstation

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.

20 Process automation and closed-loop control technology MPS® PA MPS® PA Compact Workstation

Compact Workstation Level, flow rate, pressure and temperature closed-loop control systems

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 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 distur- bance in the level control system or as an on-off valve for emergency switch-off.

www.festo-didactic.com 21 Process automation and closed-loop control technology MPS® PA MPS® PA Compact Workstation

Compact Workstation Level, flow rate, pressure and temperature closed-loop control systems

Piping and instrument flow chart (1) Scope of delivery of the Compact An important part of project work Workstation in process engineering is develop- Basic version including manual with- ing a piping and instrument flow out actuation components chart. A piping and instrument flow chart explains the electrical, meas- Mechanical components, fully uring and control technology func- assembled tions using measuring points and – 2 containers final control elements. The measure- – Reservoir ment variable or another input vari- – Plug-in piping system able, its processing, its direction of – Aluminium profile benches action and directional specifications – Mounting frame 1 and positions should follow from – Profile plate 700 x 700 x 32 mm the chart. Sensors Mounting frame (2) – 2 capacitive sensors Can be equipped with accessories – 2 float switches for controllers, control unit and/or – 1 process drive signal box touchpanel. The activation and/or – Ultrasound sensor control devices can be replaced in – Flow sensor just seconds. – Pressure sensor – PT100 temperature sensor Pneumatic drive (3) With ball valve and signal box. Train- Actuation components ing aims: Design and application ar- – Pump 2 eas of various metering and shut-off – Proportional directional control devices when controlling the flow of valve liquids. – Ball valve with pneumatic drive – Heater Intelligent in the field – closed- loop control with the CPX/FEC Electrical components valve terminal and the FED 120 – I/O connection board with measur- touchpanel (4) ing transducer The Festo Front End Controller with – Motor controller with relay integrated web server and Ethernet – I/O terminal, SysLink, 8 I/8 O interface is ideally suited to current – Analogue terminal, SysLink,15-pin communication tasks. Compact Workstation On request 3 Commissioning and training on-site upon request.

Accessories – Trolley – Power supply unit for the mounting frame – Control kit

Recommended training media: – Fluid Lab®-PA including EasyPort – Web-based training program, Fun- 4 damentals of open and closed-loop control

22 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Compact Workstation

Control variants of the Compact Workstation

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/314C-2DP – 1 x Festo CPX-FEC® EasyPort – 1 x EduTrainer Compact S7- – 1 x control unit – 1 x Fluid Lab®-PA, individual licence 313C/314C-2DP – 1 x Ethernet cable, crossover – 1 x EasyPort – 1 x control unit – 2 x I/O data cable – 1 x RS232 data cable – 2 x I/O data cable – 1 x analogue cable – 1 x mains cable – 1 x analogue cable – 1 x I/O data cable Note: – 1 x analogue cable Note: FST software and programming STEP 7 software and MPI cable must cable must be ordered separately if be ordered separately if required. required.

Control kit S2: Control kit F3: I/O simulation box, digital/ Siemens SIPART DR19 controller Festo CPX-FEC® with FED analogue – 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 – 1 x I/O data cable Note: – 1 x analogue cable FST software and programming cable must be ordered separately if required.

Control Kit S1: EduTrainer Compact S7-313C On request Control Kit PC2: Fluid Lab-PA + EasyPort On request Control Kit S1-DP: EduTrainer Compact S7-314C-2DP On request I/O simulation box, digital/analogue On request Control Kit S2: Siemens controller SIPART DR19 On request Control Kit F2: Festo CPX-FEC On request Control Kit F3: Festo CPX-FEC + FED On request

www.festo-didactic.com 23 MPS® PA Stations and Complete systems

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.

24 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

The new learning system for process automation

Practical training Slide, flap or ball valve Investment protection Boundless variety The exclusive use of industrial The correct valve in use. A well thought-out modular design It is only logical that the MPS® PA components underlines the with clear-cut interfaces facilitates stations can be combined with necessary practicality and ensures Sensors adaptation to future developments stations from the greater MPS® a speedy transfer of knowledge Typical process engineering sensors in components as well as open-loop family. After all, it is this possibility from a training scenario to practical assume control of temperature, and closed-loop control systems. of combination with MPS® stations application. level, flow rate and pressure in the This means that the system can be that makes the MPS® PA an MPS® PA. adapted to new requirements. interesting proposition for basic and further training in many industries which are dominated by process automation but still require elements from production automation.

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 25 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Either: Or: Simply build it yourself MPS® PA commissioning service

Every MPS® PA station comes Simply commission it ... and you‘re To ensure that your training projects And if you wish ... completely assembled and tested ready to go! run smoothly right from the start, on the profile plate with MPS® PA we offer: 3. Useful tips on how to get the trolley, touch panel and 24 V power On request, we can also commission most from the MPS® PA: pack. systems for you – particularly in the 1. Complete technical – Applications case of larger systems. commissioning of your new system: – Enhancements A controller board with analogue – Seminars inputs and outputs is required The range of applications of the additionally. system and the station programs Are you planning a commissioning and documentation are presented. and training session? For efficient operation in the lesson, Depending on the equipment, We recommend: we also recommend: commisioning is performed for the Per Station: 1.5 days – EasyPort following products: – Fluid Lab®-PA – Station Order no. 555647 – PID industrial controller – PID industrial controller – Workbook with tasks and solutions – EasyPort and Fluid Lab®-PA

2. Training: You will learn how to operate stations and how to use them in your lesson. Depending on the equipment, training is provided on the following products: – Station – PID industrial controller – Soft PID in the PLC – EasyPort and Fluid Lab®-PA

The commissioning and training can thus be adapted to suit your needs.

26 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

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

The MPS® 204 Complete system section shows a fully configured system.

MPS® PA stations can be combined as follows:

Stations Possible direct downstream station

Filtration Mixing Reactor Bottling

Filtration + + + Mixing + + + Reactor + + +

24-month Festo Didactic warranty 27 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

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 valve. The filtered liquid reaches the second tank via the flap 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 output always supplies the correct measurement 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.

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 valve with COPAC linear actuator.

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.

28 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Filtration station 544253 Training aims for project work Recommended training media (with trolley, colour touch panel, mounting frame and power supply unit) – Set-up, wiring and commissioning of a system for process technology Also order: – Selection, application and Open-loop and closed-loop control with PLC: actuation of process valves PLC board with SIMATIC S7-313C 533526 – Measurement of electrical and SIMATIC S7 connecting cable set 544296 process-related variables such as PLC board with CPX-FEC 541187 level and pressure Festo CPX connecting cable set 544297 – Set-up and commissioning of PLC board with Allen Bradley MicroLogix 1500 544300 control circuits Allen Bradley MicroLogix connecting cable set 544298 – Analysis of control processes and PLC board with Mitsubishi MELSEC 544301 control circuits Mitsubishi MELSEC connecting cable set 544299 – Parameterisation and optimisation – Fluid Lab®-PA Or alternative: of P, PI or PID controllers – WBT Fundamentals of open and SIMATIC S7 EduTrainer Compact 313C 533018 – Drafting of open-loop and closed- closed-loop control SIMATIC S7 connecting cable set 544296 loop control programs – Design and simulation program For working with Fluid Lab®-PA: – Process operation and monitoring FluidSIM® Pneumatics Fluid Lab-PA DE/EN/ES/FR 544304 – Inspection, maintenance and EasyPort USB 548687 servicing Also order: PC data cable RS232 male-female 162305 Workbook MPS® PA RS232 USB adapter 540699 I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141

MPS® PA For simple commissioning, simulation and display using the simulation box: Arbeitsbuch Simulation box, digital/analogue 526863 I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141 For professional control using industrial controllers: PID industrial closed-loop controller 544293

Necessary accessories Replacement filter cartridge 544303

548590 DE Power cable for power supply unit ➔ Internet

DE 548590 EN 548591 ES 548582 FR 548593

www.festo-didactic.com 29 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

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 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 variable-area 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 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.

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.

Signal converters convert all analogue signals from the station to standard signals from 0 – 10 V.

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

30 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Mixing station 544254 Training aims for project work Recommended training media (with trolley, colour touch panel, mounting frame and power supply unit) – Construction, wiring and commissioning of a system for Also order: process technology Open-loop and closed-loop control with PLC: – Selection, application and PLC board with SIMATIC S7-313C 533526 connection of various flow sensors SIMATIC S7 connecting cable set 544296 – Measurement of electrical and PLC board with CPX-FEC 541187 process-related variables such as Festo CPX connecting cable set 544297 level and flow rate PLC board with Allen Bradley MicroLogix 1500 544300 – Design and commissioning of Allen Bradley MicroLogix connecting cable set 544298 control circuits PLC board with Mitsubishi MELSEC 544301 – Analysis of control processes and Mitsubishi MELSEC connecting cable set 544299 control circuits – Fluid Lab®-PA Or alternative: – Parameterisation and optimisation – Web-based training program, SIMATIC S7 EduTrainer Compact 313C 533018 of P, PI or PID controllers Fundamentals of open and closed- SIMATIC S7 connecting cable set 544296 – Drafting of open-loop and closed- loop control For working with Fluid Lab®-PA: loop control programs – Design and simulation program Fluid Lab-PA DE/EN/ES/FR 544304 – Process operation and monitoring FluidSIM® Pneumatics EasyPort USB 548687 – Inspection, maintenance and PC data cable RS232 male-female 162305 servicing Also order: RS232 USB adapter 540699 Workbook MPS® PA I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141 For simple commissioning, simulation and display using the simulation box:

MPS® PA Simulation box, digital/analogue 526863 Arbeitsbuch I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141 For professional control using industrial controllers: PID industrial closed-loop controller 544293

Necessary accessories Power cable for power supply unit ➔ Internet

548590 DE

DE 548590 EN 548591 ES 548582 FR 548593

www.festo-didactic.com 31 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Reactor station

Function The reactor station brings liquid to the right temperature. 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 acti- vating the recipes is achieved by means of temperature control. The temperature sensor (PT100 resistance thermometer) supplies a unit signal of 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.

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.

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.

32 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Reactor station 544255 Training aims for project work Recommended training media (with trolley, colour touch panel, mounting frame and power supply unit) – Construction, wiring and commissioning of a system for Also order: process technology Open-loop and closed-loop control with PLC: – Selection, application and PLC board with SIMATIC S7-313C 533526 connection of temperature sensors SIMATIC S7 connecting cable set 544296 – Measurement of electrical and PLC board with CPX-FEC 541187 process-related variables such as Festo CPX connecting cable set 544297 level and temperature PLC board with Allen Bradley MicroLogix 1500 544300 – Use and connection of measuring Allen Bradley MicroLogix connecting cable set 544298 transducers PLC board with Mitsubishi MELSEC 544301 – Design and commissioning of Mitsubishi MELSEC connecting cable set 544299 control circuits – Fluid Lab®-PA Or alternative: – Analysis of control processes and – Web-based training program open SIMATIC S7 EduTrainer Compact 313C 533018 control circuits and closed-loop control SIMATIC S7 connecting cable set 544296 – Parameterisation and optimisation For working with Fluid Lab®-PA: of P, PI or PID controllers Also order: Fluid Lab-PA DE/EN/ES/FR 544304 – Drafting of open-loop and closed- Workbook MPS® PA EasyPort USB 548687 loop control programs PC data cable RS232 male-female 162305 – Process operation and monitoring RS232 USB adapter 540699 – Inspection, maintenance and

MPS® PA I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 servicing Arbeitsbuch Analogue cable, parallel 529141 For simple commissioning, simulation and display using the simulation box: Simulation box, digital/analogue 526863 I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141 For professional control using industrial controllers: PID industrial closed-loop controller 544293

548590 DE Necessary accessories Power cable for power supply unit ➔ Internet DE 548590 EN 548591 ES 548582 FR 548593

www.festo-didactic.com 33 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Bottling station

Function The bottling station fills bottles with liquid. The liquid is pumped into the dosing tank from the reservoir. 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.

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

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, proportioning and filling play an important role here.

Optical sensors, adjustable using background suppression, monitor transportation on the conveyors of the 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.

34 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

Bottling station 544256 Training aims for project work Recommended training media (with trolley, colour touch panel, mounting frame and power supply unit) – Construction, wiring and commissioning of a system for Also order: process technology Open-loop and closed-loop control with PLC: – Selection and application of filling PLC board with SIMATIC S7-313C 533526 level sensors SIMATIC S7 connecting cable set 544296 – Measurement of electrical and PLC board with CPX-FEC 541187 process-related variables such as Festo CPX connecting cable set 544297 level PLC board with Allen Bradley MicroLogix 1500 544300 – Design and commissioning of Allen Bradley MicroLogix connecting cable set 544298 control circuits PLC board with Mitsubishi MELSEC 544301 – Analysis of control processes and Mitsubishi MELSEC connecting cable set 544299 control circuits – Fluid Lab®-PA Or alternative: – Parameterisation and optimisation – Design and simulation program SIMATIC S7 EduTrainer Compact 313C 533018 of P, PI or PID controllers FluidSIM® Pneumatics SIMATIC S7 connecting cable set 544296 – Drafting of open-loop and closed- – Web-based training program, For working with Fluid Lab®-PA: loop control programs Fundamentals of open and closed- Fluid Lab-PA DE/EN/ES/FR 544304 – Process operation and monitoring loop control EasyPort USB 548687 – Inspection, maintenance and PC data cable RS232 male-female 162305 servicing Also order: RS232 USB adapter 540699 Workbook MPS® PA I/O data cable with SysLink connectors (IEEE 488) at both ends 4031 Analogue cable, parallel 529141 For simple commissioning, simulation and display using the simulation box:

Necessary accessories Bottle set 544302 Power cable for power supply unit ➔ Internet

548590 DE

DE 548590 EN 548591 ES 548582 FR 548593

www.festo-didactic.com 35 Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

MPS® PA 204 Complete system

With a P, PI or PID control algorithm, At a constant flow rate, the three The pressure regulation ensures In the Filling station the level of the (closed-loop) control technology input materials are mixed into a a constant high filtering quality dosing tank is recorded with an is taught in a demonstrative and recipe on the Mixing station. The by means of back-flushing. The analogue level sensor. By way of the practical manner. The temperature flow rate is recorded by an electronic pressure sensor features an LCD continuously controllable pump the sensor – for the Reactor station a flow sensor with an impeller, and is display, analogue output and controller regulates the level to the PT100 resistance thermometer is additionally displayed with a float- switching output, always delivering appropriate nominal value. During used – delivers a uniform signal of 0 type flow meter. The controller sets the correct value. A constant high filling, the level in the dosing tank – 10 V via the measuring transducer. the required flow rate by way of the quality is maintained by means of is kept constant, thereby optimising By way of the continuously con- analogue controlled pump. the proportional-pressure regulator. the filling quality. trollable heater the controller sets the nominal temperatures and keeps them constant.

36 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Process automation and closed-loop control technology MPS® PA MPS® PA Stations and MPS® PA 200 Complete systems

MPS PA 204 SIMATIC S7-300 544248 Included in the scope of delivery: MPS PA 204 Festo CPX-FEC 544249 Various facilities for measuring, MPS PA 204 Allen Bradley ML 1500 544250 controlling and regulating MPS PA 204 Mitsubishi MELSEC FX1N 544251 – Simplifies commissioning, PLC control packages include: simulation and display using SIMATIC S7-300 the simulation box – 4 x PLC board with SIMATIC S7-313C, 1 x programming cable – Multi-media measuring, con- – 1 x STEP 7 Professional for Training programming software trolling, regulating, operating, – 4 x SIMATIC S7 connecting cable set monitoring and commissioning Festo CPX-FEC® using Fluid Lab® PA. – 4 x Festo CPX-FEC® PLC board, 1 x programming cable – Start processes in the PLC or – 1 x FST programming software, 4 x Festo CPX connecting cable set monitor them with the touch panel Allen Bradley ML 1500 – The control task can be handled – 4 x Allen Bradley PLC board with Micro Logix 1500, 1 x programming cable by the PLC or by the industrial – 1 x RS-Logix 500 Starter programming software, 4 x Allen Bradley connecting cable set controller also provided for each Mitsubishi MELSEC station. The controller parameters – 4 x PLC board with FX1N, 1 x programming cable are then set on the touch panel or – 1 x GX IEC Developer FX Trainer Package programming software directly on the industrial controller. – 4 x Mitsubishi connecting cable set All process variables are displayed in a user-friendly way – including The MPS® PA 204 system contains everything you need for training: trend graphs – both on the touch Stations: Filtering, mixing, reactor, filling (with trolley), colour touch panel, mounting frame panel and on the industrial and power supply unit controller. Accessories: 4 x simulation box digital/analogue, 1 x bottle set Control technology: 1 x PLC control package, 1 x EMERGENCY-STOP board, 2 x EMERGENCY- The PA complete system MPS® STOP control panel, 4 x EasyPort, 4 x PID industrial controller provides everything needed for an Software: 4 x FluidLab® PA training software efficientstart in measurement and control technology.

Successful project work based on Function Special training aims Also order: modular construction The system consists of the Filtering, – Set-up, wiring and commissioning Workbook MPS® PA Mixing, Reactor and Filling stations. of a system for process technology Learning by doing – the MPS® PA The Filtering station filters a fluid. – Measurement of electrical and system offers accessible, hands-on The filtrate is pumped out of the process engineering variables such processtechnology. Some project

MPS® PA firsttank via different process valves as level, flow rate, pressure and Arbeitsbuch ideas can be implemented in a flash, through the filter into the second temperature and risk-free. tank. Thefiltered fluid is added to – Set-up and commissioning of the first tank in the Mixing station. control circuits The Mixingstation mixes different – Assessment of control response recipes from three storage tanks. – Networking of process engineering The finished mixtureis pumped to systems the Reactor station. The Reactor – Process operation and monitoring, station regulates the temperatureof system management the fluid. Different temperature – Selection, deployment and control 548590 DE profiles, with different mixing times, of process fittings arerun depending on the selected – Analysis of controlled systems and DE 548590 recipe. The Filling station bottles control circuits EN 548591 the fluid.The bottles are carried on – Parameter setting and optimisation ES 548592 conveyor belts to the filling position. of P, PI or PID controllers FR 548593 A pneumaticseparator marshals the – Writing open-loop and closed-loop bottles. The bottles are filled with control programs differentquantities from the dosing – Process operation and monitoring tank, depending on the selected – Inspection, maintenance and recipe. servicing

www.festo-didactic.com 37 Process automation and closed-loop control technology MPS® PA Accessories and optional components

Accessories and optional components

1 1 PID industrial closed-loop 2 PLC board with CPX-FEC® 3 Set of bottles controller PLC board with modular controller For the filling of fluids in MPS® PA The MPS® PA closed-loop controller and FST programming environment. Bottling station. The set comprises with P, PI or PID control algorithm 20 bottles with the diameter of 40 permits the control of dynamic – Power supply: 24 V DC mm, height of 22 mm and capacity processes in MPS® PA stations. – Digital inputs: 16 (24 V DC) of 50 ml. The controller is a universal multi- – Digital outputs: 16 (24 V DC, Order no. 544302 channel process and program maximum 500 mA) controller with a registration function – Analogue inputs: 2 (12 Bit, 4 PA workpiece set for monitoring signal curves. The 0 – 10 V, 0/4 – 20 mA) To fill liquids into the MPS® PA setpoint specification is transferred – Analogue outputs: 2 (12 Bit, Bottling station. The workpieces 2 to the controller via a 15-pin Sub-D 0 – 10 V, 0/4 – 20 mA) are compatible with the MPS® interface. A further 15-pin Sub-D – SysLink interfaces: stations. For example, the pot interface senses the actual value 1x cable for connection to station, in the Pick&Place station can and an actuator is controlled 1x cable for connection to console, be sealed with the lid. The set using the manipulated variable. 1x lead for connection to comprises 6 x housing black, 6 x Parameterisation and configuration EMERGENCY-STOP housing red, 6 x housing silver, of the controller is possible using – Serial interfaces: 6 x housing transparent, 24 x lid the controller itself or using a setup 1x RS232 programming interface black. Dimensions: Height H = 25 program. – Ethernet interfaces: mm, Diameter, outside D = 40 mm, 1x TCP/IP, 10 Mbit/s Volume V = 15 ml. Consisting of: – Integrated web server Order no. 554301 – Device with dimensions 144 mm x Order no. 541187 130 mm for a DIN control panel cut- Operator unit out measuring 92 mm x 92 mm and RS232 programming cable Touch screen for the adjustable an installation depth of 170 mm The RS232 programming cable display of processes and data. – Installed in a 19“ control panel for the CPX-FEC® enables direct – Interface for RS232 and Profibus connection to a PC. Scope of delivery: DP, effected via a 9-pin Sub-D plug Order no. 151915 – Festo 5.6“ 256 colour FED-500 3 connection display – 4 mm safety sockets for the 24 V FST for FEC® – Programming software FED voltage supply FST for FEC® contains convenient Designer (multilingual) – CD-ROM with setup program and functions for programming, testing, – RS232 programming cable for programming cable for convenient commissioning and servicing of loading projects configuration using a PC automation projects. The reliable – Angled plate for mounting onto a – The device can be integrated in a programming languages statement slotted profile plate data network using the PROFIBUS list (STL) or ladder diagram (LDR) are Order no. 541146 DP interface available for programming. 4 – Modules can be retrofitted by the user Includes user and training manuals. – UL certification Software and training manual on CD- ROM (DE/EN). – System requirement for the setup program: System requirements – PC with Win95, 98, NT4.0, WIN – PC with Win 95/98/NT4.0/2000/XP 2000, WIN ME, WIN XP – CD-ROM drive – At least Pentium 100 DE 537927 – 32 MB RAM EN 537928 – 15 MB space on hard disk – CD-ROM drive Order no. 544293

38 www.festo-didactic.com Process automation and closed-loop control technology MPS® PA Accessories and optional components

Accessories and optional components

1 Profile plate 700/700 2 Trolley 3 Tool set 1 This board is twice as wide as the The trolley makes an MPS® station The tool set is an aid to easy working above-mentioned board; this allows a compact and mobile unit. The sta- on MPS® stations. two MPS® stations to be set up on tion is easy to mount on the trolley. one profile plate. Both sides have The PLC board can also be fitted. Ap- A practical mini-systainer includes: slots, so if necessary parts can be propriate through-holes in the side – 200 mm steel rule mounted on both sides. The slots panels enable orderly routing of ca- – Open-jawed spanners size 7, 8, are compatible with the ITEM profile bles. The front side is equipped with 9, 10 system. mountings for the control panel. The – Adjustable spanner trolley is supplied complete with – Side cutter The plate is supplied with caps for castors. – Insulation-stripping pliers 2 the sides. – Wire end sleeve pliers – Height: 32 mm – Height (incl. castors, to bottom – Screwdriver set, hex, 1.5 – 6 – Grid spacing (from slot to slot): edge of profile plate): 750 mm – Screwdriver, hex, 0.9; 1.3 50 mm – Width: 700 mm – Screwdriver, cross-head, – Width: 700 mm – Depth: 700 mm PZ02 – short – Length: 700 mm Order no. 541139 – Screwdriver, flat, 2.5 x 75; 4.0 x 100 We recommend the use of the appro- – Screwdriver, flat, 1.2 – 1.6 priate rubber feet for mounting on – Tubing cutter tables, order no. 158343. – Fibre-optic cable cutter Order no. 159410 – Workpiece, red, black, silver – 100 x cable binders 2.5 x 100 – 100 x wire end sleeves 0.25 3 – 100 x wire end sleeves 0.75 Order no. 539767

www.festo-didactic.com 39 Hybrid training factories AFB factory Training factories for hybrid production processes

AFB factory hybrid production

Megatrend: Hybrid automation Hybrid industries are the industries It’s a fact that production and which require systems and solutions process automation have be- for both process and production come inseparable in almost all engineering. The most striking ex- manufacturing environments. amples are the food, confectionery Hybrid automation represents the and tobacco industries and the convergence of production and pharmaceutical industry. process automation which is more than logical, given the trend towards Whether process and production convergence of the two automation oriented, or hybrid production, Festo techniques in the so-called hybrid Didactic training factories offer a industries. unique range of facilities for training in automation for all industries – from incoming goods, through process and production engineering departments, to outgoing goods.

40 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

The mix is the key Flexibility Mechatronics is also making its mark Making processes more flexible, outside production automation. systemising product quality, Intelligent drive solutions, featuring responding faster to new market high-precision mechanical com- trends – the drinks industry has ponents, a range ofdifferent drives, much more to do in this dayand measured data acquisition and age than merely quenching our evaluation as well as integrated thirst. On the one hand there is communications interfaces, ensure a need to establishand maintain safe, optimised process automation a broad product spectrum and too. introduce new products in order to generate new demand, while on the other, legislation is increasingly demanding greater transparency of manufacturing processes.

www.festo-didactic.com 41 Hybrid training factories AFB factory Training factories for hybrid production processes

Innovative technology and innovative learning

Innovative technology Pneumatic and electric drive technology from Festo is a by- word for innovationin industrial and process automation – from the single product through to the turnkey solution. With the AFB training factory we are for the first time delivering a learning environment which consciously incorporates trends and innovations from all areas of automation technology: – Electric and pneumatic linear drive units – Semi-rotary drives and grippers – Valves and valve terminals – Sensors – Vision and control systems

The AFB training factory is designed and equipped like a state-of- the-artindustrial plant, based on the automation know-how and engineering experience of Festo.

Innovative learning Only by engaging in innovative learning using innovative technology can trainees be optimally prepared for their future work. Comprehensive documentation, software tools for simulation and visualisation and a variety of WBTs complete the AFB range of facilities.

42 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

In focus: the production process for six-packs

Six-packs are produced in four zones of the hybrid training factory. The following processes are mapped: – Production of the liquid – Production and feed of the caps – Bottle feed – Transport – Packaging – Storage – Order compilation – Logistics

Zone 4 Transport and logistics

Zone 3 Zone 1 Production automation Process automation

Zone 2 Filling and packing

www.festo-didactic.com 43 Hybrid training factories AFB factory Training factories for hybrid production processes

The production zones

Zone 1 Specialist knowledge of pro- Zone 2 In the training factory, for example, Process automation gramming, such as recipe pre- Filling and packing the position and fill level of each paration, or of plant documentation, bottle and the state of completion Filtering, mixing, temperature such as reading and drafting R-I flow- Not only dosing, filling, capping and of each lot is recorded by various control; recording, evaluating and charts or EMSR location diagrams packing, but also the acquisition, optical sensors and a high-speed controlling typical process variables are key focus areas in the training. storage and reliable management camera. The production data can such as temperature, level, pressure Control technology plays a key role of product and quality data are key be fully tracked by means of RFID or flow rate; pumping fluids; in process automation, in order to tasks in this section of the training tags in the bottle caps. A range of shutting off pipelines; installing, ensure high product quality. The factory. automation components, such as commissioning or maintaining processes selected for the training belts with electric drives, various butterfly valves, slide valves or factory and the transparent design Technologies such as RFID are handling units, programmable logic ball valves. These are just some of the stations enables control becoming ever more prevalent in controllers and the latest operator examples of the wide variety of technology to be taught in a practical the production environment, in control and monitoring tools, possibilities in this section of the and visual manner. order to cope with the continually trainees are provided with an ideal training factory. increasing number of product platform to learn these key aspects. variants and to comply with the more stringent legal requirements in terms of product quality in the food or pharmaceuticals sector. Full recording of all ingredients or components used and the factors influencing the manufacture of a product must be ensured. Vision and sensor systems also play a key role in improving product quality and production flexibility.

44 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

Zone 3 In the training factory in this Zone 4 Chaotic or systematic warehousing, Production automation section the caps are produced, Transport and logistics optimisation of the material flow, tested and fed to the bottles by the planning and prioritisation of orders Fast cycle times, part gripping, filling station. Programmable logic Almost all production facilities need are the key areas of focus in this handling, detection, differentiation, controllers monitor and control logistics functions such as materials section of the factory. separation and mounting are the production process. Various transportation or warehousing. At characteristic features of production sensors record the end positions the AFB training factory, too, this Particular demands are placed on automation – the classic world of the actuators or identify and is a key aspect: Empty six-packs line automation in this section too, of the mechatronics engineer. differentiate between the work- have to be conveyed to the order however: Programming controllers, adjusting pieces. Typical actuators used in compilation station or placed in – Signals from the transport systems sensors, operating, maintaining and production automation, such as storage. Completed six-packs are must be sent over long distances servicing individual lines in a plant linear cylinders, swivel cylinders, delivered just in time, or stored in an to the transport controller. are typical activities. motors, parallel grippers or vacuum interim facility. – High-performance drive units and suction cups ensure fast, precise positioning systems ensure fast, movement. precise movement in the automatic warehouse. – The communications required for this are based on systems such as the AS interface or CAN.

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AFB training factory

Optimum operator control Everything in hand Tried and proven New Whether via touch panel, visua- Whether bottle or six-pack, the The MPS® stations, which have Automation technology is taught lisation system or control panel, professional handling units in the been deployed for training pur- using state-of-the-art equipment; all the stations and the entire AFB training factory ensure a safe, poses thousands of times all over not just the new MPS® PA stations, training factory can be operated and precise, fast material flow. the world, supply the caps in but also the automatic warehouse, monitored in a highly user-friendly the training factory. The stations the filling station and the order way. particularly enable an optimum level compilation station. of highly sophisticated training in mechatronics.

46 24-month Festo Didactic warranty Hybrid training factories AFB factory Training factories for hybrid production processes

AFB-FMRQ-BP-DSPB On request Visualisation Either an overview of the complete Package plant or access to each individual Comprising: station is available; the visualisation Stations system at the AFB training factory Zone 1: MPS® PA filtering*, mixing*, reactor*, filling (quality sampling)* stations permits monitoring of all signals Zone 2: AFB filling and order compilation stations and provides trend graphs of the Zone 3: MPS® distribution**, separation**, processing**, buffering** and handling analogue process variables, with stations** remote access to the various Zone 4: AFB pallet transport system, AFB automatic warehouse and AFB incoming goods functions and monitoring of all and outgoing goods stations. processes. All stations communicate Software and media via TCP-IP with the visualisation STEP 7 Trainer Package programming software, CIROS® Automation Suite, Fluid Lab®-PA, computer. Mechatronics Assistant, WinCC RFID option * Including mobile base frame, touch panel and S7-300 PLC board. Full tracking and documentation ** Including mobile base frame, MPS® control panel and S7-300 PLC board. of the entire production process is demanded in more and more areas of industry. The AFB training factory also makes this possible: Production data such as the recipe or batch identifier are stored on the mobile data carriers fixed to each individual bottle and can be checked prior to shipping. This means that state-of- the-art RFID technology can now be integrated highly demonstratively into automation training.

Function completed six-packs can be placed – Application of frequency converters The AFB training factory produces in interim storage via the belt – Use of multi-axis handling systems complete six-packs. All the produc- rotation system or delivered for for handling and palletising tion steps involved are covered, from shipping. Empty six-packs can be – Networking sensors and actuators production of the liquid through to conveyed back into the system on via AS-interface packing of the containers and storage roller conveyors and either placed – Use and commissioning of a CAN and shipping of the finished product. in storage or fed directly into the network production process. – Networking automated systems The process automation section with Ethernet TCP-IP of the plant is where the liquid Training content – Measurement and control of is produced: Raw materials are The multitude of stations and the electrical and process engineering filtered, mixed together with other technologies embedded in them variables such as level, flow rate, ingredients according to different permit an investigation of almost pressure and temperature recipes, temperature-controlled and all relevant areas of control and – Process operation and monitoring, stored ready for use. In-line samples automation technology. system management can be taken from the ongoing – Use of RFID technology – Selection, deployment and control process before the liquid reaches – Vision systems and camera of process fittings the filling station. Bottles from a belt inspection conveyor are filled and capped on – Use and programming of PLCs a rotary indexing table. The bottles – Application of various handling are then sealed with machined and devices and grippers tested caps and packed into six- – Application of various electrical packs. Depending on the order, the drives (DC, AC)

www.festo-didactic.com 47 Hybrid training factories AFB factory Training factories for hybrid production processes

AFB filling station

The filling station includes a large number of functions typical to the foodindustry: Bottle feed by conveyor, dosing with a dosing cylinder and filling and capping on a rotary indexing table.

The station can be operated both as a stand-alone unit orin conjunction with other stations.

In stand-alone operation the caps must be fed manually. When operated inconjunction with other stations, the caps can be fed by way of a handlingstation (MPS®). Filled and capped bottles are forwarded by conveyor to the next station (order compilation).

The liquid being filled is stored in a tank on the station. The tank can befilled manually or way of additional process stations (e.g. MPS® PA).

The station is controlled by a PLC unit and operator control is via touch panel. Individual step and continuous cycle options are available. Status and messagesare indicated graphically on the panel.

Special training aims – Set-up, wiring and commissioning of an automated station – Use of pneumatic linear units with variable stroke – Use of pneumatic linear swivel units – Controlling and monitoring material flow on a conveyor and a rotary indexing table – Dosing and filling – Process operation and monitoring

Order no. On request

48 www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

AFB order compilation station

With a high-precision 2-axis industrial handling system, 2 by 3 bottles are packed into each six-pack on the order compilation station.

The bottles are carried on conveyor belts to the handling station. A high- speed camera checks the six-packs.

The camera features a built-in controller which handles the complete image evaluation process.

With its TCP-IP interface and the additional CAN master interface, the camera enables wide-ranging communication options.

The station is controlled via a PLC board. Different operation modes can be selected on the control panel.

Specific training content – Set-up, wiring and commissioning of an automated station – Use of pneumatic handling unit with gripper – Controlling and monitoring material flow by conveyor – Vision systems, quality and process control with intelligent cameras

Order no. On request

www.festo-didactic.com 49 Hybrid training factories AFB factory Training factories for hybrid production processes

AFB automatic warehouse station

The automatic warehouse can hold up to 16 six-packs on 4 levels each with 4 bays. A cartesian 3-axis handling system is used for stock movement. 2 toothed belt axes are driven by intelligent servomotors with an integrated servo amplifier, controller and CAN bus interface.

The third axis is executed as a rodless linear unit with precision guides.

The station is controlled by a PLC board with CAN master. The colour touch panel of the automatic warehouse provides user-friendly operation and monitoring.

Items can be easily taught-in, and stock levels clearly initialised and modified.

Specific training content – Set-up, wiring and commissioning of an automated station – Use of pneumatic linear units – Electric drive and control technology – Intelligent CAN bust technology – Warehousing and logistics – Process operation and monitoring

Order no. On request

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AFB incoming goods/outgoing goods station

Full six-packs awaiting shipping are placed by the pneumatic 3-axis handling unit on one of the two outgoing goods ramps. The handling unit features a pneumatic linear gripper to grip the six-packs.

The axes used are pneumatic linear axes developed specially for industrial assembly and handling systems.

Empty six-packs can be fed in by way of the incoming goods conveyor.

The station is controlled by a PLC board. Different operation modes can be selected on the control panel.

Specific training content – Set-up, wiring and commissioning of an automated station – Use of pneumatic handling units with gripper – Handling technology – Controlling and monitoring material flow by conveyor belt and roller conveyor

Order no. On request

www.festo-didactic.com 51 Hybrid training factories AFB factory Training factories for hybrid production processes

AFB pallet transport system

The material flow within the AFB lines is implemented by the pallet transport system. The six-packs are conveyed to the individual stations on pallets which are equipped with an identification system. The transport system features 4 stop points, and can be expanded at any time.

The belt segments are driven by 4 AC motors.

The control is handled by a PLC with frequency inverter – professionally housed in the control cabinet. Communication with the stop points is via AS interface. The pneumatic stoppers are controlled using industrial valve terminals.

Specific training content – Set-up, wiring and commissioning of an automated station – Use of AC motors – Electrical drive technology – Use of frequency inverters – Pallet identification – AS interface fieldbus technology – Material flow and logistics – Protection circuits – Design of industrial control cabinets

Order no. On request

52 www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

AFB factory, focus on bulk goods New!

Found everywhere! Practical training Conveying of bulk goods or Everything under control There is a worldwide market behind The handling of bulk goods requires complete production process? Stations are controlled using the the term „bulk goods“. In almost special know-how. The exclusive use The stations are specially designed most modern automation and every branch of production, bulk of typical industrial components in for training on bulk goods and can computer technology. With system goods can be found as raw materials, the learning stations emphasises be used individually as well as in a visualisation the entire system can semi-finished materials or finished the required hands-on experience network with the stations of the AFB be viewed or each individual station parts. Whether building materials, and ensures the quick transfer of factory. This offers a training factory can be accessed; it enables the such as sand, gravel and cement, knowledge from training to practice. that includes the complete process monitoring of signal statuses, the or foodstuffs, such as grain and chain, from providing and preparing remote access of different functions sugar – bulk goods must be stored, raw materials, to quality testing, and the monitoring of all processes, dispensed, weighed, transported or packaging, storage and finally the directly on the system using a touch packaged. processing of customer orders. panel or via the master computer.

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AFB stations, dispensing/sorting bulk goods New!

Different types of conveying A wide range of processes are used in production systems for handling bulk goods. It therefore makes sense that these can also be found in the AFB training stations for dispensing and sorting:

Conveying with a conveyor In the dispensing station, the conveyor acts as a pressure feed. Corn is dispensed from its container via the conveyor to a funnel and is transported to the next station by means of compressed air.

Screw conveyor With the screw conveyor, the bulk goods are carefully conveyed, making optimal dispensing possible. The dispensing screw is driven by a servo motor with a built-in controller.

High-speed quality checking and diagnostics Imperfect grains are detected during conveying and automatically separated. This requires the quick detection and reaction of the actuators, which the human eye can hardly follow. To support the diagnostics and commissioning of these fast motion sequences, an intelligent compact camera system with up to 2000 images per second are used in the AFB factory. This means that the latest diagnostic techniques can be taught.

AFB station dispensing bulk goods Order no. On request AFB station sorting bulk goods Order no. On request

54 www.festo-didactic.com Hybrid training factories AFB factory Training factories for hybrid production processes

One training factory – over 100 different training systems

More than 15 stations can be integrated into the AFB training factory. Inaddition to the new AFB stations it also features stations from the MPS® familyand stations from the new MPS® PA product line.

The unique interface and communications concept enables quick and easymodification of the factory layout.

This means the stations can be deployed at any time individually or in smallgroups for teaching purposes, and the AFB training factory can be assembled indifferent project stages.

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