Qualification solutions

for process automation

 Process automation

Professional, industry-focused qualification solutions

for process automation

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

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

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

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

 Process automation

Challenging – The process industry

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

On the other hand, chemical prod-

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

www.festo-didactic.com 3
 Process automation
Filtering, mixing, tempering and filling
as in industry
Modular
The modularity of the learning sys-
tem enables you to realise a diverse
range of configurations for typical
production processes from very dif-
ferent 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 coat-
ing technology
– Experts in food, confectionery and
fruit juice technology
– Experts in water supply, sewage
technology, pipe, canal and indus-
trial services
– Chemical engineers
– Pharmaceutical engineers
– Biotechnicians
– Paper technicians
– Systems engineers for sanitary,
heating and air conditioning tech-
nology
 Process automation

Train efficiently

Festo – The partner to the

process industry

Festo is fast becoming a key part-

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

– Water supply and disposal industry

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

Why stop production to facilitate

training?

It is prohibitively expensive to shut

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

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

 Process automation

Understanding process automation –

By means of seminars and workshops

Open seminar on measurment and Specific customer training course

The goal of Festo Didactic is to
offer further training that not
only supports personnel in com-
panies with current problems,
but that also provides new ap-
proaches to future tasks.
Festo is fast becoming a key
partner to the process industry.
Close coordination with our par-
ent 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.
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 technol-
ogy. They will learn about the basic
structure, mode of operation and
application of process engineer-
ing systems and be able to use this
equipment. The procedure for the
identification of control systems, se-
lection of a suitable controller and
definition and setting of control pa-
rameters will also be explained.
Customer-specific training course for
those employed in the areas of main-
tenance, servicing and operational
support.
The following training aims are con-
veyed 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 mod-
ern PLCs)

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

On request

6 www.festo-didactic.com

Fluid Lab®-PA can be used to teach
and demonstrate the fundamentals
of control technology. The main com-
ponents 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 operat-
ing 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 con-
trol 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 proc-
ess 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 sig-
nals can also be switched and the
signal states of the inputs read off.
General PC system settings can also
be made here.
Process automation
Fluid Lab®-PA
„Process Sequence“ menu item
The process sequence of each sta-
tion 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 proc-
ess 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 dis-
play or saving as a .jpg file
„Analysis“ menu item
Analyses of a wide range of proc-
ess components can be directly per-
formed using predefined exercises,
for example:
– Recording of sensor characteristics
– Recording of pump characteristics
– Recording of heating characteris-
tics
This permits a fast and thorough un-
derstanding of the typical process
components.
„2-Point Controller“ and
„Continuous Controller“ menu item
For easy parameterisation of the re-
quired controller with an immedi-
ate effect on the process. One click
of the mouse starts various control-
ler functions for the selected control
system. Documentation of the con-
troller parameters is also straight-
forward. The measured values and
characteristic curve profiles can be
easily printed out.
DE/EN/ES/FR 544304
Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 7
 MPS® PA – The new learning system for process automation

MPS® PA – The new learning system for process automation

Teaching today using the

technology of tomorrow

MPS® PA, an innovative learning sys-

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

Practical training Sensors

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

8 24-month Festo Didactic warranty


Investment protection
A well thought-out modular design with clear-cut interfaces facilitates adapta-
tion 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 re-
quirements.
MPS® PA – The new learning system for process automation
Boundless variety
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 automa-
tion but still require elements from production automation.
www.festo-didactic.com 9
 MPS® PA – The new learning system for process automation

Measuring and controlling as in industry

The closest thing to reality Components Operation and configuration Advantages

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

Simulation box – Simple commissioning of an

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

Fluid Lab®-PA – Commissioning and testing of an

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

PLC – Programming of process se-

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

PLC with external industrial Same as PLC, plus:

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

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

Combining stations

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

The MPS® 204 complete system sec-

tion shows a fully configured system.

24-month Festo Didactic warranty 11

 MPS® PA 204 Complete system
MPS® PA 204 Complete system
Control technology is clearly and
practically explained using the P, PI
or PID control algorithm. The temper-
ature sensor – the reactor station us-
es a PT100 resistance thermometer –
supplies a unit signal of 0 – 10 V via
the measuring transducer. The con-
troller approaches the setpoint tem-
perature via the continuously control-
lable 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 addi-
tionally displayed using a variable-
area flowmeter. The controller ad-
justs the necessary flow rate via the
pump with analogue control.
Pressure control ensures constant-
ly high filter quality during flushing.
The pressure sensor with LCD dis-
play, analogue output and switching
output always supplies the correct
measurement variable. The control-
ler ensures constantly high filter
quality during rinsing via the propor-
tional 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 Special training aims

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

MPS PA 204 with SIMATIC S7-300 control package 544248

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

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

Successful project work thanks to modular structure

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

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

Filtration station

Function

The filtration station filters liquids.

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

Measurement and control
Sensors detect the filling level of the
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 constant-
ly high filter quality during flushing.
The pressure sensor with LCD dis-
play, analogue output and switching
output always supplies the correct
measured variable. The controller
with P, PI or PID control algorithm
ensures constantly high filter qual-
ity during rinsing via the proportional
pressure regulator. Control technolo-
gy is clearly and practically explained
in this way.

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

 MPS® PA Stations

Shutting off, opening, closing

The right selection of process valve,

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

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

Complete Filtration station 544253

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

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

24-month Festo Didactic warranty 15

 MPS® PA Stations
Mixing station
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 addi-
tionally 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 in-
tegrated comparator. The controller
16 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com
Function
The mixing station mixes different
recipes from three reservoir tanks.
The liquid from one of the three
reservoir tanks is pumped into the
main tank in a controlled manner by
opening the respective two-way ball
valve. The finished mixture can be
pumped to the next station via a sec-
ond pump – or pumped back to the
reservoir tank.
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 typ-
ical components from process engi-
neering. Pumps and process valves,
various sensors for signal detection
as well as electronic modules for
signal conversion permit the right
„training mix“.

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

Complete Mixing station 544254

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

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

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

Reactor station

Function

The reactor station tempers a liquid.

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

Measurement and control
Sensors detect the filling level of the
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 tem-
perature profiles when activating
the recipes is achieved by means of
temperature control. The tempera-
ture sensor (PT100 resistance ther-
mometer) supplies a unit signal of
0 – 10 V via the measuring transduc-
er. 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. Sim-
ple control exercises, for example
control using the two-point control-
ler, can be realised using the reactor
station. Control technology is clearly
and practically explained in this way.

18 24-month Festo Didactic warranty

 MPS® PA Stations

Heating and stirring

Key basic operations in many proc-

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

Infinitely adjustable heating with
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.
Stirrer with DC motor.
Signal converters convert all ana-
logue signals from the station to
standard signals from 0 – 10 V. Prac-
tical for the purpose of experimen-
tation: integrated comparators also
supply purely binary signals.

Complete Reactor station 544255

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

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

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

 MPS® PA Stations

Bottling station

Function

The bottling station fills bottles with

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

Measurement and control The filling level of the dosing tank
is detected in the filling station us-
ing 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 characteristics of the control
process can be modified using hand
valves already integrated. Control
technology is clearly and practically
explained in this way.

The filling level in the dosing tank is

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

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

Transporting, separating, filling

Few segments of the diversified

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

Complete Bottling station 544256

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

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

24-month Festo Didactic warranty 21

 Process automation – Networked system

Networked system with 3 or 4 stations

Adjustable centrifugal pump to en-
sure the right flow for every station.
Sipart DR19 controller from
Siemens – now fitted in all stations.
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.

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


Function
A networked system enables level
control, flow rate control, pressure
control and temperature control sys-
tems to be operated simultaneously.
Each station is equipped with a Sie-
mens DR19 and can therefore also
be operated individually. The sta-
tions are connected to the host com-
puter (PC) via Profibus DP. Access
to the process variables of all sta-
tions 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 in-
creased later by merging the stations
into one system.
System with 3 stations On request
Comprising:
level, flow rate and temperature control
as well as a standard connecting
station
– 3x industrial controller DR19 in the
ER mounting frame
– 1x EduTrainer® with S7-313C-2DP
– 4x mobile trolley
– 4x power supply unit in the mounting
frame
– 1x individual licence STEP 7
– 1x licence for WinCC or InTouch
– 1x licence for SIMATIC PDM
– 1x Profibus card CP 5611
– 1x set of Profibus cables
– Technical documentation
– Initial start-up at Festo Didactic
Commissioning and training on-site upon request.
Process automation – Networked system
Training aims
This system complements the train-
ing aims of the Compact Worksta-
tion.
– Commissioning and maintenance
personnel:
Realizing bus networks. From plan-
ning, design and configuration
through to realisation.
– Operators:
Process operation, monitoring and
performance training as part of
system management.
The networked system can be sup-
plied as a version with 4 stations
(level control, flow rate control, pres-
sure control and temperature con-
trol) or as a version with 3 stations
(no pressure control). Integrated systems: SIMATIC WinCC is a PC-based con-
from the control station to the field trol and monitoring system designed
In both cases, a connecting station Modern communication technology for visualising and controlling proc-
comprising a pump and 8 x 2/2-way enables you to „see“ the sensor from esses, sequences and machines.
solenoid valves controls the flow of the control room. The critical ques-
water between the stations. Six or tion remains as to which signals are InTouch is an interactive system
eight capacitive sensors (depend- relevant for display or which inter- for visualising, monitoring and con-
ing on whether there are 3 stations vention options should be made trolling industrial processes on IBM
or 4 stations respectively) monitor accessible to individual groups of compatible computers.
the level of the containers. Supplied people. The system provides a quick
with a SIPART DR19 controller and insight into complex relationships
S7-313-2DP. and points to trends in the latest
technologies and methods through
the use of hardware and software
from market leaders.
System with 4 stations On request Also order
Comprising: For simple commissioning, simulation and display using the simulation box:
level, flow rate, pressure and temperature Simulation box, digital/analogue 526863
control as well as a standard connecting SysLink cable 034031
station Analogue cable 529141
– 4x industrial controller DR19 in the Control variants
ER mounting frame See Compact Workstation
– 1x EduTrainer® with S7-313C-2DP
– 5x mobile trolley Recommended training media
– 5x power supply unit in the mounting – Fluid Lab®-PA, including EasyPort, digital/analogue
frame – Web-based training program, Fundamentals of open and closed-loop control
– 1x individual licence STEP 7
– 1x licence for WinCC or InTouch
– 1x licence for SIMATIC PDM
– 1x Profibus card CP 5611
– 1x set of Profibus cables
– Technical documentation
– Initial start-up at Festo Didactic
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
Scope of delivery of the
Compact Workstation
(Basic version including manual
without actuation components)
24 www.festo-didactic.com
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
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
Optimisation relative
to your space requirement
Maybe you‘re restricted in the
amount of space you have available
but you want each of your training
workstations to offer a high level of
complexity. If so then the Compact
Workstation with four integrated
closed-loop control systems is the
solution for you. As shown in the
flow chart, the individual control sys-
tems can be activated by simply re-
positioning the ball valves. The flex-
ible piping system enables you to
change the flow scheme or integrate
other components quickly and easily.
Function
The four control systems in the Com-
pact Workstation can be operated
individually. The level and flow rate
control systems can be structured as
a cascade control system through the
addition of an appropriate controller.
The layout of the sensors and servo
drives permits experimentation with
both continuous (e.g. P, I, PI, PID) and
discontinuous action controller types
(e.g. 2-point controllers). The pump
can either be controlled directly or
operated in controlled speed mode.
The manipulated variable of the con-
troller in the flow rate and pressure
control systems can alternatively act
upon a proportional directional con-
trol valve. A ball valve with pneu-
matic drive is built into the return
between the high-level container
and the lower reservoir. The pneu-
matic drive can be used to simulate a
“load” for switching on a disturbance
in the level control system or as an
on-off valve for emergency switch-off.
Compact Workstation On request
Commissioning and training on-site upon
request.
 Process automation – Compact Workstation

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

Control variants

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

24-month Festo Didactic warranty 25

 Hybrid processes

Hybrid processes

Boundless variety

Qualification solutions and training

factories for production and process
automation.

Tell us what you need – we‘ll design

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

The well thought-out modular de-

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

26 www.festo-didactic.com

AFB –
The modular concept factory for all
hybrid production tasks
Production automation and process automation
The learning system for all processes
associated with production automa-
tion and process automation.
– Production
– Handling of seals
– Packaging
– Filling
– Transportation and routing
– Storage
– Input/output
The ideal solution for hybrid pro-
duction process requirements in
the food sector. The platform con-
nects stations and elements from
the MPS® Modular Production Sys-
tem with stations from the MPS® PA
learning system and the Compact
Workstation.
The system is therefore complete-
ly modular and new processes and
training content can be added grad-
ually. Project work with hands-on
training can take place at individual
stations, on partially integrated pro-
duction lines and in a fully integrated
learning factory.
Customer-specific solutions
Information on customer projects: www.festo-didactic.com
Hybrid processes
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 sta-
tion demonstrates how a continu-
ous flow process is brought into line
with a gradual container filling proc-
ess. The students experience an op-
erational 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.
27
Festo Didactic GmbH & Co. KG

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

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

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