Festo MPS PA Compact User manual

MPS
®
PA Compact
Workstation
EN
12/08
Process automation
MPS
®
PA Compact
Workstation
Manual

2
© Festo Didactic MPS
®
PA Compact Workstation
This station has been developed and produced solely for vocational and further
training purposes in the field of automation and communication. The company
undertaking the training and / or the instructors is / are to ensure that trainees
observe the safety precautions described in the manuals provided.
Festo Didactic herewith excludes any liability for damage or injury caused to
trainees, the training company and / or any third party, which may occur if the
system is in use for purposes other than purely for training, unless the said damage
/ injury has been caused by Festo Didactic deliberately or through gross negligence.
Order No.: BE.TW.0004
Description: Manual
Designation: MPS® PA Compact Workstation
Status: 12/2008
Authors: Jürgen Helmich, ADIRO
Graphics: Jürgen Helmich, ADIRO
Layout: Jürgen Helmich, ADIRO
© Adiro Automatisierungstechnik GmbH, 73734 Esslingen, Germany, 12/2008
Internet: www.festo.com/didactic http://www.festo.com/didactic/de/ProcessAutomation
e-mail: [email protected]m
The copying, distribution and utilisation of this document as well as the communication of its contents
to others without express authorisation of is prohibited. Offenders will be held liable for the payment
of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Intended use

© Festo Didactic MPS
®
PA Compact Workstation 3
Intended use ___________________________________________________________ 2
Contents ______________________________________________________________ 3
1 Introduction _______________________________________________________ 5
1.1 Training contents _______________________________________________ 6
1.2 Important notes ________________________________________________ 7
1.3 Duty of the operating authority____________________________________ 7
1.4 Duty of trainees ________________________________________________ 7
1.5 Risks involved in dealing with the MPS® PA Compact Workstation ______ 8
1.6 Warranty and liability ____________________________________________ 9
1.7 Use for intended purpose ________________________________________ 9
Notes on safety ________________________________________________________11
2 Technical data_____________________________________________________13
3 Transport / Unpacking / Scope of delivery _____________________________15
4 Design and function ________________________________________________17
4.1 Level monitoring_______________________________________________20
4.2 Pump ________________________________________________________24
4.3 Proportional valve _____________________________________________25
4.4 Heating ______________________________________________________26
4.5 2W ball valve with pneumatic rotary drive __________________________28
4.6 Level control function___________________________________________29
4.7 Flow rate control function _______________________________________31
4.8 Pressure control function________________________________________33
4.9 Temperature control system _____________________________________35
4.10 I/O-board __________________________________________________37
4.11 Mouting frame ______________________________________________38
5 Commissioning ____________________________________________________39
5.1 Workstation___________________________________________________40
5.2 Visual check __________________________________________________40
5.3 Cable connections _____________________________________________41
5.3.1 Simulation box digital/analog and MPS® PA Compact Workstation 41
5.3.2 Easyport digital/analog and MPS® PA Compact Workstation______43
5.3.3 EduTrainer Siemens S7-300 and MPS® PA Compact Workstation __45
5.3.4 EduTrainer Logo and MPS® PA Compact Workstation ____________47
5.3.5 EduTrainer Festo CPX-FEC IT and MPS® PA Compact Workstation __49
5.3.6 EduTrainer Allen Bradley and MPS® PA Compact Workstation_____52
5.4 Pneumatic connection __________________________________________55
5.5 Voltage supply ________________________________________________55
5.6 Adjusting sensors______________________________________________56
5.6.1 Capacitive proximity sensor B113/B114 _______________________56
5.6.2 Float switch S111/S112/S117 _______________________________57
6.6.3 Ultrasonic sensor B101 _____________________________________58
5.7 Choosing controlled system _____________________________________59
5.8 Allocation list of inputs and outputs ______________________________61
5.9 Loading the PLC program________________________________________62
Contents

Contents
4
© Festo Didactic MPS
®
PA Compact Workstation
5.9.1 Siemens S7 300 CPU 313C __________________________________62
5.9.2 Festo FEC-CPX _____________________________________________63
5.9.3 Allen Bradley controller _____________________________________64
5.10 Filling and deaeration ________________________________________65
5.11 Start sequence S7 programm “Level” ___________________________66
5.12 Notice _____________________________________________________67
6 Maintenance ______________________________________________________69
7 Appendix _________________________________________________________71
Designation of equipment _____________________________________________71
Parts lists___________________________________________________________71
Process flowsheets___________________________________________________71
EMCS block diagrams_________________________________________________71
EMCS ______________________________________________________________71
Electrical circuit diagrams _____________________________________________72
Electropneumatic circuit diagrams ______________________________________72
Program listings _____________________________________________________72
Data sheets _________________________________________________________72

© Festo Didactic MPS
®
PA Compact Workstation 5
The Festo Didactic Learning System for process automation and technology is
designed to meet a number of different training and vocational requirements. The
systems and stations of the MPS
®
PA Compact Workstation facilitate industry-
orientated vocational and further training and the hardware consists of didactically
suitable industrial components.
The MPS
®
PA Compact Workstation station provides you with an appropriate system
for practice-orientated tuition of the following key qualifications
•Social competence,
•Technical competence and
•Methodological competence
Moreover, training can be provided to instill team spirit, willingness to cooperate
and organisational skills.
Actual project phases can be taught by means of training projects, such as:
•Planning,
•Assembly,
•Programming,
•Commissioning,
•Operation,
•Maintenance and
•Trouble shooting.
1
Introduction

Introduction
6
© Festo Didactic MPS
®
PA Compact Workstation
Training contents covering the following subjects can be taught:
•Mechanics
–Mechanical construction of a station
•Process Engineering
–Reading and drawing flow charts and dokumentation
•Pneumatics
–Piping connections of pneumatic components
•Electrical technology
–Correct wiring of electrical components
•Sensors
–Correct use of sensors
–Measuring of non-electrical, process and control variables
•PLC
–Programming and use of a PLC
–Programming of alternative (OR) branches
–Fieldbus technology
•Closed-loop control technology
–basics of closed-loop control technology
–Extension of measuring chains into closed control loops
–Analyze a closed-loop system
–P, I, D-control
–Optimize a closed-loop system
•Closed-loop controller
–Configuration, assigning operation parameters and optimization of a
closed-loop controller
•Commissioning
–Commissioning of a closed-loop system
–Commissioning of a process engineering system
•Fault finding
–Systematic fault finding on a process engineering system
–Examination and mantainence of a process engineering system
–Operation and observation of a process
Topics for project work
•Selection of electrical components
–level sensor
•Savety check of a tank
–how to use a float sensor
1.1
Training contents

Introduction
© Festo Didactic MPS
®
PA Compact Workstation 7
The basic requirement for safe use and trouble-free operation of the
MPS
®
PA Compact Workstation is to observe the fundamental safety
recommendations and regulations.
These operating instructions contain important notes concerning the safe operation
of the MPS
®
PA Compact Workstation.
The safety recommendations in particular must be observed by anyone working on
the MPS
®
PA Compact Workstation.
Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.
The operating authority undertakes to ensure that the MPS
®
PA Compact
Workstation is used only by persons who:
•are familiar with the basic regulations regarding operational safety and accident
prevention and who have received instructions in the handling of the MPS
®
PA
Compact Workstation,
•have read and understood the chapter on safety and the cautionary notes in
these operating instructions and confirmed this by signing,
•are regularly vetted to ensure safe working.
Prior to commencing work, all persons assigned to working on the MPS
®
PA Compact
Workstation have a duty to:
•observe the basic regulations regarding operational safety and the prevention of
accidents,
•read the chapter on safety and the cautionary notes in these operating
instructions and to confirm that they have understood these by signing.
1.
Important notes
1.3
Duty of the operating
authority
1.4
Duty of trainees

Introduction
8
© Festo Didactic MPS
®
PA Compact Workstation
The MPS
®
PA Compact Workstation is designed according to state of the art
technology and in compliance with recognised safety regulations. However when
using the system there is nevertheless a risk of physical or fatal injury to the user or
third parties or of damage being caused to the machinery or other material assets.
The MPS
®
PA Compact Workstation is to be used only:
•for its intended purpose and
•in an absolutely safe conditions.
Faults impairing safety must be rectified immediately!
1.5
Risks involved in dealing
with the MPS
®
PA Compact
Workstation

Introduction
© Festo Didactic MPS
®
PA Compact Workstation 9
In principle all of our „Terms and Conditions of Sale“ apply. These are available to
the operating authority upon conclusion of the contract at the latest. Warranty and
liability claims for persons or material damage are excluded if these can be traced
back to one or several of the following causes
•Use of the machine not in accordance with its intended purpose
•Incorrect assembly, commissioning, operation and maintenance of the machine
•Operation of the machine using faulty safety equipment or incorrectly fitted or
non operational safety or protective devices
•Non observance of notes in the operating instructions regarding transport,
storage, assembly, commissioning, operation, maintenance and setting up of the
machine
•Unlawful constructional modifications on the machine
•Inadequate monitoring of machine components subject to wear
•Incorrectly carried out repairs
•Catastrophes as a result of foreign objects and acts of force major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the
training company and /or other third parties which may occur during the use /
operation of the system other than purely in a training situation, unless such
damage has been caused intentionally or due to gross negligence by Festo Didactic.
This system has been developed and produced exclusively for vocational and further
training in the field of automation and communication. The training authority and /
or the instructors is / are to ensure that trainees observe the safety precautions
described in the manual provided.
The use of the system for its intended purpose also includes:
•following all advice in the operating instructions and
•carrying out inspection and maintenance work.
1.6
Warranty and liability
1.7
Use for intended purpose

Introduction
10
© Festo Didactic MPS
®
PA Compact Workstation

© Festo Didactic MPS
®
PA Compact Workstation 11
General
•Trainees must only work on the station under the supervision of an instructor.
•Observe the data in the data sheets for the individual components, in particular
all notes on safety!
Electrics
•Electrical connections are to be wired up or disconnected only when power is
disconnected!
•Use only low voltages of up to 24 V DC.
•The heating is using 230 V AC. Work on components using electrical connections
of 230 V AC must be carried out by qualified personnel. Please refer to safety
regulations for commissioning (DIN VDE 0113, EN 60204).
Pneumatics
•Do not exceed the permissible pressure of 8 bar (800 kPA).
•Do not switch on compressed air until you have established and secured all
tubing connections.
•Do not disconnect air lines under pressure.
•Particular care is to be taken when switching on the compressed air. Cylinders
may advance or retract as soon as the compressed air is switched on.
Mechanics
•Securely mount all components on the plate.
•No manual intervention unless the machine is at rest.
•The pump can be mounted horizontally or vertically. If mounted, the ouput of the
pump must point upwards. The pump must be mounted so that is is flooded (see
also data sheet).
Notes on safety

Notes on safety
12
© Festo Didactic MPS
®
PA Compact Workstation
Process engineering
•Before filling the tanks with water switch of power supply!
Switch of power supply 24 VDC and 230 VAC (110 VAC)!
•The use of tap water in quality of drinking water (recommended), ensures a
prolonged maintenance-free operation of the system (proportional valve and
pump).
•The maximum operating temperature of the tanks must not exceed +65 °C.
•Do not operate the heating unit unless the heating element is fully immersed in
fluid.
•Do not operate the piping system with a system pressure higher than 0,5 bar.
•Do not operate the pump without fluid, running dry or used for sea water or
contaminated fluids.
•Please empty fluids from the system (tanks, piping, close valves) before you
make changes at the piping system.
•It is possible to drain the fluids inside the MPS® PA Compact Workstation by
opening hand valve V105
•Do not left the water inside the tanks for a longer time. It is possible, that
bacteria as legionella grow up, which can cause diseases.

© Festo Didactic MPS
®
PA Compact Workstation 13
Parameter Value
max. operating pressure piping system 50 kPa (0.5 bar)
power supply for station 24 V DC
profile plate 700 x 700 x 32 mm
dimensions 700 x 700 x 907 mm
Weight
(volumetric) flow rate of the pump ~5 l/min
tank volume 10 l max.
flexible piping system DN10 (∅
a
15mm)
digital inputs 7
digital outputs 5
analog inputs 4
analog outputs 2
amount of tanks 3
output range control element pump (0...24 VDC) voltage 0...10 V
2/2W-proportional valve voltage 0...10 V
heating element 230 VAC
(power 1000 W)
On/Off
(control relay 24 VDC)
working range closed-loop system for level control 0...10 l mm
measuring range level sensor 0…9 l
signal range level sensor current 4...20 mA
working range closed-loop system for flow rate control 0...7 l/min
measuring range flow sensor 0,3...9,0 l/min
signal range flow sensor frequence 0...1200 Hz
working range closed-loop system for pressure control 0...30 kPa (0...300 mbar)
measuring range pressure sensor 0…10 kPa (0…100 mbar)
signal range pressure sensor voltage 0...10 V
working range closed-loop system for temperature control 0...60° C
measuring range temperature sensor -50° C…+150° C
signal range temperature sensor resistance PT100
Technical data

Technical data
14
© Festo Didactic MPS
®
PA Compact Workstation

© Festo Didactic MPS
®
PA Compact Workstation 15
Transport
The MPS
®
PA Compact Workstation is delivered in a container with a pallet base.
The container must be transported on a suitable fork lift truck at all times and must
be secured against tipping or falling off.
The carrier and Festo Didactic are to be notified immediately of any damage caused
during transport.
Unpacking
Carefully remove the padding material in the container box when unpacking the
station. When unpacking the station, make sure that none of the station assemblies
have been damaged.
Check the station for any possible damaged once unpacked. The carrier and Festo
Didactic are to be notified immediately of any damage.
Scope of delivery
Check the scope of delivery against the delivery note and the order. Festo Didactic
must be notified immediately of any discrepancies.
3
Transport /
Unpacking / Scope of delivery

Transport / Unpacking / Scope of delivery
16
© Festo Didactic MPS
®
PA Compact Workstation

© Festo Didactic MPS
®
PA Compact Workstation 17
MPS
®
PA Compact Workstation
The MPS
®
PA Compact Workstation combines 4 closed-loops with digital and analog
sensors and actuators. With a PLC or a controller it is possible to use them
individually or cascaded:
•level controlled system
•flow rate controlled system
•pressure controlled system
•temperature controlled system
4
Design and function

Design and function
18
© Festo Didactic MPS
®
PA Compact Workstation
PI diagram MPS
®
PA Compact Workstation (ISA 5.5 / ISA 5.1 Standard)
It is possible to work with following functions by using the 4 closed-loop systems:
•two point control of a level control system with a analog standard signal
•continuous control of a level control system with a analog standard signal
•continuous control of a flow rate control system with a pump as controlled
system and a impulse signal for frequence measuring
•continuous control of a flow rate control system with a proportional valve
(controlled system) and a impulse signal for frequence measuring
•continuous control of a flow rate control system with a pump as controlled
system and with a analog standard signal
•continuous control of a flow rate control system with a proportional valve as
controlled system and with a analog standard signal
•continuous control of a pressure control system with a pump as controlled
system and with a analog standard signal
•continuous control of a pressure control system with a proportional valve as
controlled system and with a analog standard signal
•two point control of a temperature control system with a analog standard signal

Design and function
© Festo Didactic MPS
®
PA Compact Workstation 19
The basic components of the MPS® PA Compact Workstation are:
•Analog ultrasonic sensor
•Flow sensor with frequency signal
•Pressure sensor, piezoresistive
•Pressure gauge for 0…1bar
•PT100 temperature sensor
•2x Capacitive proximity switch for min/max level in lower tank
•Float switch for threshold function (electromechanical) in upper tank
•Float switch for overflow alarm monitoring in lower tank
•Float switch as a protection for the heating system
•Centrifugal pump
•Motor Controller for pump
•Proportional valve with electronic control module
•Heating system with integrated control relay
•2W ball valve with pneumatic rotary drive (SYPAR) with sensor box
•I/O Terminal
•Terminal for analog signals
•Signal converter: current to voltage, frequency to voltage, PT100 to voltage
•PLC or closed-loop controller
•control panel
•Piping system incl. 4 transparent segments
•Pressure tank (reactor)
•Water tanks
•Manual valve
•Manual ball valve for drain
•Service Unit
•19’’ mounting frame for ER units or A4
•carriage
The functions of each closed-loop system result in the specified combination of the
(manual-) valves. Also they depend on the programming, configuration or
parametrizing of the PLC/ controlling system.

Design and function
20
© Festo Didactic MPS
®
PA Compact Workstation
Following technical examples for level monitoring are integrated into the MPS® PA
Compact Workstation:
•proximity switches
•float switch for overflow savety
•float switch for threshold function
Two capacitive proximity switches B113 (1) and B114 (2) are located on the side of
the lower tank B101 and mounted on a profile plate. The proximity switches can be
mechanically adjusted. The sensing distance through the tank wall can be adjusted
with a screw. The binary 24 V input signals are connected to the I/O-terminal XMA1.
1
2
Level monitoring with capacitive proximity switches B113 and B114
The minimum level of the tank B101 is indicated by the lower sensor B113. At
minimum level the heating element E104 should be totally immersed into the liquid.
The maximum level of the tank B101 is indicated by the upper sensor B114.
At reset position of the system both sensors have to be activated.
4.1
Level monitoring
Proximity switches