Festo MPS PA User manual

Festo Didactic
696690 en
09/2019
8079866
Bottling Learning System
MPS
PA
Station
s
Operating instructions

Order number: 696690 (PC.TW.0018)
Revision level: 09/2019 V3.0.1
Authors: Jürgen Helmich, Frank Ebel
Layout: Festo Didactic
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2019
[phone] www.festo-didactic.com
[phone] [email protected]
Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, is prohibited. Offenders will be held liable for damages. All rights
reserved, in particular the right to file patent, utility model and registered design applications.
For the sake of readability
throughout these operating instructions, all gender-specific
terms are to be considered to refer to both
the feminine and the masculine form,
e
xcept when referring to a particular person.
CAUTION
These operating instructions must always be available to the user.
The operating instructions must be read before commissioning.
The safety instructions must be observed
Non-observance may result in severe personal injury or damage to property.

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Contents
1 General requirements for operating the devices _______________________________________________7
2 Pictograms _____________________________________________________________________________8
3 Intended use __________________________________________________________________________ 10
4 For your safety ________________________________________________________________________ 11
4.1 Important information _______________________________________________________________ 11
4.2 Obligations of the operating company __________________________________________________ 11
4.3 Obligations of the trainees ___________________________________________________________ 11
4.4 Dangers when handling the components and systems _____________________________________ 12
5 Work and safety instructions_____________________________________________________________ 13
5.1 General remarks____________________________________________________________________ 13
5.2 Mechanical system__________________________________________________________________ 13
5.3 Electrical system ___________________________________________________________________ 14
5.4 Pneumatics________________________________________________________________________ 15
5.5 Process technology _________________________________________________________________ 16
6 Technical data_________________________________________________________________________ 17
6.1 General data_______________________________________________________________________ 17
6.2 Pin allocation table _________________________________________________________________ 18
6.2.1 Digital terminal _________________________________________________________________ 18
6.2.2 Analog terminal_________________________________________________________________ 19
6.2.3 Control panel___________________________________________________________________ 20
7 Transport/unpacking/scope of delivery____________________________________________________ 21
7.1 Transport _________________________________________________________________________ 21
7.2 Unpacking_________________________________________________________________________ 21
7.3 Scope of delivery ___________________________________________________________________ 21
8 Setup ________________________________________________________________________________ 22
8.1 The Bottling Learning System _________________________________________________________ 22
8.2 The Bottling Station _________________________________________________________________ 23
8.2.1 Main components _______________________________________________________________ 24
8.2.2 Small parts included in the scope of delivery of the station______________________________ 25
8.2.3 RI flow diagram _________________________________________________________________ 25
8.3 Function of the level system __________________________________________________________ 26
8.4 Pump_____________________________________________________________________________ 27
8.5 Level monitoring ___________________________________________________________________ 27
8.5.1 Capacitive proximity sensors ______________________________________________________ 28
8.5.2 Float switch ____________________________________________________________________ 28
8.5.3 Ultrasonic sensor _______________________________________________________________ 28

Bottling Learning System
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8.6 Conveyor belts with diffuse light sensors________________________________________________ 29
8.7 Pneumatic separator ________________________________________________________________ 30
8.8 2/2-way dosing valve________________________________________________________________ 31
8.9 Compressed air supply ______________________________________________________________ 31
8.10 Electrical connection technology _____________________________________________________ 32
8.10.1 Connection board ______________________________________________________________ 32
8.10.2 Mounting frame _______________________________________________________________ 33
8.10.3 19″frame_____________________________________________________________________ 34
8.11 PLC EduTrainer Universal S7-1512C ___________________________________________________ 35
8.12 Control console with operator unit TP700 Comfort _______________________________________ 36
8.13 EasyPort and FluidLab-PA closed-loop V5 ______________________________________________ 36
8.14 USB device server _________________________________________________________________ 37
8.15 Trolley 700 _______________________________________________________________________ 37
9 Operation ____________________________________________________________________________ 38
9.1 Operation as an individual station _____________________________________________________ 38
9.2 Operation as a downstream station ____________________________________________________ 38
10 Sequence description__________________________________________________________________ 39
10.1 Sequence description of the bottling process ___________________________________________ 39
10.2 Start-up prerequisites ______________________________________________________________ 39
10.2.1 Individual station ______________________________________________________________ 39
10.2.2 Station with downstream station__________________________________________________ 39
10.3 Initial position ____________________________________________________________________ 39
10.4 Sequence ________________________________________________________________________ 39
10.4.1 Automatic mode, batch bottling __________________________________________________ 39
10.4.2 Automatic mode, continuous bottling ______________________________________________ 40
10.4.3 Manual mode _________________________________________________________________ 41
11 Commissioning _______________________________________________________________________ 42
11.1 Workstation ______________________________________________________________________ 43
11.2 Filling and emptying________________________________________________________________ 43
11.3 Power supply _____________________________________________________________________ 44
11.4 Compressed air supply _____________________________________________________________ 44
11.5 Actuation with PLC EduTrainer and control console ______________________________________ 44
11.5.1 Cable connections between station and EduTrainer PLC _______________________________ 44
11.5.2 Cable connections between control console and PLC EduTrainer ________________________ 46
11.5.3 Establishing 1-bit communication connections ______________________________________ 46
11.5.4 Load sample project ____________________________________________________________ 49
11.5.5 Starting the sequence __________________________________________________________ 50
11.5.6 Operation on the control console with operator unit TP700 Comfort _____________________ 50

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11.6 Actuation with EasyPort 19 “_________________________________________________________ 55
11.7 Adjusting sensors _________________________________________________________________ 56
11.7.1 Capacitive proximity sensor ______________________________________________________ 56
11.7.2 Float switch, cover installation____________________________________________________ 57
11.7.3 Ultrasonic sensor ______________________________________________________________ 57
12 Maintenance and troubleshooting _______________________________________________________ 59
12.1 Maintenance______________________________________________________________________ 59
12.2 Error in the piping system and tanks __________________________________________________ 60
12.3 Error in the pneumatic system _______________________________________________________ 60
12.4 Error in the electrical system_________________________________________________________ 61
12.5 Mechanical faults__________________________________________________________________ 61
12.6 Error due to parameterization ________________________________________________________ 62
13 Further information and updates ________________________________________________________ 63
14 Disposal ____________________________________________________________________________ 63
15 List of figures ________________________________________________________________________ 64

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1General requirements for operating the devices
General requirements for safe operation of the devices:
•National regulations for operating electrical systems and equipment must be observed in commercial
facilities.
•The laboratory or classroom must be overseen by a supervisor.
–A supervisor is a qualified electrician or a person who has been trained in electrical engineering,
knows the respective safety requirements and safety regulations and whose training has been
documented accordingly.
The laboratory or the classroom must be equipped with the following devices:
•An emergency-off device must be provided.
–At least one emergency-off device must be located within, and one outside of the laboratory or the
classroom.
•The laboratory or classroom must be secured so that operating voltage and compressed air supply
cannot be activated by any unauthorized persons, for example with:
–A key switch
–Lockable on-off valves
•The laboratory or classroom must be protected by residual current devices (RCDs).
–Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices.
–Type B residual current circuit breakers with a residual current of ≤ 30 mA must be used.
•The laboratory or classroom must be protected by overcurrent protection devices.
–Fuses or circuit breakers
•No damaged or defective devices may be used.
–Damaged devices must be banned from further use and removed from the laboratory or classroom.
–Damaged connecting cables, pneumatic tubing and hydraulic hoses represent a safety risk and
must be removed from the laboratory or classroom.

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2Pictograms
This document and the hardware described in it include warnings concerning possible hazards which may
arise if the system is used incorrectly. The following pictograms are used:
DANGER
... indicates an
imminently hazardous situation that will result in fatal or severe personal
injury if not avoided.
Danger of crushing
.
Never reach into the system
while in operation.
WARNING
… indicates a
potentially hazardous situation which may result in fatal or severe personal
injury if not avoided.
Strong optical radiat
ion.
N
on-observance may result in severe personal injury.
CAUTION
... indicates a
possibly
hazardous situation which may result in moderate or slight personal
injury if not avoided.
Hot
surfaces.
Non
-observance may result in burns.

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General information about a hazard
Switch off the device and unplug the power supply connection before assembly,
repair, maintenance, and cleaning.
Observe the user documentation, in particular all safety instructions. Non-
observance may result in severe personal injury or damage to property.
Electric shock
Laser beam
Strong optical radiation
Hot surfaces
Danger of crushing
Infeed by rotating rollers
Loud noises
Lifting heavy loads
Warnung vor ungewolltem Einzug

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3Intended use
Festo Didactic systems and components must only be used:
•For their intended use in teaching and training applications
•When their safety functions are in perfect condition
Festo Didactic systems and components are designed in accordance with the latest technology and
recognized safety rules. However, life and limb of the user and third parties may be endangered and the
components may be impaired if they are used incorrectly.
The Festo Didactic learning system has been developed and produced exclusively for education and training
in the field of automation technology. The training company and/or trainers must ensure that all apprentices
observe the safety precautions described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the device in situations that serve any purpose other
than training and/or vocational education, unless such damage has been caused by Festo Didactic due to
malicious intent or gross negligence.

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4For your safety
4.1 Important information
Knowledge of the basic safety instructions and safety regulations is a fundamental prerequisite for safe
handling and trouble-free operation of Festo Didactic components and systems. This manual includes the
most important instructions for safe use of Festo Didactic components and systems.
In particular, the safety instructions must be adhered to by all persons who work with Festo Didactic
components and systems. Furthermore, all pertinent accident prevention rules and regulations that are
applicable at the respective place of use must be adhered to.
4.2 Obligations of the operating company
The operator undertakes only to allow those persons to work with the Festo Didactic components and
systems who:
•Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of Festo Didactic components and systems.
•Have read and understood the chapter concerning safety and the warnings in this manual.
Personnel should be tested at regular intervals to ensure that they are safety-conscious in their work habits.
4.3 Obligations of the trainees
All persons who have been entrusted to work with Festo Didactic components and systems shall complete
the following steps before beginning work:
•Read the chapter about safety and warnings in this manual,
•Familiarize themselves with the basic regulations regarding occupational safety and accident prevention

For your safety Bottling Learning System
12 © Festo Didactic 696690
4.4 Dangers when handling the components and systems
Festo Didactic systems and components are designed in accordance with the latest technology and
recognized safety rules. However, life and limb of the user or third parties may be endangered and the
machine or other property may be damaged during their use.
Festo Didactic systems and components must only be used:
•for their intended purpose
•when in perfect working condition.
WARNING
Malfunctions which could impair safety must be
eliminated immediately!
CAUTION
Improper repairs or modifications may result in unfore
seeable operating states. Do not
carry out repairs
on the device.

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5Work and safety instructions
5.1 General remarks
•Trainees should work with the circuits only under the supervision of an instructor.
•Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices (RCDs).
•Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
•Malfunctions which might impair safety must not be generated when the device is operated for training
purposes.
•Wear your personal protective equipment (safety goggles, safety shoes) when working on the circuits.
5.2 Mechanical system
•Switch off the power supply.
– Switch off both the working power and control power before working on the circuit.
– Only reach into the setup when it is at a complete standstill.
– Be aware of potential overtravel times of actuators.
•Mount all of the components securely on the profile plate.
•Make sure limit switches are not operated from the front.
•Risk of injury during troubleshooting.
Use a tool to operate the limit switches, for example a screwdriver.
•Set all components up so that it’s easy to activate the switches and interrupters.
•Follow the instructions regarding positioning of the components.

Work and safety instructions Bottling Learning System
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5.3 Electrical system
•Risk of fatal injury in case of interrupted PE conductor!
– The protective conductor (yellow-green) must not be interrupted, either inside or
outside of the device.
– The insulation of the protective conductor must never be damaged or removed.
•Risk of death from series connection of power supply units!
Contact voltages of greater than 25 V AC or 60 V DC are not permissible.
Coming into contact with voltages of greater than 50 V AC or 120 V DC may be fatal.
– Do not connect voltage sources in series.
•Risk of death due to electric shock!
Protect the outputs of the power supply units (output sockets/terminals) and cables connected to them
from direct contact.
– Only use cables with adequate insulation and electric strength.
– Use safety sockets with fully shrouded contact points.
•Disconnect from all sources of electric power!
– Switch off the power supply before working on the circuit.
– Please note that electrical energy may be stored in individual components.
Information on this issue is available in the datasheets and operating instructions included
with the components.
–-Caution!
Capacitors inside the device may still be charged even after being
disconnected from all sources of voltage.
•Devices with a grounding terminal must always be grounded.
– If a ground connection (green/yellow laboratory socket) is available, it must always be connected
to protective ground. The protective grounding must always be connected first (before voltage) and
disconnected last (after voltage).
– Some devices have high leakage current. These devices must be additionally grounded with
a protective earth conductor.
•Use safety extra-low voltages only: max. 24 V DC.
•The power supply unit must be operated only with a power supply with a grounding conductor.
•Establishing and disconnecting electrical connections
– Electrical connections may be established only in the absence of voltage.
– Electrical connections may be disconnected only in the absence of voltage.

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•Maximum permissible current loads for cables and devices must not be exceeded.
– Always compare the current ratings of the device, the cable and the fuse to ensure that they match.
– In the event that these are not the same, use a separate upstream fuse in order to
provide appropriate overcurrent protection.
•Use only connecting cables with safety plugs for electrical connections.
•When laying connecting cables, make sure they are not kinked or pinched.
•Do not lay cables over hot surfaces.
– Hot surfaces are indicated by a corresponding warning symbol.
•Make sure that connecting cables are not subjected to continuous tensile loads.
•The device is not equipped with a built-in fuse unless otherwise specified in the technical data.
•Pull the plug only when disconnecting connecting cables; never pull the cable.
•Hazard-free operation of the device is no longer possible in the case of:
– Visible damage
– Malfunction
– Incorrect storage
– Incorrect transport.
– Switch off the power supply immediately.
– Protect the device against an inadvertent restart.
5.4 Pneumatics
•Depressurize the system.
–Switch off the compressed air supply before working on the circuit.
–Use pressure gauges to check whether the entire circuit is pressure-free.
–Please note that energy may be stored in reservoirs.
Information on this issue is available in the datasheets and operating instructions included
with the components.
•Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
•Do not switch on the compressed air until all the tubing connectors have been joined and secured.
•Do not disconnect tubing while under pressure.
•Do not attempt to seal or plug pneumatic tubing or plug connectors with your hands or fingers.
•Risk of injury when switching on compressed air!
Cylinders can advance and retract automatically.

Work and safety instructions Bottling Learning System
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•Risk of accident due to advancing cylinders.
– Always position pneumatic cylinders so that the piston rod’s working space is unobstructed over
the entire stroke range.
– Make sure that the piston rod cannot collide with any rigid components of the setup.
•Risk of accident due to pneumatic tubing slipping off!
– Use shortest possible barbed tubing connectors.
– If pneumatic tubing slips off:
Switch off the compressed air supply immediately.
•Pneumatic circuit setup:
Connect the devices with plastic tubing with an outside diameter of 4 or 6 mm. Push the pneumatic
tubing into the push-in connector as far as it will go.
•Switch off the compressed air supply before dismantling the circuit.
•Dismantling the pneumatic circuit
Press the blue release ring down so that the pneumatic tubing can be pulled out.
•Noise due to escaping compressed air
–Noise caused by escaping compressed air may damage your hearing. Reduce noise by using
pneumatic mufflers, or wear hearing protection if noise cannot be avoided.
–All of the exhaust ports of the components included in the equipment set are equipped with
mufflers. Do not remove these mufflers.
5.5 Process technology
Always fill the containers in a de-energized state!
Switch off the power supply 24 V DC and 230 V AC!
•Use tap water of drinking water quality (recommended) to ensure longer maintenance-free operation of
the stations (valves, pump, etc.).
•The maximum operating temperature of the containers of +65°C must not be exceeded.
•Only start up the heater when the heating element is completely immersed in the liquid.
•The maximum operating pressure for the liquid in the pipes must not exceed 0.5 bar.
•Do not allow the pump to run dry. The pump must not be used with seawater, contaminated liquids or
viscous media.
•Drain the liquid in the stations/system before making changes in the piping layout.
•The liquid in the station can be drained by opening the drain valves!
•No liquid should be left in the system for a long period of time, as bacteria such as Legionella can form
in it.

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6Technical data
6.1 General data
Parameter Value
Operating pressure (compressed air) 600 kPa (6 bar)
Max. operating pressure in piping (water) 50 kPa (0.5 bar)
Operating voltage 24 V DC, 4 A, ≤ 100 W output power, SELV/PELV limited
power supply (LPS)
Digital inputs/outputs
Inputs: 7
Outputs: 6
Analog inputs/outputs
Inputs: 1
Outputs: 1
Max. 24 V DC
Max. 0.5 A per output
Max. 4 A total
Signal range of the actuators Pump (0...24 V DC) Voltage 0...10 V
Working range of the level system 0...2.7 l
Measuring range of the level sensor 50…270 mm
Signal of the sensor of the level system Voltage 0...10 V
Electrical connection 24-pin IEEE-488 socket (SysLink)
15-pin ISO 4903 socket (D-sub)
Pneumatic connection Plastic tubing with 6 mm outside diameter
Compressed air consumption at 600 kPa (continuous cycle) ~1 l/min
Process connections Flexible piping system DN10 (∅a15mm)
Volumetric flow rate of the pump ~ 10 l/min
Volume of the dosing tank / Main tank max. 3 l / 10 l
Dimensions of the station 700 x 700 x 920 mm
Dimensions of the profile plate 700 x 700 x 32 mm
Weight 48 kg
Subject to change

Work and safety instructions Bottling Learning System
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6.2 Pin allocation table
6.2.1 Digital terminal
I/O Reference
designation
Designation Terminal SysLink
Pin
SysLink
Wire color
I0 -TF1 Switch point comparator, level reached, ultrasonic sensor BL1 Tank VE2 9 13 Gray-pink
I1 -BG2 Capacitive proximity switch, upper limit of the storage tank VE1 10 14 Red-blue
I2 -BG3 Capacitive proximity sensor, lower limit of the storage tank VE1 11 15 White-green
I3 -BG4 Diffuse light sensor, bottle at the beginning of the conveyor 12 16 Brown-green
I4 -BG5 Diffuse light sensor, bottle at the filling position 13 17 White-
yellow
I5 -BG6 Diffuse light sensor, bottle at the end of the conveyor 14 18 Brown-
yellow
I6 15 19 White-gray
I7 -KF10 Overflow alarm of the relay contact, collection error 16 20 Gray-brown
Q0 -MA1 Motor pump PL1 ON, conveying into the filling container 1 1 White
Q1 -MB2 Solenoid valve V403 OPEN, filling bottle 2 2 Brown
Q2 -MA31 / -
MA32
Conveyor motors ON, bottle transport forward 3 3 Green
Q3 -MB4 Activate the separator, separate the bottle 4 4 Yellow
Q4 -MA5 Motor PL2 pump ON, conveying to the next station 5 5 Gray
Q5 6 6 Pink
Q6 7 7 Blue
Q7 8 8 Red
24 V A 24 V power supply for outputs 24 VA 9+10 Black
24 V B 24 V power supply for inputs 24VB 21+22 White-pink
GND A 0 V power supply for outputs GND A 11 Brown-pink
GND A 0 V power supply for outputs GND A 12 Purple
GND B 0 V power supply for inputs GND B 23+24 White-blue
Note
Cable jumpers are connected from emergency off to bit 1.5 on all preferred PLC versions.

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6.2.2 Analog terminal
I/O Reference
designation
Designation Terminal D-sub
Pin
D-sub
Color
UE1 -BL1 Ultrasonic sensor, level 0-2.5 L, tank VE2 1 8 Red
UE2 2 7 Blue
UE3 3 15 White-
yellow
UE4 4 14 Brown-green
IE1 5 5 Gray
IE2 6 4 Yellow
IE3 7 13 White-gray
IE4 8 12 Red-blue
UA1 -MA1 Motor speed setting pump PL1, manipulated variable 0-100% 9 1 White
UA2 10 2 Brown
IA1 11 10 Gray-pink
IA2 12 9 Black
24 V B 24 V power supply for inputs VB
GND B 0 V power supply for inputs GB 6 Pink
24 V A 24 V power supply for outputs VA
GND A 0 V power supply for outputs GA 3 Green

Work and safety instructions Bottling Learning System
20 © Festo Didactic 696690
6.2.3 Control panel
I/O
Reference
designation
Designation Terminal SysLink
Pin
SysLink
Wire color
I0 -SF1 START button 13 Gray-pink
I1 -SF2 STOP button (NC contact) 14 Red-blue
I2 -SF3 AUTO/MAN key switch 15 White-green
I3 -SF4 RESET button 16 Brown-green
I4 I4 Communication input I4 17 White-
yellow
I5 I5 EMERGENCY STOP (NC contact) 18 Brown-
yellow
I6 I6 Communication input I6, successor station process ready 19 White-gray
I7 I7 Communication input I7, successor station ready for bottle 20 Gray-brown
Q0 -PF1 Indicator light START 1 White
Q1 -PF2 Indicator light RESET¶ 2 Brown
Q2 -PF3 Indicator light function Q1 3 Green
Q3 -PF4 Indicator light function Q2 4 Yellow
Q4 Q4 Communication output Q4, station ready for process 5 Gray
Q5 Q5 Communication output Q5, station ready for bottle 6 Pink
Q6 Q6 Communication output Q6 7 Blue
Q7 Q7 Communication output Q7 8 Red
24 V A 24 V power supply for outputs 9+10 Black
24 V B 24 V power supply for inputs 21+22 White-pink
GND A 0 V power supply for outputs 11 Brown-pink
GND A 0 V power supply for outputs 12 Purple
GND B 0 V power supply for inputs 23+24 White-blue
Note
Communication input I5 is used as an EMERGENCY-STOP signal input in PLC EduTrainers.
The inputs and outputs of the control panel are located on the second byte of the EduTrainer.