Festo MPS PA Compact Manual
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Festo MPS PA Compact Manual

Festo MPS PA Compact Manual

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

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Summary of Contents for Festo MPS PA Compact

  • Page 1 Process automation ® PA Compact Workstation Manual ® PA Compact Workstation 12/08...

  • Page 2: Intended Use

    / 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...

  • Page 3: Table Of Contents

    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 Pneumatic connection __________________________________________ 55...
  • Page 4 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...

  • Page 5: Introduction

    1 Introduction 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.

  • Page 6: Training Contents

    – 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 ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 7: Important Notes

    • 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. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 8: Risks Involved In Dealing With The Mps Pa Compact Workstation

    Workstation ® 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! ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 9: Warranty And Liability

    • 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.
  • Page 10 Introduction ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 11: Notes On Safety

    • 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). ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 12 • 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...

  • Page 13: Technical Data

    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 ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 14 Technical data ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 15: Transport / Unpacking / Scope Of Delivery

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

  • Page 17: Design And Function

    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 ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 18 • 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 ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 19 • 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. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 20: Level Monitoring

    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. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 21 V102 and pump P101. If changed electrically the overflow switch also can be used to turn off the pump or valve with a relay circuit or for signal indication to a emergency relay. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 22 Level monitoring with float switch for threshold function S112 The binary 24 V input signals (nc) is connected to the I/O-terminal XMA1. The cable of the switch has a plug connection for easy connect/disconnect on changing the mounting position. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 23 Float switch as switch-on protection for heating The cable of the switch has a plug connection and is connected directly to the heating and to the connecting cable for the I/O- connecting board. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 24: Pump

    0 (UA1 at X2) is setting the speed of the pump from 0 to 10 V. Please also see the data sheet of the pump for further savety instructions! ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 25: Proportional Valve

    The standard analog signal is transformed into a pulse-width modulation (PWM) and the opening of the valve is infinitely adjustable. The frequence of the PWM can be adapted for different valve types. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 26: Heating

    • Critical temperature at the micro controller of the heating: at a semiconductor temperature of around 90°C the heating is internal automatically switched off. If the temperature value drops below 85 °C the heating is switched on again. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 27 Is the ON-time raised, also the thermal power is. PWM with a puls-widht ration of 75% PWM with a puls-widht ration of 50% OFF-time ON-time time periode thermal power ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 28: Ball Valve With Pneumatic Rotary Drive

    The two binary 24 VDC signals (S115 and S116) are connected as inputs to the I/O-terminal XMA1. There is also a visual indication of the drive position for the operator. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 29: Level Control Function

    The controlled filling level system can be used as an I- or PT1 controlled system. Controlled level system – upper container B102 with ultrasonic sensor B101 (measuring point ‘LIC B102’) ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 30 A1, too. The transformer changes the analog current signal into a standard voltage signal (0…10 V). The standard voltage signal is also connected to the analog terminal X2 (UE1). ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 31: Flow Rate Control Function

    Manipulated value is the voltage of the valve coil, which sets the stroke of the valve piston. The pump P101 is running with a constant revolution speed. For disturbance is it possible to partly or totally open/close the hand valve V104. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 32 A2, too. The transformer changes the frequency signal into a standard voltage signal (0…10 V). The standard voltage signal is also connected to the analog terminal X2 (UE2). ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 33: Pressure Control Function

    P101 is running before using closed-loop control. It is recommended to setup the water level of the pressure tank at half level with V107 for a opmtimal work range during closed-loop control. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 34 P101 switched off. Please notice that the water level of the pressure container cannot drop below the level of the lower tank B101. Maybe it can be necessary to pump water from lower to upper tank B102. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 35: Temperature Control System

    A PT100 sensor B104 (2) is used for measuring the system temperature at measuring point ‘TIC B104’ in the form of an actual value. The actual value should be kept on a certain temperature also if disturbances or set point changes occur. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 36 The standard voltage signal is connected to the analog terminal X2 (UE4). The heating is controlled by a internal relay. With a digital ouput (O1 at XMA1) the relay can be switched on/off. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 37: I/O-Board

    0-10 V standard voltage signal. Staring current limiter: limits the maximum starting current of the motor controller to prevent voltage drops at the controller. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 38: Mouting Frame

    • 19“ control panel with 3 push buttons, 1 key switch and 4 indicator • 19“ Communication panels with 4 inputs and 4 outputs available at 4 mm safety sockets (only use with 19” control panel) • 19“ EMERGENCY STOP panel ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 39: Commissioning

    Conenct voltage supply Choose controlled system Loading the PLC program Fill tank Deaerate pipe system Start controller Choose setpoint Run closed-loop ® Flow chart for commissioning the MPS PA Compact Workstation ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 40: Workstation

    • The correct installation and condition of the compressed air connections • The mechanical components for visual defects (tears, loose connections etc.) Eliminate any damage detected prior to starting up the station! ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 41: Cable Connections

    (red = + / blue = — ). Notice By using the crossover analoge cable with the simulation box only the first two analog cannels (0 = Level; 1 = Flow) can be displayed. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 42 SysLink-cabel, I/O- data cabel with SysLink, 20 pin (black endings, Order No. 167197) Analog terminal Analog cabel, 15-pin, cross over (red endings) 24 V DC power supply Connector cable 24 V DC for simbox power supply ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 43: Easyport Digital/Analog And Mps ® Pa Compact Workstation

    • Easyport– power supply unit: connect 4 mm safety plugs (red and blue) of the simbox and power supply unit with 4 mm safety plugs cable (red = + / blue = —). ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 44 SysLink-cabel, I/O- data cabel with SysLink, 20 pol (black endings, Order No. 167197) Analog terminal Analog cabel, 15-polig, parallel (Order-No. 529141) 24 V DC power supply universal cable set with 4 mm safety plugs (red/blue) USB cable ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 45: Edutrainer Siemens S7-300 And Mps

    4 mm safety plugs cable (red = + / blue = — ). • PC /controller – PLC: Connect your PC to the PLC by means of a programming cable. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 46 Analog cabel, 15-pin, parallel (Order-No. 529141) 24 V DC power supply universal cable set with 4 mm safety plugs (red/blue) Control panel (optional) Connector Syslink-cable on the right side of the control panel from the backside ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 47: Edutrainer Logo And Mps Pa Compact Workstation

    4 mm safety plugs cable (red = + / blue = — ). • PC /controller – PLC: Connect your PC to the PLC by means of a programming cable. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 48 SysLink-cabel, I/O- data cabel with SysLink, 20 pin (black endings, Order No. 167197) Analog terminal Analog cabel, 15-pin, parallel 24 V DC power supply universal cable set with 4 mm safety plugs (red/blue) ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 49: Edutrainer Festo Cpx-Fec It And Mps Pa Compact Workstation

    PA Compact Workstation EduTrainer CPX-FEC and Touchpanel FED500 in mounting frame All cable connections are described as an example for a EduTrainer Festo CPX-FEC IT with the Compact Workstation. • CPX-FEC – station: connect the XMA plug of the PLC /controller with the XMA1 socket of the I/O terminal (2) of the station with a SysLink cable (3).
  • Page 50 TCP/IP terminal of CPX-FEC terminal (1) with crossover ethernet cable (9). Notice The CPX-FEC EduTrainer is likely to be used with a touch display (FED500) or visualization with InTouch or VipWin. ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 51 Commissioning Cable connections MPS® PA Compact Workstation – EduTrainer Festo CPX-FEC IT EduTrainer Festo CPX-FEC IT I/O terminal SysLink SysLink-cabel, I/O- data cabel with SysLink, 20 pol (black endings, Order No. 167197) Analog terminal Analog cabel, 15-polig, crossover (red endings, Order No. 533039)

  • Page 52: Edutrainer Allen Bradley And Mps Pa Compact Workstation

    X2 socket of the analog terminal (6) of the station with a analog cable (7). • PC /controller – PLC: Connect your PC to the PLC by means of an serial data cable (9). ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 53 4 mm safety plugs (red/blue) Touch panel, Panel view Computer for programming Communication cable to controller (see next page) Communication cable to Panel view (see next page) Communication cable to PC (see next page) ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 54 1761-NET-AIC to PanelView Plus 600 DH 485 Communication Cable 1761-CBL-AM00 ( 45 cm ) from 1761-NET-AIC to Micrologix 1500 RS 232 Communication Cable 1747-CP3 ( 3 m ) from 1761-NET-AIC to Programming PC ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 55: Pneumatic Connection

    • The voltage supply of the complete station is provided via the PLC or controller. • Heating element: Connect the 230 VAC shock proof plug of the power supply with the main cable to the fast circuit breakter with main power supply. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 56: Adjusting Sensors

    The proximity sensors must be triggered by the liquid in the tank. If there is no liquid in the tank, there must be no signal available. 4. Check the positioning and setting of the proximity sensor by repeatedly filling and emptying the tank. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 57: Float Switch S111/S112/S117

    The float must turn upwards 4. Check the positioning and setting of the sensor by repeated filling and emptying. Note Make sure that the flow always moves freely and is not stuck due to dirt. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 58: Ultrasonic Sensor B101

    The LED must be illuminated even if the level of liquid is minimal. The sensor must be re-adjusted via the securing nuts if this is not the case. Note Make sure that the emitter side of the sensor is always clean. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 59: Choosing Controlled System

    For the Compact Sytem following control types can be used: • PLC, e.g. Simatic S7-300 CPU 313C • industrial close-loop controller • EasyPort analog with educational software Fluid Lab  • Simulation box digital/analog ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 60 V109 Hand valve closed closed closed closed closed closed V110 Hand valve open/closed closed closed closed closed closed V112 Choosing controlled system of MPS® PA Compact Workstation ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 61: Allocation List Of Inputs And Outputs

    TIC B104 AI 3 Process value PV, temperature in tank B101 Analogue outputs (X2) P101 AQ 0 Manipulated output CO, pump P101 V106 AQ 1 Manip. output CO, proportional valve V106 ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 62: Loading The Plc Program

    7. Dearchive the file COMPACT_S7.zip in the directory Sources_Quellen\ Step7_PLC_Program\ of the CD-ROM supplied 8. Select the project for your PLC hardware and the s7-program “Level” and load it to the PLC 9. CPU switch in RUN position ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 63: Festo Fec-Cpx

    Commissioning 5.9.2 Festo FEC-CPX • Controller: Festo FEC CPX • Programming software: Festo FST Version 4.10 1. Connect the PC and controller using the programming cable TTL-RS232 1. Switch on the power pack 2. Switch on compressed air supply 3. Release EMERGENCY-STOP pushbutton (if available) 4.

  • Page 64: Allen Bradley Controller

    – If the COMM 0. LED is goes out, the memory of the PLC is reset and is ready for the programs to be downloaded. 5. Open the project file 061024_WORKSTATIO_1.RSS in the directory Sources\AllenBradley_PLC of the CD-ROM provided. 6. Download the project to the controller. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 65: Filling And Deaeration

    11. Switch of pump P101 (or STOP program) 12. There will be loss of water in the piping system visible in the lower tank after deaeration. Refill lower tank and compensate the water (as described in 5.). ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 66: Start Sequence S7 Programm "Level

    19. The program is stopped automatically if the water level in the lower storage tank is lower than the limit switch B113 (deactivated). By pressing STOP pushbutton the ball valve V102 is closed and the pump P101 switched off. The sequence program is stopped. ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 67: Notice

    Loop Parameter“ or at SCADA system. If the setpoint choosen is to high the water level in the lower tank is dropped below limit switch B113 and the sequence is automatically stopped. Reset system and choose a smaller setpoint! ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 68 Commissioning ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 69: Maintenance

    Also wipe dry with a soft fluff-free cloth. Please notice savety information of data sheets! ® © Festo Didactic • MPS PA Compact Workstation...
  • Page 70 Maintenance ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 71: Appendix

    • 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 ® © Festo Didactic • MPS PA Compact Workstation...

  • Page 72: Electrical Circuit Diagrams

    ® Electropneumatic circuit PA Compact Workstation , electropneumatic diagrams Program listings S7 Symbols table S7 Overview S7 Sequential function chart S7 Function block diagram Data sheets Collection of PCS data sheets ® © Festo Didactic • MPS PA Compact Workstation...

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