Documente Academic
Documente Profesional
Documente Cultură
Workbook
548591 EN
12/06
Intended use
The Festo Didactic Learning System has been developed and produced solely for
vocational and further training purposes in the field of process automation and
technology. The company undertaking the training and/or the instructors is/are to
ensure that trainees observe the safety precautions specified in this workbook.
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.
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2007
Internet: www.festo-didactic.com
e-mail: did@de.festo.com
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2 © Festo Didactic GmbH & Co. KG • MPS PA
Contents
Preface ___________________________________________________________ 7
Introduction__________________________________________________________ 8
Safety and operating instructions ________________________________________ 9
Learning system for process automation _________________________________ 10
Training aims and project work _________________________________________ 12
Allocation of training aims and exercises _________________________________ 14
MPS® PA components _________________________________________________ 22
Allocation of components and exercises __________________________________ 27
Methodological training aid for the instructor______________________________ 31
Methodological structure of the exercises_________________________________ 32
Designation of equipment _____________________________________________ 33
Basic definition ______________________________________________________ 33
Electrical components_________________________________________________ 33
Pneumatic components _______________________________________________ 35
Process-engineering components _______________________________________ 36
CD-ROM contents ____________________________________________________ 40
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Contents
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Contents
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Contents
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Preface
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 modular production system for Process Automation
(MPS® PA) facilitate vocational and further training in line with industrial practice.
The hardware is comprised of didactically prepared industrial components.
The MPS® PA stations provide you with an appropriate system whereby the following
key qualifications can be taught in a practice-related form
• Social competence
• Technical competence
• Methodological competence
In addition to this, team work, willingness to cooperate and organisational skills can
also be practised.
Actual project phases can be taught in training projects which include:
• Planning
• Assembly
• Programming
• Commissioning
• Operation
• Optimisation of control parameters
• Maintenance
• Fault finding
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© Festo Didactic GmbH & Co. KG • MPS PA 7
Introduction
This workbook is a component part of the learning system for process automation
and technology of Festo Didactic GmbH & Co. KG. The system represents a sound
basis for practice-oriented vocational and further training and facilitates a quick and
practice-related introduction to the technologies such as measuring and open and
closed-loop control of process-related variables.
Practice-oriented First comes „learning by doing“ and understanding the effective relationships within
qualification a control loop. Based on this you will gain the necessary knowledge regarding
formulas and calculation.
The control loops and control functions of the MPS® PA stations replicate actual
processes:
Mixing, tempering, filtration and bottling as performed in industry.
The MPS® PA learning system meets the multifaceted training requirements in a wide
range of different branches of industry, e.g.:
Clear trend: Reducing process costs, improving system reliability, preventing component wear
From open to closed-loop and tear, e.g. process-optimised operation of pumps, evaluating diagnostic data,
control these are current topics which can be optimally pursued with the MPS® PA learning
system.
• Modular – suitable for use as individual stations or in combination in the form of
a complete system.
• Safe – learning and working in a safe environment.
• Flexible – convertible in the blink of eye for different control variants.
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8 © Festo Didactic GmbH & Co. KG • MPS PA
Safety and operating instructions
In the interest of your own safety you should follow the safety instructions in the
manuals of the MPS® PA stations.
General
• Trainees must only work on the MPS® PA stations under the supervision of an
instructor.
• Observe the data sheets referring to the individual components, in particular all
notes regarding safety!
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© Festo Didactic GmbH & Co. KG • MPS PA 9
Learning system for process automation
Training documentation
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10 © Festo Didactic GmbH & Co. KG • MPS PA
Learning system for process automation
Courses
Venues, dates and prices can be found in the current course planner.
Further training media is detailed in our catalogues and on the Internet. The learning
system for process automation is continually updated and expanded. The
transparency sets, films, CD-ROMs and DVDs as well as technical books are available
in several languages.
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© Festo Didactic GmbH & Co. KG • MPS PA 11
Training aims and project tasks
Training contents Training contents from the following areas can be carried out:
• Mechanics
– Mechanical construction of a station
• Process engineering
– Reading and preparation of flow diagrams and documentation
– Piping up of process engineering components
– System analysis
• Pneumatics
– Piping up of pneumatic components
• Electrotechnology
– Correct wiring of electrical components
• Sensor technology
– Correct use of sensors
– Measurement of non-electrical, process engineering and closed-loop control
variables
• Closed-loop control technology
– Fundamentals of closed-loop control technology
– Expansion of measuring chains into closed control loops
– Analysis of controlled systems
– Use of controllers
• PLC
– Programming and use of a PLC
– Structure of a PLC program
• Commissioning
– Commissioning of a process engineering system
– Commissioning of a control loop
• Fault finding
– Systematic fault finding on a process engineering system
– Inspecting, maintaining and servicing of process engineering systems
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12 © Festo Didactic GmbH & Co. KG • MPS PA
Training aims and project tasks
Topics for project tasks Project tasks covering the following topics can be carried out:
The tuition and training media is available in several languages and is designed both
for use in the classroom and self-tuition.
In terms of software, computer training programs and programming software are
available for programmable logic controllers.
A comprehensive range of courses covering the contents of the technology packages
completes the range of vocational and further training programmes.
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© Festo Didactic GmbH & Co. KG • MPS PA 13
Allocation of training aims and exercise
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MPS PA Filtration station
Exercises
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.3.1
1.3.2
1.3.3
Training aims
Functional description
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Contents
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Contents
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Exercises MPS• PA Filtration station
Training aims • To familiarise yourself with the design and mode of operation of the filtration
station.
• To be able to read and amend flow diagrams.
• To be able to read and amend pneumatic circuit diagrams.
• To familiarise yourself with the design and mode operation of a filter.
• To familiarise yourself with the design and mode of operation of a pump.
• To familiarise yourself with the design and mode of operation of a pressure
sensor.
• To familiarise yourself with the design and mode of operation of a process valve
• To familiarise yourself with the design and mode of operation of a limit switch.
• To be able to establish the allocation of the sensors and actuators of the station
and represent these in an allocation list.
• To be able to plot and analyse characteristic curves.
• To be able to create a program.
• To be able to determine the operating range and operating point of a controlled
system.
• To be able to identify a controlled system and determine the order of a system.
• To be able to configure a two-position controller and evaluate the control
response.
• To be able to configure continuous-action controllers (P, PI, PID) and evaluate the
control response.
• To be able to parameterise continuous-action controllers (P, PI, PID) according to
the Ziegler-Nichols tuning method.
Information The filtration station is to be used for the partial automation of a production process
in your company. In order to commission the station at a later stage, you are to
familiarise yourself with the functioning of the station and the most important
process components.
• For the analysis of the station you can use the digital/analogue simulation box;
digital/analogue EasyPort with FluidLab® PA or PLC with touch panel.
• You will find information regarding the station and process components in the
station manual, operating instructions and data sheets.
Project assignment 1. Answer the questions and solve the exercises regarding the fundamentals of the
training contents mentioned.
2. Analyse and amend the circuit diagrams.
3. Draw up the allocation list.
4. Determine the characteristics of the components and then evaluate the
components.
5. Create the logic program.
6. Check the circuit sequence.
7. Determine the operating point of the controlled system.
8. Identify the controlled system and determine the order of the system.
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Exercises MPS® PA Filtration station
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Exercises MPS® PA Filtration station
Name: Date:
Information The filtration station filters a liquid which is pumped through the filter from the
waste water tank via a gate valve. The filtered liquid reaches the pure water tank via
a butterfly valve. The filter can be back-flushed by means of a flushing program. To
remove deposits, controlled compressed air is additionally blasted through the filter
to remove any particles.
Planning You will find the necessary information in the manual of the MPS® PA filtration
station.
The component designations can be found in the electrical circuit diagram and in the
P&I diagram of the station.
Implementation – Determine and complete the designations of the process components in the
system photo below.
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Exercises MPS® PA Filtration station
Name: Date:
2
F101
3 Gate valve
4
V103
Evaluation You will find two different inscriptions for the gate valve in the electrical circuit
diagram or P&I diagram.
– Explain the difference.
Comprehension questions
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Exercises MPS® PA Filtration station
Name: Date:
Information The P&I diagram is a technical drawing used in process technology. It represents the
process steps in schematic form. The P&I diagram expresses the geometric course of
the piping and also represents the open and closed-loop control components
according to DIN 10628. Measured variables are also referred to as
EMCS points in accordance with DIN 19227-1 (EMSR points).
Planning You will find the necessary information in the manual of the MPS® PA filtration
station.
The designations and symbols of the components can be found in the workbook
introduction.
Implementation – Collect the information regarding the correct designation and symbols and
complete the P&I diagram for the filtration station.
P&I diagram
The designation of components in the P&I diagram enables you to analyse the
functioning of the system.
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Exercises MPS® PA Filtration station
Name: Date:
LS-
LA+
Digital pump
Evaluation – State the difference between the designations of the measuring points
LA+ and LS+?
Comprehension questions
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Exercises MPS® PA Filtration station
Name: Date:
Planning You will find the necessary information in the manual of the MPS® PA filtration
station.
The circuit diagrams, designations and symbols of components can be found in the
workbook introduction, the technical documentation of the MPS® PA station and in
FluidSIM® Pneumatics.
Implementation – Collect the information regarding the correct designation and symbols of
pneumatic components and complete the pneumatic circuit diagram for the
filtration station.
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Exercises MPS® PA Filtration station
Name: Date:
5/2-way valve
Comprehension questions
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Exercises MPS® PA Filtration station
Name: Date:
Information Different process components are used in the MPS® PA filtration station. The
technical data regarding the function of components within the station are of major
significance.
Planning You will find the necessary information in the manual of the MPS® PA Filtration
station.
The data sheets and circuit diagrams of process components can be found in the
technical documentation of the MPS® PA station.
Proportional-
Setpoint voltage [V] ______
pressure
Pressure range [bar] ______
regulator
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Exercises MPS® PA Filtration station
Name: Date:
Evaluation – Describe the design and function of the proportional pressure regulator.
Comprehension questions
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Exercises MPS® PA Filtration station
Name: Date:
Information In order to analyse the function of the MPS® PA filtration station, the station is to be
controlled by means of the digital/analogue simulation box; digital/analogue
EasyPort with FluidLab®-PA or PLC with touch panel. This enables you to allocate the
output and input signals. The allocation list forms the basis of programming a
process sequence of the station.
Planning You will find the necessary information in the manual of the MPS® PA filtration
station.
The data sheets and circuit diagrams of process components can be found in the
technical documentation of the MPS® PA station.
DI 1
DI 2
DI 4
DI 5
DI 6
DI 7
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Exercises MPS® PA Filtration station
Name: Date:
DO 0
DO 2
DO 3
DO 4
DO 5
DO 6
DO 7
Manipulated variable Y,
1CO1 AO 0
Proportional pressure regulator
Check Observe the status of all inputs and outputs and enter the result in the table.
Compare the input/output signal with the status displays on the digital/analogue
simulation box, digital/analogue EasyPort with FluidLab®-PA or PLC with touch
panel.
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Exercises MPS® PA Filtration station
Name: Date:
Evaluation – Describe the behaviour of the analogue final control element (proportional
pressure regulator) when actuated via analogue signal.
Comprehension questions
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