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Design and function

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© Festo Didactic • MPS

®

PA Compact Workstation

The increasing fluid level into the upper tank B102 is monitored at a certain
minimum level by float switch S112 (1). If the mounting position is changed the
switch can also indicate the decreasing level.

1

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.

Threshold function

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Summary of Contents for MPS PA Compact

Page 1: ...MPS PA Compact Workstation EN 12 08 Process automation MPS PA Compact Workstation Manual ...

Page 2: ...mage 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 Pro...

Page 3: ...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 _____________________________...

Page 4: ...___69 7 Appendix _________________________________________________________71 Designation of equipment _____________________________________________71 Parts lists___________________________________________________________71 Process flowsheets___________________________________________________71 EMCS block diagrams_________________________________________________71 EMCS _____________________________...

Page 5: ...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 ...

Page 6: ...ology 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 e...

Page 7: ...S 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...

Page 8: ...en 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 Workst...

Page 9: ...ifications 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 trainin...

Page 10: ...Introduction 10 Festo Didactic MPS PA Compact Workstation ...

Page 11: ...e 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...

Page 12: ...d 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 f...

Page 13: ...eating 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 ...

Page 14: ...Technical data 14 Festo Didactic MPS PA Compact Workstation ...

Page 15: ...ge 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...

Page 16: ...Transport Unpacking Scope of delivery 16 Festo Didactic MPS PA Compact Workstation ...

Page 17: ... 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 ...

Page 18: ...s 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 p...

Page 19: ...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 ...

Page 20: ...ximity 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 in...

Page 21: ...hich activate a reed contact 1 Level monitoring with float switch for overflow savety S111 The binary 24 V input signals no is connected to the I O terminal XMA1 The signal of the overflow switch should activate a alarm function in the PLC program and has effect on ball valve V102 and pump P101 If changed electrically the overflow switch also can be used to turn off the pump or valve with a relay ...

Page 22: ...at switch S112 1 If the mounting position is changed the switch can also indicate the decreasing level 1 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 Threshold function ...

Page 23: ...tinuing heating if filling level undershoots the critical point The heating must be sourrounded completely by the fluid 1 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 Switch on protection for heating ...

Page 24: ... piping system to from the pump should be filled with fluid The pump is driven by the motor controller A4 and relay K1 With a digital output O2 at XMA1 it is possible to switch from digital binary control to analog control variable from 0 to 24 V At digital binary control O2 0 the pump is turn on off with a additional output O3 at XMA1 At analog control O2 1 the drive voltage from analog output si...

Page 25: ...he flow through the valve 1 Controlling element proportional valve V106 The control electronic of the proportional valve is activated with a binary output O4 at XMA1 A analog signal from channel 1 UA2 at X2 is driving the signal input of the proportional valve with a standard analog signal from 0 to 10 V The standard analog signal is transformed into a pulse width modulation PWM and the opening of...

Page 26: ...it unless the heating element is fully immersed in fluid Critical temperature at the heat element at temperature around 50 60 C the heating is internal automatically switched off If the temperature value drops below 45 C the heating is switched on again Critical temperature at the micro controller of the heating at a semiconductor temperature of around 90 C the heating is internal automatically sw...

Page 27: ...ating as a continous output element a pulse width modulation PWM is used The control is clocking the ON and OFF time of the heating The time periode T is constant e g 10s By changing the ON time t1 of the heating the thermal power Q is manipulated Is the ON time raised also the thermal power is PWM with a puls widht ration of 75 Q t t2 t1 T PWM with a puls widht ration of 50 t1 OFF time t2 ON time...

Page 28: ...pper tank B102 into the lower tank B101 is controlled with the ball valve of the rotary drive 5 4 3 2 1 2 way ball valve V102 with pneumatical rotary drive 1 brass ball valve 2 solenoid 3 5 2 way valve with port pattern to NAMUR 4 rotary drive type SYPAR scotch yoke principle 5 sensor box The end position sensing attachment 5 consists of two electrical micro switches with roller lever The two bina...

Page 29: ... controlled system is to regulate the filling level of a fluid in a reservoir tank The controlled filling level system can be used as an I or PT1 controlled system 2 1 Controlled level system upper container B102 with ultrasonic sensor B101 measuring point LIC B102 4 6 Level control function ...

Page 30: ... characteristic curve of the ultrasonic sensor please see data sheet The fluid quantity of the pump P101 can be a binary or manipulated value For controlling system a two position or a continuous element can be used see also EMCS block diagrams For disturbance is it possible to partly or totally open close the ball valve V102 to drain the upper into the lower tank or open close hand valve V104 The...

Page 31: ...ic vane sensor B102 2 in the form of an actual value The actual value should be kept on a certain flow rate also if disturbances or set point changes occur For controlling system a continuous element can be used see also EMCS block diagrams There are two operation modes flow rate control by the means of the pump P101 as controlled system Manipulated value is the voltage of the pump which sets the ...

Page 32: ... I O terminal XMA1 I0 Please see the manual of the PLC for maximum input frequency of binary inputs The signal level is depending on the applied supply voltage 8 24 V The pulse signal can be processed with a PLC with integrated counter inputs The frequency signal is connected to the measuring transformer A2 too The transformer changes the frequency signal into a standard voltage signal 0 10 V The ...

Page 33: ...pressure tank is detected by means of a piezoresistive relative pressure sensor in the form of an actual value The actual value should be kept on a certain pressure also if disturbances or set point changes occur As controlling system a continuous element can be used see also EMCS block diagrams During control a pressure is build up and controlled from liquid to gaseous medium in the pressure cont...

Page 34: ...led system 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 V109 The standard voltage signal is also connected to the analog terminal X2 UE3 Additionally the tank pressure can be read with a pressure gauge To empty the p...

Page 35: ...f time delay 2 1 Controlled temperature system reactor container B101 with temperatur sensor B104 measuring point TIC B104 The water in the reactor container B101 of the heat exchanger E104 is heated by means of a heating element and is recirculated by means of the pump P101 A PT100 sensor B104 2 is used for measuring the system temperature at measuring point TIC B104 in the form of an actual valu...

Page 36: ... controlling system a two point element can be used see also EMCS block diagrams For disturbance is it possible to use cold fluid or f g ice cubes or mix with water from the upper tank The resistance of the temperature sensor is connected to the measuring transformer A3 The transformer changes the resistance into a standard voltage signal 0 to 10 V The standard voltage signal is connected to the a...

Page 37: ... manipulated variable y of pump and proportional valve 4 Relay K1 Control of the pump If K1 is active the pump can be controlled with a continous manipulation voltage of 0 10V 5 Power relay K106 activating power electronic fort he proportional valve 6 Motor controller binary and analogue control of the pump 7 Measuring transducer I U signal of the ultrasonic sensor for level measurement will be co...

Page 38: ...45 x 240 x 170 mm e g EduTrainer SIMATIC S7 1 small EduTrainer H x B X T 85 x 240 x 170 mm e g control panel 2 1 Mounting frame The 19 control panel is suitable for following operation or indication units 19 power supply 24 V DC 4 5A 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 1...

Page 39: ...g to the rules of operation Prepare work station Visual check Loading the PLC program Connect cables Conenct pneumatic lines Commissioing Choose setpoint Run closed loop Conenct voltage supply Fill tank Choose controlled system Deaerate pipe system Start controller Flow chart for commissioning the MPS PA Compact Workstation 5 Commissioning ...

Page 40: ...ed and adjusted MPS PA Compact Workstation A control console A PLC board or controller device A power supply unit 24 V DC 4 5 A A compressed air supply of 6 bar 600 kPA approx suction capacity of 50 l min A PC with installed PLC programming software A visual check must be carried out before each commissioning Prior to starting up the station you will need to check The electrical connections The co...

Page 41: ...ation connect the Syslink plug of the simbox with the XMA1 socket of the I O terminal 2 of the station with a SysLink cable 3 Simulation box D A station connect the analog plug of the simbox with the X2 socket of the analog terminal 4 of the station with analog cable 5 Simulation box D A power supply unit connect 4 mm safety plugs red and blue of the simbox and power supply unit with 4 mm safety p...

Page 42: ...PA Compact Workstation Simulationbox 1 SimBox digital analog 2 I O terminal SysLink 3 SysLink cabel I O data cabel with SysLink 20 pin black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 pin cross over red endings 6 24 V DC power supply 7 Connector cable 24 V DC for simbox power supply Key ...

Page 43: ...Digital I O of the Easyport with the XMA1 socket of the I O terminal 2 of the station with a SysLink cable 3 Easyport station connect the analog plug Analog I O of the Easyport with the X2 socket of the analog terminal 4 of the station with analog cable 5 Easyport PLC Connect your PC to the Easyport by means of a USB data cable Easyport power supply unit connect 4 mm safety plugs red and blue of t...

Page 44: ... Compact Workstation Simulationbox 1 Easyport USB 2 I O terminal SysLink 3 SysLink cabel I O data cabel with SysLink 20 pol black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 polig parallel Order No 529141 6 24 V DC power supply 7 universal cable set with 4 mm safety plugs red blue 8 USB cable Key ...

Page 45: ...th the XMA1 socket of the I O terminal 2 of the station with a SysLink cable 3 PLC controller station connect the analog plug 1 C of the PLC controller with the X2 socket of the analog terminal 4 of the station with analog cable 5 PLC controller control panel connect the XMA plug 1 C with the XMA plug of the control panel PLC controller power supply unit connect 4 mm safety plugs red and blue of t...

Page 46: ...pact with S7 300 CPU 313C 314C 2DP 2 I O terminal SysLink 3 SysLink cabel I O data cabel with SysLink 20 pin black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 pin parallel Order No 529141 6 24 V DC power supply 7 universal cable set with 4 mm safety plugs red blue 8 Control panel optional Connector Syslink cable on the right side of the control panel from the backside Key ...

Page 47: ...plug 1 A of the Edutrainer with the XMA1 socket of the I O terminal 2 of the station with a SysLink cable 3 PLC controller station connect the analog plug 1 B of the PLC controller with the X2 socket of the analog terminal 4 of the station with analog cable 5 PLC controller power supply unit connect 4 mm safety plugs red and blue of the PLC controller and power supply unit with 4 mm safety plugs c...

Page 48: ...ons MPS PA Compact Workstation Logo Edutrainer 1 Logo EduTrainer 2 I O terminal SysLink 3 SysLink cabel I O data cabel with SysLink 20 pin black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 pin parallel 6 24 V DC power supply 7 universal cable set with 4 mm safety plugs red blue Key ...

Page 49: ...t of the I O terminal 2 of the station with a SysLink cable 3 CPX FEC station connect the analog plug of the PLC controller with the X2 socket of the analog terminal 4 of the station with the analog cable 5 CPX FEC power supply unit connect 4 mm safety plugs red blue and yellow of the PLC controller to power supply unit with 4 mm safety plugs cable red blue yellow ground CPX FEC PLC Connect your P...

Page 50: ... of the touch display to power supply unit with 4 mm safety plugs cable red blue yellow ground CPX FEC touch display connect TCP IP terminal of touch display 8 back side to TCP IP terminal of CPX FEC terminal 1 with crossover ethernet cable 9 The CPX FEC EduTrainer is likely to be used with a touch display FED500 or visualization with InTouch or VipWin Notice ...

Page 51: ...T 1 EduTrainer Festo CPX FEC IT 2 I O terminal SysLink 3 SysLink cabel I O data cabel with SysLink 20 pol black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 polig crossover red endings Order No 533039 6 24 V DC power supply 7 universal cable set with 4 mm safety plugs red blue 8 Touch display FED 500 9 Ethernet cable 2m crossover Key ...

Page 52: ...connect the XMA plug 1 A of the PLC controller with the XMA1 socket of the I O terminal 2 of the station with a SysLink cable 3 PLC controller control console connect the XMG plug 1 B of the PLC controller with the X1 socket 4 of the control console if available with with the corresponding data cable PLC controller station connect the analog plug 1 C of the PLC controller with the X2 socket of the...

Page 53: ... I O data cabel with SysLink 20 pol black endings Order No 167197 4 Analog terminal 5 Analog cabel 15 polig crossover red endings Order No 533039 6 24 V DC power supply 7 universal cable set with 4 mm safety plugs red blue 8 Touch panel Panel view 9 Computer for programming 10 Communication cable to controller see next page 11 Communication cable to Panel view see next page 12 Communication cable ...

Page 54: ...able connection between HMI PanelView Plus 600 and PLC Micrologix 1500 1 DH 485 Communication Cable 1761 CBL AS03 3 m from 1761 NET AIC to PanelView Plus 600 2 DH 485 Communication Cable 1761 CBL AM00 45 cm from 1761 NET AIC to Micrologix 1500 3 RS 232 Communication Cable 1747 CP3 3 m from 1761 NET AIC to Programming PC ...

Page 55: ... Observe technical data Connect the compressed air supply to the service unit Set the service unit at 6 bar 600 kPa The stations are supplied with 24 V DC voltage max 5 A via a power supply unit Connect the 230 VAC shock proof plug of the power supply with the main cable to the main power supply The voltage supply of the complete station is provided via the PLC or controller Heating element Connec...

Page 56: ...the attachment of the mounting bracket are assembled The electrical connection of the capacitive proximity sensor is established The power pack is switched on Procedure 1 Mount the proximity sensors onto the mounting bracket so that they do not touch the tank each at a distance of 5 mm from the tank 2 Fill the tank with liquid 3 The proximity sensors are set at the following values 2 l bottom 6 l ...

Page 57: ...e power pack is switched on Procedure 1 The float switch is to be fed from the inside of the tank through the opening in the tank cover an d the screw tightened externally 2 Connect the float switch The switch must emit a signal without any liquid 3 Fill the tank and establish whether the float switch interrupts the signal if the maximum liquid level is exceeded The float must turn upwards 4 Check...

Page 58: ...on to the fill level Note The ultrasonic sensor can be used both for rising liquid levels and falling levels Prerequisites The tank is assembled The electrical connection of the acoustic sensor is established The sensor is screwed into the tank cover such that the LED is not illuminated if the container is empty The power pack is switched on Procedure The LED must be illuminated even if the level ...

Page 59: ... at controlled level system the ultrasonic sensor is used with a signal range of 4 to 20 mA This signal is converted into a standard voltage signal of 0 to 10 V Therefore the signal input at the controlling system has to be configured Configuration of the PLC or closed loop controller is depening on the used device For the Compact Sytem following control types can be used PLC e g Simatic S7 300 CP...

Page 60: ...element Off controlling element Off Heating element E104 Off Off Off Off Off switched controll element Hand valve V101 open closed closed closed closed closed Ball valve V102 open closed closed closed closed closed closed Hand valve V103 closed closed closed open closed open Hand valve V104 closed open closed closed closed closed Drainage valve V105 closed closed closed closed closed closed Hand v...

Page 61: ...used Binary outputs XMA1 M102 O 0 Q 0 Open 2 way ball valve V102 E104 O 1 Q 1 Switch ON heating tank 101 K1 O 2 Q 2 Relay select pump 0 binary 1 analogue M1 O 3 Q 3 Switch ON pump P101 binary M106 O 4 Q 4 Switch ON proportional valve V106 O 5 Q 5 Not used O 6 Q 6 Not used O 7 Q 7 Not used Analogue inputs X2 LIC B101 UE1 AI 0 Process value PV level in tank B102 FIC B102 UE2 AI 1 Process value PV fl...

Page 62: ...nit 2 Switch on the compressed air supply 3 Release the EMERGENCY STOP switch if available 4 Overall reset PLC memory delet online MMC 5 CPU switch in STOP position 6 Start the PLC programming software 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 P...

Page 63: ...TL RS232 1 Switch on the power pack 2 Switch on compressed air supply 3 Release EMERGENCY STOP pushbutton if available 4 Wait until the PLC has completed its test routine 5 Start the programming software 6 De archive the file e g CWSLevel_FST41_CPX_FEC_V4_FED zip in the directory Sources PLC FEC of the CD ROM provided Screen shot shows an example 7 Compile the project 8 Download the project to the...

Page 64: ...ait until the PLC has completed its test routines CPU ML 1500 Set the selector switch to REM i e PROG Start the programming software Select Comms System Comms highlight controller and click onto Online Once the connection is set up go to the menu Comms and select Clear Processor Memory then confirm with OK If the COMM 0 LED is goes out the memory of the PLC is reset and is ready for the programs t...

Page 65: ...n off compressed air supply 5 Fill the lower tank B101 up to a water level of 10 l in quality of drinking water Fill up lower tank B101 with water until the upper capacitive sensor B114 is activated Float switch S111 for overflow safety function must not be activated 6 Clear of water spray 7 Switch on power supply 24 VDC 8 Switch on pump P101 and pump water to the upper tank B102 Therefore open ha...

Page 66: ... executed when the push button has been actuated 17 It program is started operation mode logic control is running and indicated with light Q1 18 The pump P101 delivers process fluid from the lower storage tank B101 into the upper reservoir tank B102 As soon as the level rise up to the float switch B112 is activated the PLC is changing operation mode from logic control to close loop control Light Q...

Page 67: ...rompted by the illuminated RESET pushbutton and executed when the pushbutton has been pressed During RESET sequence fluid is drained from upper tank B102 to lower tank B101 therefore ball valve V102 is opened until normal position is reached Setpoint and control parameter can be choosen at Step7 Online table Closed Loop Parameter or at SCADA system If the setpoint choosen is to high the water leve...

Page 68: ...Commissioning 68 Festo Didactic MPS PA Compact Workstation ...

Page 69: ... of the proximity sensor The entire station Do not use aggressive or abrasive cleaning agents Always use water in quality of drinking water If the MPS PA Compact Workstation is not used for a longer period of time all water should be drained from the system It is recommended to clean of remaining water from the piping system and from tanks by using a vaccum cleaner for fluids Also wipe dry with a ...

Page 70: ...Maintenance 70 Festo Didactic MPS PA Compact Workstation ...

Page 71: ...rtional valve as controlled system and with a analog standard signal Two point control of a temperature 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 with a analog standard signal Continuous control of a flow rate control system with a prop...

Page 72: ... EduTrainer Compact Siemens S7 313C CPX FEC Allen Bradley DR19 MPS PA Compact Workstation electropneumatic S7 Symbols table S7 Overview S7 Sequential function chart S7 Function block diagram Collection of PCS data sheets Electrical circuit diagrams Electropneumatic circuit diagrams Program listings Data sheets ...

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