compact workstation 2005 en

7/24/2019 Compact Workstation 2005 En

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1 7.08 .20 05 Fo lie 1Festo Didactic Solution Center

Process Control Systems

The new training system for process control

Process Control Compact Workstation

All in a state of flux...Measuring, controlling, regulating

with PLC, PC or controllers of your choice!


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Process technology is not only

simple like basic principles of a water

treatment process or production of

food. It can be as highly complex as a

technical processes.No matter the complexity of process

technology to learn about the fundamentals

of open and closed-loop control technology

is always the first step.

This is why Process Control System

is an important part of our

Learning System for Automation.

The concept


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To assemble, tube and pipe up, wire and

commission pneumatic process drives.

To understand the concepts of process

engineering, such as shutting off, opening,

closing and regulating . . . To be able to read and create flow diagrams and

documentation.

To operate and monitor processes via PC.

To learn about fieldbus technology and how toparameterise a fieldbus, e.g. PROFIBUS.

To learn about and work on overall processes.

To design, tube up, wire, commission,

test, maintain and repair process

engineering systems.

To measure, control and regulate

electrical and process engineering

variables such as temperature, flow,

pressure and level.

To analyse control systems,

parameterise and optimise closed-loop

control systems.

To develop, adapt and parameterise

PLC programs.

Important objectives


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Does getting into the subject of closed-loop

control really require an extensive knowledge

of mathematics?

We say NO !

We believe that practice-orientedqualification is: Learning by doing

and understanding the effective

interrelationships within a control loop.

With the knowledge gained from the process,

you are able to conclude formulas or

calculation methods.

The system can be used for open and closed-

loop control!

Multfaceted learning situation


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In order to get the maximum benefit from your investment, we recommend that you use

the system right from start of vocational training. The system can be used e.g. to start with

electrical control technology and later for the fundamentals of programmable logic

controllers. Binary input and output signals can be used for this purpose .

A simple control task could for instance be as follows:

After the start button has been pressed, the pump is started and water pumped into the

upper container. The pump is switched off once the float switch is activated. Than the

return line into the lower container is opened by reversing the pneumatic process

actuator. The pneumatic process actuator closes if a signal is generated by the upper float

switch.

Control technology


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The binary 24 V signal is wired to the

I/O terminal (SysLink interface in the

form of an input

However, it could also be used as a

safety limit switch to switch off thepump by means of a relay circuit

The switching solenoid is located

in a transparent float housing, where

it is easily visible.

Float switch in the container lid


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Depending on assembly position, thefloat switch can be used either to switch

the increasing or decreasing

water level.

The binary 24 V signal is wired to theI/O terminal in the form of an input.

However, it could also be used in the

form of a safety signal to switch off the

pump via relay circuit.

The connecting cables are fitted with a

plug/socket to facilitate conversion

with a minimum of wiring complexity.

Float switch housing for lateral installation


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Two capacitive sensors at the rear of the

lower container may be used to

monitor the level of the water.

The sensor can be mechanically

adjusted on an aluminum profile.

One important objective is setting the

sensor correctly so that it detects the water

level through the container wall.

The binary 24 V signal is wired to

the I/O terminal in the form of an input.

Capacitive level sensors see through the container wall


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A centrifugal pump with an output of approx.10 l/min ensures continuous flow of water.

The voltage can be varied by means of the

motor controller and as such the speed of the

pump.

Input 0-10 VDC, Output 0-24 VDC.

Furthermore, the pump motor could also be

switched on or off by means of a relay

circuit via digital signal.

One system two analog manipulated variables 1#2


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17.08.2005 Folie 10Festo Didactic Solution Center

The directly actuated proportional 2/2-way valveenables the flow control of fluids.

It is suitable as a remotely adjustable control

element for open and closed-loop control.

The valve piston is lifted steplessly from its seat

as a function of the solenoid coil current.

An external standard signal is converted into a

PWM signal and the opening of the valve is

therefore infinitely adjustable. The frequency can

be harmonised between the PWM signal and the

valve in use.

Standard signals 0-10VDC, 0-20mA,4-20mA

One system two analogue variables 2#2


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This compact system combines 4 controlledsystems, which can be operated individually or

in cascaded form, depending on the technical

requirements.

Examples of closed-loop control functions:

2-point control for filling level

PI controller for the pressure

controlled system

I-controller for filling level PID controller for flow rate

Closed-loop control technology


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The pump delivers a fluid from a storagecontainer into the above situated

reservoir. The level in the reservoir is

detected by means of an analog ultrasonic

sensor.

The controlled filling level system can be

used as an I or PT1 controlled system.

Acoustic sensor 4-20 mA

Controlled level system


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The pump delivers a fluid from thereservoir via a piping system.

The flow rate is detected by means of an

optoelectronic vane sensor in the form of

an actual value.

The system used is a controlled system

with self-regulation (P-controlled

system); it does not have a time delay.

The control loop in combination with the

pump (PT1 behavior) creates an easilycontrollable system.

Flow sensor with frequency signal

Controlled flow system


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Via a piping system, the pump delivers a fluidfrom a reservoir into a gas-prefilled pressure

tank. The pressure of the gas (air) in the

pressure tank is detected by means of a

piezoresistive relative pressure sensor in the

form of an actual value.

Two variations of manipulated variables:

1. Pressure control via the pump speed

2. Pressure control via the proportional

directional control valve

Pressure sensor 0-10 V

Pressure control


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The water in the reactor vessel of the heatexchanger is heated by means of a heating element

is recirculated by means of the pump.

A PT100 sensor is used for temperature sensing.

The on/off switching period of the heating element,which is the manipulated variable, determines the

heat output of the heat exchanger.

The switching voltage is 24 VDC and the supply

voltage 230 VAC.

Heater, 1000 W insulated with PT 100temperature sensor

Controlled temperature system


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Meaning and application areas forpneumatic process actuators

Sizing, configuration and adjustment of

rotary actuators used as valve actuators

viewed from the perspective of a worst-case

scenario

Analysis of media flow, gas, fluids, bulk

material

Standards for valve actuators, ISO 5211,

DIN3337, VDI/VDE 3845 Namur

Explosion protection, basic terminology,

definition of hazardous zones

Rotary actuator SYPAR, Namur valve,ball valve, electrical signal box and

water as process medium

Pneumatics in conjunction with extrusion processes


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PLC control,

e.g. Siemens S7

Commissioning/testing

using the Festo simulation

box

PC activation using Festo

EasyPort, digital/analog

Industrial controller,Siemens Sipart DR9

I/O SysLink terminal block

like Festo MPS

Electrical interfaces for customized control


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Syslink I/O module

Analog 15pin Sub-D terminal block

Top-hat rail relay

Measuring transformers

Motor controller 0-10V > 0-24 V for

the pump motor

Mechanical adaptation via

ER-frame clips

Wiring board with measuring transducer


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This frame is adjustable so that both levels

can be equipped with ER-units.

Easy to reassemble from DIN A4 to ER.

The wiring board is easy to remove

and conveniently accessible.

Cabinet frame for DIN A4 and ER units


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Size wxdxh 700 x 700 x 935 mmD + approx. 100 mm for the PLC towards

the rear

Weight approx. 45 kg

Voltage supply 24 VDC, 2 A

Compressed air supply approx. 6 bar

General technical data


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Your contact persons for further

information:

Festo Didactic Solution Center

Nael Abu-Sinni: [email protected]

Phone:+4971134671424

Fax: +49711347541424

compact workstation 2005 en

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