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!

Festo Didactic Solution Center

17.08.2005

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The concept
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.

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Important objectives
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

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 to
parameterise a fieldbus, e.g. PROFIBUS.

control systems.
To develop, adapt and parameterise
PLC programs.
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Multfaceted learning situation

Does getting into the subject of closed-loop
control really require an extensive knowledge
of mathematics?
We say NO !
We believe that practice-oriented
qualification 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 closedloop control!
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Control technology
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.

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Float switch in the container lid

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 the
pump by means of a relay circuit
The switching solenoid is located
in a transparent float housing, where
it is easily visible.

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Float switch housing for lateral installation

Depending on assembly position, the
float switch can be used either to switch
the increasing or decreasing
water level.
The binary 24 V signal is wired to the
I/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.

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Capacitive level sensors see through the container wall

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.

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One system two analog manipulated variables 1#2

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.

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One system two analogue variables 2#2

The directly actuated proportional 2/2-way valve
enables 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
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Closed-loop control technology

This compact system combines 4 controlled
systems, 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

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Controlled level system

The pump delivers a fluid from a storage
container 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

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Controlled flow system

The pump delivers a fluid from the
reservoir 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 easily
controllable system.
Flow sensor with frequency signal
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Pressure control
Via a piping system, the pump delivers a fluid
from 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

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Controlled temperature system

The water in the reactor vessel of the heat
exchanger 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 100

temperature sensor
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Pneumatics in conjunction with extrusion processes

Meaning and application areas for

pneumatic 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
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Electrical interfaces for customized control!

Industrial controller,
Siemens Sipart DR9

PLC control,
e.g. Siemens S7
PC activation using Festo
EasyPort, digital/analog
I/O SysLink terminal block
like Festo MPS
Commissioning/testing
using the Festo simulation
box
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Wiring board with measuring transducer

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

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Cabinet frame for DIN A4 and ER units

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.

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General technical data

Size wxdxh 700 x 700 x 935 mm
D + 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

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Your contact persons for further

information:
Festo Didactic Solution Center
Nael Abu-Sinni: nas@festo.com
Phone:+4971134671424
Fax: +49711347541424

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