Qualification solutions for process automation

Qualification solutions 

for process automation

Process automation 

Professional, industry-focused qualification solutions 

for process automation 

MPS ® PA 

The new learning system for 

process automation 

Filtering, mixing, tempering and 

filling as in industry 

Networked system 

With 3 or 4 stations 

Measurement and control of level, 

flow rate, pressure and temperature 

Compact Workstation 

Measurement and control of level, 

flow rate, pressure and temperature 

2 Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com


Challenging – The process industry 

Few industries have as many facets 

or are as interesting as the process 

industry, which produces a wide 

range of products for the most diverse 

areas of daily life. 

On the one hand, the chemical industry 

produces preliminary products 

for other industries. This group includes 

base chemicals, petrochemicals, 

polymers as well as refined and 

special chemicals. Key consumers include 

the automotive, packaging and 

building industries. 

Even though the end products may 

differ, automation is making huge 

leaps forward in each of these areas. 

International competition and 

the resultant pressure to continually 

increase productivity as well as 

a continuously expanding range of 

variants and strict requirements for 

process and quality assurance demand 

automation solutions. 

On the other hand, chemical products 

are used in the areas of health, 

the environment and nutrition. As 

well as the chemical and pharmaceutical 

industry, the process industry 

includes other sectors such as the 

biotechnology, paper and food industries. 

www.festo-didactic.com 

3


Filtering, mixing, tempering and filling 

as in industry 

Modular 

The modularity of the learning system 

enables you to realise a diverse 

range of configurations for typical 

production processes from very different 

industries in a safe learning 

environment. 

Training for many areas of 

application and careers 

– Electronic engineers 

– Mechatronics engineers 

– Systems engineers 

– Microtechnologists 

– Process technicians for plastic and 

rubber technology, glass and coating 

technology 

– Experts in food, confectionery and 

fruit juice technology 

– Experts in water supply, sewage 

technology, pipe, canal and industrial 

services 

– Chemical engineers 

– Pharmaceutical engineers 

– Biotechnicians 

– Paper technicians 

– Systems engineers for sanitary, 

heating and air conditioning technology 

4 www.festo-didactic.com


Train efficiently 

Festo – The partner to the 

process industry 

Festo is fast becoming a key partner 

to the process industry. It is only 

logical that the process automation 

learning system benefits from this 

know-how and is tailored to the requirements 

of different industries 

through its consistent modularisation: 

– Water supply and disposal industry 

– Food industry 

– Bulk goods industry 

– Chemical and petrochemical industries 

– Biotechnology/pharmaceutical 

industries 

– Paper industry 

Why stop production to facilitate 

training 

It is prohibitively expensive to shut 

down an industrial system to facilitate 

training. Comprehensive training 

in the individual areas of process 

automation requires industry-oriented 

model systems or training installations. 

„Learning by doing“ and 

„process orientation“ are two principles 

that are central to the successful 

imparting of the many detailed 

training aims in process technology. 

Simulation of a process engineering 

system on a PC provides the opportunity 

of using a simulation as an actual 

training system. 

Worldwide at your fingertips. Find your contact person at: www.festo-didactic.com 

5


Understanding process automation – 

By means of seminars and workshops 

The goal of Festo Didactic is to 

offer further training that not 

only supports personnel in companies 

with current problems, 

but that also provides new approaches 

to future tasks. 

Festo is fast becoming a key 

partner to the process industry. 

Close coordination with our parent 

company, Festo AG & Co. 

KG., ensures the use of the most 

modern equipment and systems 

in our learning systems and a 

source of first-hand expertise for 

our trainers. 

However our focus and methodology 

also set us apart. Our 

trainers and consultants are 

practicians. They are familiar 

with the requirements of the 

participants attending their 

courses, including those requirements 

that go beyond the 

purely technical. 

We set ourselves a high standard. 

You will immediately notice 

the difference between our 

seminars and those offered by 

other providers. We provide new 

answers to old questions – answers 

that will help you to take 

that critical step in your operational 

projects. 

Open seminar on measurment and 

control fundamentals of control 

technology 

The participants will acquire basic 

knowledge and skills in the areas 

of electrical engineering as well as 

measurement and control technology. 

They will learn about the basic 

structure, mode of operation and 

application of process engineering 

systems and be able to use this 

equipment. The procedure for the 

identification of control systems, selection 

of a suitable controller and 

definition and setting of control parameters 

will also be explained. 

Target group 

The seminar is recommended for anyone 

seeking training in the fundamentals 

of control technology. 

Training aims 

– Project planning, standards, flow 

charts 

– Analysis of the sensors, actuators, 

components and control systems in 

a system 

– Measurement transformation of 

physical measurement variables 

– Analogue value processing with 

Siemens S7 

– Analysis, recording and evaluation 

of various control processes such 

as level, flow rate, pressure and 

temperature 

– Commissioning of a test system 

– Basic principles of control technology, 

P, I, PI and PID controllers in 

theory and practice 

– Definition: Y – W – Z – X – etc., amplification, 

rate time, reset time, 

dwell time, balance time, inactive 

time 

– Setting of the control parameters 

for different control processes 

– Practical utilisation of applications 

in the process industry: 

· use of an industrial controller as 

control equipment 

· use of a Siemens SPS (S7-300) as 

control equipment 

Specific customer training course 

Customer-specific training course for 

those employed in the areas of maintenance, 

servicing and operational 

support. 

The following training aims are conveyed 

to the participants using the 

professional training equipment of 

Festo Didactic through „learning by 

doing“: 

– Cross section of all controller types 

(P, I, D, PI, PD, PID) 

– Controller technologies (Fluid Lab ® - 

PA, industrial controllers and modern 

PLCs) 

Looking for something more 

Workshop offering more complex exercises 

on practical operational support 

and maintenance, for example: 

– Replacement and reuse of sensors 

and their incorporation into a control 

process 

– Error localisation through diagnosis 

of the controller characteristics 

– Control process with inactive time 

on request 

On request 

On request 



Fluid Lab ® -PA 

Fluid Lab ® -PA can be used to teach 

and demonstrate the fundamentals 

of control technology. The main components 

required for actuating the 

MPS ® PA stations using a PC are the 

„EasyPort D/A“ and the Fluid Lab ® - 

PA software. 

Fluid Lab ® -PA can be easily installed 

on any Microsoft Windows operating 

system. 

Key features 

Three main functions are integrated 

in Fluid Lab ® -PA in combination with 

the EasyPort D/A: 

Measurement 

For detection and evaluation of 

measured variables from 8 digital/ 

4 analogue input signals. 

Open-loop control 

For binary or continuous control of 8 

digital/2 analogue outputs. 

Closed-loop control 

For freely selectable closed-loop control 

functions such as 2-point, P, I, PI 

and PID. 

Actual process or simulation 

All exercises and experiments can be 

performed online on the actual process 

in conjunction with the station 

or offline using the pre-integrated 

simulation. 

„Settings“ menu item 

The following parameters can be 

set here for the four analogue input 

channels and the sensors connected 

to them: 

– Factor 

– Offset 

– Filter 

– Inversion 

The analogue and binary output signals 

can also be switched and the 

signal states of the inputs read off. 

General PC system settings can also 

be made here. 

„Process Sequence“ menu item 

The process sequence of each station 

can be easily started from Fluid 

Lab ® -PA. All of the process steps are 

visualised and can be monitored on 

the flow chart. 

„Measuring and Control“ menu item 

All the functions of the MPS ® PA 

station can be clearly and directly 

controlled. The states of the process 

valves, pumps and sensors are 

graphically recorded, which means 

they can be directly evaluated. The 

following functions are provided for 

recording the sensor characteristics 

and determining the step response: 

– Selection of measuring channels 

– Factor for physical scale 

– Adaptation of the time scale 

– Display of the input signals 

– Setting of output signals, switching 

on/off of the manipulated variable 

– Printing of the measured value display 

or saving as a .jpg file 

„Analysis“ menu item 

Analyses of a wide range of process 

components can be directly performed 

using predefined exercises, 

for example: 

– Recording of sensor characteristics 

– Recording of pump characteristics 

– Recording of heating characteristics 

This permits a fast and thorough understanding 

of the typical process 

components. 

„2-Point Controller“ and 

„Continuous Controller“ menu item 

For easy parameterisation of the required 

controller with an immediate 

effect on the process. One click 

of the mouse starts various controller 

functions for the selected control 

system. Documentation of the controller 

parameters is also straightforward. 

The measured values and 

characteristic curve profiles can be 

easily printed out. 

DE/EN/ES/FR 544304 


7

MPS ® PA – The new learning system for process automation 


Teaching today using the 

technology of tomorrow 

MPS ® PA, an innovative learning system 

equipped with the most modern 

technical features and products from 

market leaders. 

Practical training 

The exclusive use of industrial components underlines the necessary practicality 

and ensures a speedy transfer of knowledge from a training scenario to 

practical application. 

Sensors 

Typical process engineering sensors assume control of temperature, level, flow 

rate and pressure in the MPS ® PA. 

8 24-month Festo Didactic warranty


Investment protection 

A well thought-out modular design with clear-cut interfaces facilitates adaptation 

to future developments in components as well as open-loop and closedloop 

control systems. This means that the system can be adapted to new requirements. 

Boundless variety 

It is only logical that the MPS ® PA stations can be combined with stations from 

the greater MPS ® family. After all, it is this possibility of combination with 

MPS ® stations that makes the MPS ® PA an interesting proposition for basic and 

further training in many industries which are dominated by process automation 

but still require elements from production automation. 


9


Measuring and controlling as in industry 

The closest thing to reality 

The MPS ® PA learning system is 

based on industrial standards. The 

MPS ® PA concept is based on a 

market leaders‘ automation solutions 

and trends and can be controlled 

in a number of ways: 

Components 

Operation and configuration 

Advantages 

Simulation box 

– Simple commissioning of an 

MPS ® PA station 

– Testing and commissioning of 

process components or system 

components of a station 

Fluid Lab ® -PA 

– Commissioning and testing of an 

MPS ® PA station 

– Analysis of process components 

and control processes of an MPS ® 

PA station 

– Monitoring and analysis of the 

process sequences of a station 

– Testing, configuration and optimisation 

of control processes 

(2-point, P, PI or PID controllers) 

– Analysis of the control response 

PLC 

– Programming of process sequences 

and recipe controllers 

– Analogue signal processing 

– Operation and monitoring using 

the touch panel 

– Programming of PID controllers 

– Configuration and parameterisation 

of P, PI or PID controllers 

PLC with external industrial 

controller 

Same as PLC, plus: 

– Operation of an industrial controller 

(manual operation, automatic 

operation) 

– Parameterisation of industrial 

controllers (P, PI or PID control 

algorithm) 

– Configuration of measuring ranges, 

setpoint value limits and 

alarm limits 

– Self-optimisation with oscillation 

or step response method 



Combining stations 

The new interface concept offers 

many possibilities for direct combination 

of individual MPS ® PA stations. 

Various aspects determine the decision 

as to which combination is required: 

– Training aims 

– Supplementation of existing 

stations 

– Budget 

MPS ® PA stations can be 

combined as follows: 

Stations 

Filtration 

Mixing 

Reactor 

Possible direct downstream station 

Filtration Mixing Reactor Bottling 

The MPS ® 204 complete system section 

shows a fully configured system. 

24-month Festo Didactic warranty 

11

MPS ® PA 204 Complete system 


Control technology is clearly and 

practically explained using the P, PI 

or PID control algorithm. The temperature 

sensor – the reactor station uses 

a PT100 resistance thermometer – 

supplies a unit signal of 0 – 10 V via 

the measuring transducer. The controller 

approaches the setpoint temperature 

via the continuously controllable 

heater and keeps it constant. 

Using a constant flow rate, the three 

raw materials are mixed to a recipe 

in the mixing station. The flow rate is 

recorded by means of an electronic 

flow sensor with impeller and additionally 

displayed using a variablearea 

flowmeter. The controller adjusts 

the necessary flow rate via the 

pump with analogue control. 

Pressure control ensures constantly 

high filter quality during flushing. 

The pressure sensor with LCD display, 

analogue output and switching 

output always supplies the correct 

measurement variable. The controller 

ensures constantly high filter 

quality during rinsing via the proportional 

pressure regulator. 

The filling level of the dosing tank is 

detected in the bottling station using 

an analogue filling level sensor. The 

controller regulates the filling level 

to the required setpoint value via 

the continuously controllable pump. 

The filling level in the dosing tank is 

kept constant during filling, which 

optimises the quality of the filling 

process. 



Function 

The system is made up of the filtration, 

mixing, reactor and bottling stations. 

The filtration station filters a 

liquid. The filtrate is pumped from 

the first tank into the second tank 

through the filter using various process 

valves. The filtered liquid is then 

fed into the first tank in the mixing 

station. The mixing station mixes 

different recipes from three reservoir 

tanks. The finished mixture is 

pumped to the reactor station, where 

it is tempered. Depending on the 

recipe selected, different temperature 

profiles with different stirring 

times are activated. The bottling station 

fills the liquid into bottles. These 

bottles are transported to the filling 

position via conveyors. A pneumatic 

separator separates the bottles. The 

bottles are filled with different filling 

quantities from the dosing tank in 

accordance with the recipe selected. 

Special training aims 

– Construction, wiring and commissioning 

of a system for process 

technology 

– Measurement of electrical and 

process-related variables such as 

level, flow rate, pressure and temperature 

– Design and commissioning of control 

circuits 

– Evaluation of the control response 

– Networking of process engineering 

systems 

– Process operation and monitoring, 

system management 

– Selection, application and actuation 

of process valves 

– Analysis of control processes and 

control circuits 

– Parameterisation and optimisation 


– Drafting of open-loop and closedloop 

control programs 

– Process operation and monitoring 

– Inspection, maintenance and servicing 

Included in the scope of delivery: 

Various measurement and control options 

– Simple commissioning, simulation and display using the 

simulation box 

– Multimedia measurement, open and closed-loop control, operation, 

monitoring and commissioning using Fluid Lab ® -PA 

– Starting process sequences in the PLC or monitoring them 

using the touch panel 

– The PLC or the industrial controller likewise included for 

each station can assume the control function. Parameterisation 

of the controller is performed at the touch panel or 

directly at the industrial controller. All the process variables 

are shown clearly – and also as a trend – both on the 

touch panel and on the industrial controller. 

The MPS ® PA complete system offers everything required 

for an efficient start with measurement and closed-loop control 

technology. 

MPS PA 204 with SIMATIC S7-300 control package 544248 

MPS PA 204 with Festo CPX control package 544249 

MPS PA 204 with Allen Bradley ML 1500 control package 544250 

MPS PA 204 with Mitsubishi MELSEC control package 544251 

The complete system is made up of the filtration, mixing, reactor and bottling stations with 

trolleys, colour touch panels, mounting frames and power supply units and includes: 

– 4x PLC board 

(either with SIMATIC S7-313C, Festo CPX, Allen Bradley ML 1500 or 

Mitsubishi MELSEC FX1N) 

– 4x Fluid Lab ® -PA software with digital/analogue EasyPort PC interface 

– 4x digital/analogue simulation box 

– 4x industrial controller 

Supplied complete with all the necessary connecting cables. 

Successful project work thanks to modular structure 

Learning by doing – the MPS ® PA system offers process 

technology that you can really get to grips with. This allows 

you to implement your own project ideas quickly and without 

risk. 


13

MPS ® PA Stations 

Filtration station 

Function 

The filtration station filters liquids. 

The filtrate is pumped from the first 

tank into the second tank through 

the filter using a knife gate. The filtered 

liquid reaches the second tank 

via a butterfly valve with pneumatic 

semi-rotary drive. The filtered liquid 

can be pumped onwards to the next 

station using a separate pump. The 

filter can be rinsed using a rinse program. 

Regulated compressed air is 

additionally blown through the filter 

to loosen deposits. 

Measurement and control 

Sensors detect the filling level of the 

container in the filtering station. This 

permits lessons on simple control 

exercises for monitoring the pumps 

right up to complete control projects 

involving complex processes. 

Pressure control ensures constantly 

high filter quality during flushing. 

The pressure sensor with LCD display, 

analogue output and switching 

output always supplies the correct 

measured variable. The controller 

with P, PI or PID control algorithm 

ensures constantly high filter quality 

during rinsing via the proportional 

pressure regulator. Control technology 

is clearly and practically explained 

in this way. 



Shutting off, opening, closing 

The right selection of process valve, 

drive, drive accessories and control 

valve plays an important role in complex 

process sequences. The filtering 

station uses an extremely wide range 

of process components. All the valve 

actuators are actuated via a directly 

connected NAMUR valve. 

Knife gate with COPAC linear actuator. 

Butterfly valve with sturdy rack and 

pinion COPAR rotary actuator and 

large visual display. 

Three-way ball valve with SYPAR 

scotch yoke rotary actuator and large 

visual display. 

Complete Filtration station 544253 

(with trolley, colour touch panel, mounting frame and power supply unit) 

Also order 

Open-loop and closed-loop control with PLC: 

PLC board with SIMATIC S7-313C 533526 

SIMATIC S7 connecting cable set 544296 

PLC board with Festo CPX 541187 

Festo CPX connecting cable set 544297 

PLC board with Allen Bradley ML 1500 544300 

Allen Bradley ML 1500 connecting cable set 544298 

PLC board with Mitsubishi MELSEC 544301 

Mitsubishi MELSEC connecting cable set 544299 

Or alternative: 

SIMATIC S7 EduTrainer Compact 313C 533018 


For working with Fluid Lab ® -PA: 

Fluid Lab-PA 544304 

Digital/analogue EasyPort PC interface 193930 

RS232 PC data cable 162305 

RS232 USB adapter 540699 

SysLink cable 034031 

Analogue cable 529141 

For simple commissioning, simulation and display using the simulation box: 

Digital/analogue simulation box 526863 



For professional control using industrial controllers: 

Industrial controller 544293 

Recommended accessories 

Replacement filter cartridge 544303 

Mains cable for tabletop power supply unit 

On request 

Training aims for project work 



technology 

– Selection, application and actuation 

of process valves 



level and pressure 

– Design and commissioning of 










Recommended training media 

– Fluid Lab ® -PA 

– Web-based training program, 

Fundamentals of open and closedloop 

control 

– Design and simulation program 

FluidSIM ® Pneumatics 


15


Mixing station 

Function 

The mixing station mixes different 

recipes from three reservoir tanks. 

The liquid from one of the three 

reservoir tanks is pumped into the 

main tank in a controlled manner by 

opening the respective two-way ball 

valve. The finished mixture can be 

pumped to the next station via a second 

pump – or pumped back to the 

reservoir tank. 


Using a constant flow rate, the three 

raw materials are mixed to a recipe 

in the mixing station. The flow rate is 

recorded by means of an electronic 

flow sensor with impeller and additionally 

displayed using a variablearea 

flowmeter. The output signal 

from the flow sensor is converted to 

a standard signal from 0 – 10 V. The 

mixing station can also be actuated 

through binary means using the integrated 

comparator. The controller 

adjusts the necessary flow rate via 

the pump with analogue control – 

using a simple two-point controller 

or various dynamic controllers such 

as P, PI or PID. This permits a clear 

explanation of control technology on 

various levels. 



Always the right mixture 

The component mix of the mixing 

station offers a wide selection of typical 

components from process engineering. 

Pumps and process valves, 

various sensors for signal detection 

as well as electronic modules for 

signal conversion permit the right 

„training mix“. 

Sensors for detecting the filling level 

of containers. With overflow protection 

thanks to additional sensors 

on each container, thereby virtually 

eliminating the possibility of overflow. 

Signal converters convert all analogue 

signals from the station to 

standard signals from 0 – 10 V. Practical 

for the purpose of experimentation: 

integrated comparators also 

supply purely binary signals. 

Two-way ball valve with SYPAR 

scotch yoke rotary actuator, large 

optical display and directly connected 

NAMUR valve. 

Complete Mixing station 544254 


Also order 




























On request 




technology 

– Selection, application and connection 

of various flow sensors 



level and flow rate 


circuits 













control 




17


Reactor station 

Function 

The reactor station tempers a liquid. 

Depending on the recipe selected, 

different temperature profiles with 

different stirring times are activated. 

A cooling pump is activated to cool 

the liquid. The tempered liquid can 

be pumped onwards to the next station 

using a separate pump. 


Sensors detect the filling level of the 

reservoir in the reactor station. This 

facilitates lessons on simple control 

exercises for monitoring the pumps 

right up to complete control projects 

involving complex processes. 

Exact adherence to the various temperature 

profiles when activating 

the recipes is achieved by means of 

temperature control. The temperature 

sensor (PT100 resistance thermometer) 

supplies a unit signal of 

0 – 10 V via the measuring transducer. 

The controller with P, PI or PID 

control algorithm can approach the 

setpoint temperature values via the 

dynamically controlled heating unit 

and keep the values constant. Simple 

control exercises, for example 

control using the two-point controller, 

can be realised using the reactor 

station. Control technology is clearly 

and practically explained in this way. 



Heating and stirring 

Key basic operations in many process 

engineering systems involve 

heating and stirring. The components 

of the reactor station are designed 

to permit a wide range of experiments 

in this area. 

Infinitely adjustable heating with 

control signal from 0 – 10 V. A safe 

experimental environment permits 

integrated linking of the heater with 

the integrated temperature switch 

– thus ruling out the possibility of 

„running dry“ in a practical way. 

Stirrer with DC motor. 

Signal converters convert all analogue 

signals from the station to 

standard signals from 0 – 10 V. Practical 

for the purpose of experimentation: 

integrated comparators also 

supply purely binary signals. 

Complete Reactor station 544255 


Also order 




























On request 




technology 

– Selection, application and connection 

of temperature sensors 



level and temperature 

– Use and connection of measuring 

transducers 


circuits 













control 


19


Bottling station 

Function 

The bottling station fills bottles with 

liquid. The liquid is pumped into the 

dosing tank from the reservoir. The 

bottles are transported to the filling 

position via conveyors. A pneumatic 

separator separates the bottles. The 

bottles are filled with different filling 

quantities from the dosing tank in 

accordance with the recipe selected. 


The filling level of the dosing tank 

is detected in the filling station using 

an analogue filling level sensor. 

The controller regulates the filling 

level to the required setpoint value 

via the dynamically controlled pump 

(0 – 10 V). 

The filling level in the dosing tank is 

kept constant during filling, which 

optimises the quality of the filling 

process. Various control algorithms 

such as P, PI or PID can be applied 

and optimised during experiments. 

The characteristics of the control 

process can be modified using hand 

valves already integrated. Control 

technology is clearly and practically 

explained in this way. 



Transporting, separating, filling 

Few segments of the diversified 

process industry are associated with 

such a wide range of end products 

as the food industry. All foodstuffs, 

whether dairy products, baked 

goods, juice, beer or wine have their 

own requirements with regard to the 

handling and production of the corresponding 

end products. Transporting, 

separating, dosing and bottling 

play an important role here. 

Optical sensors, adjustable using 

background suppression, monitor 

transportation on the conveyors of 

the filling station. 

The pneumatic separator ensures 

that there is never more than one 

bottle at the filling position. 

The filling quantity can be easily adjusted 

by selecting different recipes. 

Complete Bottling station 544256 


Also order 



























Set of 20 x 100 ml bottles 544302 


On request 




technology 

– Selection and application of filling 

level sensors 



level 


circuits 













control 




21

Process automation – Networked system 

Networked system with 3 or 4 stations 

Adjustable centrifugal pump to ensure 

the right flow for every station. 

Sipart DR19 controller from 

Siemens – now fitted in all stations. 

A standard connecting station with 

2/2-way solenoid valve and S7-300 

controller controls the interaction of 

the individual stations. 

An alternative connecting station 

with pneumatic process actuators 

from Festo, Namur valves and CPX 

valve terminal actuation is also 

available. 


Process automation – Networked system 

Function 

A networked system enables level 

control, flow rate control, pressure 

control and temperature control systems 

to be operated simultaneously. 

Each station is equipped with a Siemens 

DR19 and can therefore also 

be operated individually. The stations 

are connected to the host computer 

(PC) via Profibus DP. Access 

to the process variables of all stations 

is provided by the operation 

and visualisation software InTouch 

or WinCC. 

Step by step to greater complexity 

Training starts with individual groups 

of students at the individual stations 

tackling tasks of similar complexity. 

The complexity can be gradually increased 

later by merging the stations 

into one system. 

Training aims 

This system complements the training 

aims of the Compact Workstation. 

– Commissioning and maintenance 

personnel: 

Realizing bus networks. From planning, 

design and configuration 

through to realisation. 

– Operators: 

Process operation, monitoring and 

performance training as part of 

system management. 

The networked system can be supplied 

as a version with 4 stations 

(level control, flow rate control, pressure 

control and temperature control) 

or as a version with 3 stations 

(no pressure control). 

In both cases, a connecting station 

comprising a pump and 8 x 2/2-way 

solenoid valves controls the flow of 

water between the stations. Six or 

eight capacitive sensors (depending 

on whether there are 3 stations 

or 4 stations respectively) monitor 

the level of the containers. Supplied 

with a SIPART DR19 controller and 

S7-313-2DP. 

Integrated systems: 

from the control station to the field 

Modern communication technology 

enables you to „see“ the sensor from 

the control room. The critical question 

remains as to which signals are 

relevant for display or which intervention 

options should be made 

accessible to individual groups of 

people. The system provides a quick 

insight into complex relationships 

and points to trends in the latest 

technologies and methods through 

the use of hardware and software 

from market leaders. 

SIMATIC WinCC is a PC-based control 

and monitoring system designed 

for visualising and controlling processes, 

sequences and machines. 

InTouch is an interactive system 

for visualising, monitoring and controlling 

industrial processes on IBM 

compatible computers. 

System with 3 stations 

On request 

System with 4 stations 

On request 

Also order 

Comprising: 

level, flow rate and temperature control 

as well as a standard connecting 

station 

Comprising: 

level, flow rate, pressure and temperature 

control as well as a standard connecting 

station 


Simulation box, digital/analogue 526863 



– 3x industrial controller DR19 in the 

ER mounting frame 

– 1x EduTrainer ® with S7-313C-2DP 

– 4x mobile trolley 

– 4x power supply unit in the mounting 

frame 

– 1x individual licence STEP 7 

– 1x licence for WinCC or InTouch 

– 1x licence for SIMATIC PDM 

– 1x Profibus card CP 5611 

– 1x set of Profibus cables 

– Technical documentation 

– Initial start-up at Festo Didactic 

– 4x industrial controller DR19 in the 

ER mounting frame 

– 1x EduTrainer ® with S7-313C-2DP 

– 5x mobile trolley 

– 5x power supply unit in the mounting 

frame 

– 1x individual licence STEP 7 

– 1x licence for WinCC or InTouch 

– 1x licence for SIMATIC PDM 

– 1x Profibus card CP 5611 

– 1x set of Profibus cables 

– Technical documentation 

– Initial start-up at Festo Didactic 

Control variants 

See Compact Workstation 


– Fluid Lab ® -PA, including EasyPort, digital/analogue 

– Web-based training program, Fundamentals of open and closed-loop control 

Commissioning and training on-site upon request. 

Information on customer projects: www.festo-didactic.com 

23

Process automation – Compact Workstation 

Compact Workstation with level, flow rate, 

pressure and temperature closed-loop control systems 

Optimisation relative 

to your space requirement 

Maybe you‘re restricted in the 

amount of space you have available 

but you want each of your training 

workstations to offer a high level of 

complexity. If so then the Compact 

Workstation with four integrated 

closed-loop control systems is the 

solution for you. As shown in the 

flow chart, the individual control systems 

can be activated by simply repositioning 

the ball valves. The flexible 

piping system enables you to 

change the flow scheme or integrate 

other components quickly and easily. 

Function 

The four control systems in the Compact 

Workstation can be operated 

individually. The level and flow rate 

control systems can be structured as 

a cascade control system through the 

addition of an appropriate controller. 

The layout of the sensors and servo 

drives permits experimentation with 

both continuous (e.g. P, I, PI, PID) and 

discontinuous action controller types 

(e.g. 2-point controllers). The pump 

can either be controlled directly or 

operated in controlled speed mode. 

The manipulated variable of the controller 

in the flow rate and pressure 

control systems can alternatively act 

upon a proportional directional control 

valve. A ball valve with pneumatic 

drive is built into the return 

between the high-level container 

and the lower reservoir. The pneumatic 

drive can be used to simulate a 

“load” for switching on a disturbance 

in the level control system or as an 

on-off valve for emergency switch-off. 

Scope of delivery of the 


(Basic version including manual 

without actuation components) 

Mechanical components, 

fully assembled 

– 2 containers 

– Reservoir 

– Plug-in piping system 

– Aluminium profile benches 

– Mounting frame 

– Profile plate 700 x 700 x 32 mm 

Sensors 

– 2 capacitive sensors 

– 2 float switches 

– 1 process drive signal box 

– Ultrasound sensor 

– Flow sensor 

– Pressure sensor 

– PT100 temperature sensor 

Actuation components 

– Pump 

– Proportional directional control 

valve 

– Ball valve with pneumatic drive 

– Heater 

Electrical components 

– I/O connection board with 

measuring transducer 

– Motor controller with relay 

– I/O terminal, SysLink, 8 I/8 O 

– Analogue terminal, SysLink, 15-pin 

Compact Workstation On request 

Commissioning and training on-site upon 

request. 


Process automation – Compact Workstation 

Piping and instrument flow chart 

An important part of project work 

in process engineering is developing 

a piping and instrument flow 

chart. A piping and instrument flow 

chart explains the electrical, measuring 

and control technology functions 

using measuring points and 

final control elements. The measurement 

variable or another input variable, 

its processing, its direction of 

action and directional specifications 

and positions should follow from 

the chart. 

Mounting frame 

Can be equipped with accessories 

for controllers, control unit and/or 

touchpanel. It can also be converted 

from the ER format to DIN A4 format 

at any time by the user. The activation 

and/or control devices can be 

replaced in just seconds. 

Pneumatic drive 

With ball valve and signal box. Training 

aims: Design and application areas 

of various metering and shut-off 

devices when controlling the flow of 

liquids. 

Intelligent in the field – 

closedloop control with the CPX/ 

FEC valve terminal and the FED 120 

touchpanel 

The Festo Front End Controller with 

integrated web server and Ethernet 

interface is ideally suited to current 

communication tasks. 

Control variants 

Control kit S1: 

Siemens SIMATIC EduTrainer ® 

Compact with S7-313C 

– 1 x EduTrainer Compact S7-313C 

– 1 x control unit 

– 2 x I/O data cable 

– 1 x analogue cable 

Note: STEP 7 software and MPI 

cable must be ordered separately 

if required. 

Control kit S1-DP 

On request 

Control kit S1 

On request 

Control kit S2: 

Siemens SIPART DR19 controller 

– 1 x SIPART DR19 with serial interface 

integrated in ER frame 

– 1 x PDM software for parameterisation 

and configuration of the DR19 

controller 

– 1 x serial data cable 



Control kit S2 

On request 

Control kit F2: 

Festo CPX/FEC ® valve terminal 

– 1 x Festo CPX/FEC ® 

– 1 x control unit 

– 1 x Ethernet cable, crossover 



Note: FST software and programming 


if required. 

Control kit F2 

On request 

Control kit F3: 

Festo CPX/FEC ® with FED 

– 1 x Festo CPX/FEC ® 

– 1 x Ethernet cable, crossover 

– 1 x FED-120 touchpanel 



Note: FST software and programming 


if required. 

Control kit F3 

On request 

Control kit PC2: 

Fluid Lab ® -PA software licence with 

EasyPort 

– 1 x Fluid Lab ® -PA, individual licence 

– 1 x EasyPort D/A 

– 1 x RS232 data cable 

– 1 x mains cable 



Control kit PC2 

On request 

I/O simulation box, 

digital/analogue 

– 1 x simulation box incl. mains cable 

– 1 x I/O data cable, crossover 

– 1 x analogue cable, crossover 

I/O simulation box 

On request 

Visualisation with WinCC or InTouch 

on request. 

Accessories for the 


– Trolley 

– Tabletop power supply or power 

supply unit for the mounting frame 

– Control kit 


– Fluid Lab ® -PA, including EasyPort, 

digital/analogue 



control 


25

Hybrid processes 


Boundless variety 

Qualification solutions and training 

factories for production and process 

automation. 

Tell us what you need – we‘ll design 

your ideal learning environment and 

establish the required dependencies 

at process level. We look forward to 

designing solutions with you for special 

topics such as: 

– Water treatment 

– Cooling and refrigeration 

technology 

– pH value measurement 

– Conductivity measurement 

– Pneumatics in process engineering, 

for example slide valve actuators 

with positioners, specifically 

for the paper industry. 

MPS ® PA, 

combined with MPS ® stations 

It is only logical that the MPS ® PA 

(process automation) stations can 

be combined with stations from the 

greater MPS ® family. This makes 

MPS ® an interesting proposition for 

basic and further training in many 

industries which are dominated by 

process automation but still require 

elements from production automation. 

The well thought-out modular design 

with clear-cut interfaces protects 

your investment and facilitates 

adaptation to future developments 

in components as well as open-loop 

and closed-loop control systems. 

This means that the system can be 

adapted to new requirements. 

26 

www.festo-didactic.com


Production automation and process automation 

AFB – 

The modular concept factory for all 

hybrid production tasks 

The learning system for all processes 

associated with production automation 

and process automation. 

– Production 

– Handling of seals 

– Packaging 

– Filling 

– Transportation and routing 

– Storage 

– Input/output 

The ideal solution for hybrid production 

process requirements in 

the food sector. The platform connects 

stations and elements from 

the MPS ® Modular Production System 

with stations from the MPS ® PA 

learning system and the Compact 

Workstation. 

The system is therefore completely 

modular and new processes and 

training content can be added gradually. 

Project work with hands-on 

training can take place at individual 

stations, on partially integrated production 

lines and in a fully integrated 

learning factory. 

Customer-specific solutions 

You have specific requirements 

Numerous installations across the 

globe have given rise to a range of 

solutions with a particular focus on 

hybrid automation. 

An example of this is provided by 

Siemens AG Professional Education 

Berlin, whose mixing and filling station 

demonstrates how a continuous 

flow process is brought into line 

with a gradual container filling process. 

The students experience an operational 

process showing the entire 

sequence of an automated customer 

order processing system. 

Detailed information on this and 

other projects can be found on the 

website: 


under Services ➔ References. 

Information on customer projects: www.festo-didactic.com 

27

Festo Didactic GmbH & Co. KG 

Rechbergstraße 3 

73770 Denkendorf/Germany 

Tel. ++49 (0)711/3467-0 

Fax ++49 (0)711/34754-88500 


did@festo.com 

56943 en

Qualification solutions for process automation

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