en v3.0.2 LP696686 MPS-PA Mixing Station Operating Instructions and PDC

8079863
Mixing Learning System
MPS PA
Stations
Operating instructions
Festo Didactic
696686 en
09/2019
Order number: 696686 (PC.TW.0024)
Revision level: 09/2019 V3.0.1
Authors: Jürgen Helmich, Frank Ebel
Layout: Festo Didactic
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2019
+49 711 3467-0 www.festo-didactic.com

+49 711 34754-88500 did@festo.com
Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, is prohibited. Offenders will be held liable for damages. All rights
reserved, in particular the right to file patent, utility model and registered design applications.
For the sake of readability throughout these operating instructions, all gender-specific
terms are to be considered to refer to both the feminine and the masculine form,
except when referring to a particular person.
CAUTION
These operating instructions must always be available to the user.
The operating instructions must be read before commissioning.
The safety instructions must be observed
Non-observance may result in severe personal injury or damage to property.
Contents
1 General requirements for operating the devices _______________________________________________7
2 Pictograms _____________________________________________________________________________8
3 Intended use __________________________________________________________________________ 10
4 For your safety ________________________________________________________________________ 11

4.1 Important information _______________________________________________________________ 11
4.2 Obligations of the operating company __________________________________________________ 11
4.3 Obligations of the trainees ___________________________________________________________ 11
4.4 Dangers when handling the components and systems _____________________________________ 12
5 Work and safety instructions _____________________________________________________________ 13

5.1 General remarks ____________________________________________________________________ 13
5.2 Mechanical system__________________________________________________________________ 13
5.3 Electrical system ___________________________________________________________________ 14
5.4 Pneumatics ________________________________________________________________________ 15
5.5 Process technology _________________________________________________________________ 16
6 Technical data_________________________________________________________________________ 17
6.1 General data _______________________________________________________________________ 17
6.2 Pin allocation table _________________________________________________________________ 18
6.2.1 Digital terminal _________________________________________________________________ 18
6.2.2 Analog terminal _________________________________________________________________ 19
6.2.3 Control panel ___________________________________________________________________ 20
7 Transport/unpacking/scope of delivery____________________________________________________ 21
7.1 Transport _________________________________________________________________________ 21
7.2 Unpacking_________________________________________________________________________ 21
7.3 Scope of delivery ___________________________________________________________________ 21
8 Setup ________________________________________________________________________________ 22
8.1 The Mixing Learning System __________________________________________________________ 22
8.2 The Mixing Station __________________________________________________________________ 23
8.2.1 Main components _______________________________________________________________ 24
8.2.2 Small parts included in the scope of delivery of the station ______________________________ 25
8.2.3 RI flow diagram _________________________________________________________________ 25
8.3 Function of the flow system ___________________________________________________________ 26
8.4 Pump_____________________________________________________________________________ 27
© Festo Didactic 696686 3

8.5 Level monitoring ___________________________________________________________________ 27

8.5.1 Capacitive proximity sensors ______________________________________________________ 28
8.5.2 Float switch ____________________________________________________________________ 28
8.5.3 Flow sensor, magnetic-inductive ___________________________________________________ 28
8.6 2-way ball valve with pneumatic quarter-turn actuator _____________________________________ 29
8.7 Compressed air supply ______________________________________________________________ 30
8.8 Electrical connection technology_______________________________________________________ 31
8.8.1 Connection board _______________________________________________________________ 31
8.8.2 Mounting frame_________________________________________________________________ 32
8.8.3 19″ frame ______________________________________________________________________ 33
8.9 PLC EduTrainer Universal S7-1512C ____________________________________________________ 34
8.10 Control console with operator unit TP700 Comfort _______________________________________ 35
8.11 EasyPort and FluidLab-PA closed-loop V5 ______________________________________________ 35
8.12 USB device server _________________________________________________________________ 36
8.13 Trolley 700 _______________________________________________________________________ 36
9 Function ______________________________________________________________________________ 37
9.1 Function as individual station _________________________________________________________ 37
9.2 Operation as a downstream station ____________________________________________________ 37
10 Sequence description__________________________________________________________________ 38
10.1 Sequence description of the mixing process ____________________________________________ 38
10.2 Start-up prerequisites ______________________________________________________________ 38
10.2.1 Individual station ______________________________________________________________ 38
10.2.2 Station with downstream station __________________________________________________ 38
10.3 Initial position ____________________________________________________________________ 38
10.4 Sequence ________________________________________________________________________ 38
10.4.1 Automatic mode without downstream station _______________________________________ 39
10.4.2 Automatic mode with downstream station __________________________________________ 39
10.4.3 Manual mode _________________________________________________________________ 40
11 Commissioning _______________________________________________________________________ 41
11.1 Workstation ______________________________________________________________________ 42
11.2 Filling and emptying________________________________________________________________ 42
11.3 Power supply _____________________________________________________________________ 43
11.4 Compressed air supply _____________________________________________________________ 43
11.5 Actuation with PLC EduTrainer and control console ______________________________________ 43
11.5.1 Cable connections between station and EduTrainer PLC _______________________________ 43
11.5.2 Cable connections between control console and PLC EduTrainer ________________________ 45
11.5.3 Establish 1-bit communication connections _________________________________________ 45
11.5.4 Load sample project ____________________________________________________________ 46
11.5.5 Starting the sequence __________________________________________________________ 47
11.5.6 Operation on the control console with operator unit TP700 Comfort _____________________ 48
4 © Festo Didactic 696686

11.6 Actuation with EasyPort 19″ _________________________________________________________ 53

11.7 Adjusting sensors _________________________________________________________________ 54
11.7.1 Capacitive proximity sensor ______________________________________________________ 54
11.7.2 Float switch, cover installation____________________________________________________ 55
11.7.3 Float switch, lateral installation ___________________________________________________ 55
11.7.4 Flow sensor, electromagnetic ____________________________________________________ 56
12 Maintenance and troubleshooting _______________________________________________________ 57

12.1 Maintenance______________________________________________________________________ 57
12.2 Error in the piping system and tanks __________________________________________________ 58
12.3 Error in the pneumatic system _______________________________________________________ 59
12.4 Error in the electrical system _________________________________________________________ 60
12.5 Mechanical faults __________________________________________________________________ 60
12.6 Error due to parameterization ________________________________________________________ 61
13 Further information and updates ________________________________________________________ 62
14 Disposal ____________________________________________________________________________ 62
15 List of figures ________________________________________________________________________ 63


1 General requirements for operating the devices
General requirements for safe operation of the devices:

• National regulations for operating electrical systems and equipment must be observed in commercial
facilities.
• The laboratory or classroom must be overseen by a supervisor.
– A supervisor is a qualified electrician or a person who has been trained in electrical engineering,
knows the respective safety requirements and safety regulations and whose training has been
documented accordingly.
The laboratory or the classroom must be equipped with the following devices:
• An emergency-off device must be provided.
– At least one emergency-off device must be located within, and one outside of the laboratory or the
classroom.
• The laboratory or classroom must be secured so that operating voltage and compressed air supply
cannot be activated by any unauthorized persons, for example with:
– A key switch
– Lockable on-off valves
• The laboratory or classroom must be protected by residual current devices (RCDs).
– Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices.
– Type B residual current circuit breakers with a residual current of ≤ 30 mA must be used.
• The laboratory or classroom must be protected by overcurrent protection devices.
– Fuses or circuit breakers
• No damaged or defective devices may be used.
– Damaged devices must be banned from further use and removed from the laboratory or classroom.
– Damaged connecting cables, pneumatic tubing and hydraulic hoses represent a safety risk and
must be removed from the laboratory or classroom.

2 Pictograms
This document and the hardware described in it include warnings concerning possible hazards which may
arise if the system is used incorrectly. The following pictograms are used:
DANGER
... indicates an imminently hazardous situation that will result in fatal or severe personal
injury if not avoided.
Danger of crushing.
Never reach into the system while in operation.
WARNING
… indicates a potentially hazardous situation which may result in fatal or severe personal
Strong optical radiation.

Non-observance may result in severe personal injury.
CAUTION
... indicates a possibly hazardous situation which may result in moderate or slight personal
Hot surfaces.
Non-observance may result in burns.

Mixing Learning System Pictograms
General information about a hazard
Switch off the device and unplug the connection for power supply before
assembly, repair, maintenance and cleaning work.
Observe the user documentation, in particular all safety instructions. Non-

observance may result in severe personal injury or damage to property.
Warning of electric shock
Warning – laser radiation
Warning of strong optical radiation
Warning of hot surfaces
Warning of crushing hazard
Warning of drawing in due to rotating rollers
Warning of loud noises
Warning of lifting heavy loads
Warning of accidental retraction

3 Intended use
Festo Didactic systems and components must only be used:

• For their intended use in teaching and training applications
• When their safety functions are in perfect condition
Festo Didactic systems and components are designed in accordance with the latest technology and
recognized safety rules. However, life and limb of the user and third parties may be endangered and the
components may be impaired if they are used incorrectly.
The Festo Didactic learning system has been developed and produced exclusively for education and training
in the field of automation technology. The training company and/or trainers must ensure that all apprentices
observe the safety precautions described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the device in situations that serve any purpose other
than training and/or vocational education, unless such damage has been caused by Festo Didactic due to
malicious intent or gross negligence.

4 For your safety
4.1 Important information

Knowledge of the basic safety instructions and safety regulations is a fundamental prerequisite for safe
handling and trouble-free operation of Festo Didactic components and systems. This manual includes the
most important instructions for safe use of Festo Didactic components and systems.
In particular, the safety instructions must be adhered to by all persons who work with Festo Didactic
components and systems. Furthermore, all pertinent accident prevention rules and regulations that are
applicable at the respective place of use must be adhered to.
4.2 Obligations of the operating company

The operator undertakes only to allow those persons to work with the Festo Didactic components and
systems who:
• Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of Festo Didactic components and systems.
• Have read and understood the chapter concerning safety and the warnings in this manual.
Personnel should be tested at regular intervals to ensure that they are safety-conscious in their work habits.
4.3 Obligations of the trainees

All persons who have been entrusted to work with Festo Didactic components and systems shall complete
the following steps before beginning work:
• Read the chapter about safety and warnings in this manual,
• Familiarize themselves with the basic regulations regarding occupational safety and accident prevention

For your safety Mixing Learning System
4.4 Dangers when handling the components and systems

Festo Didactic systems and components are designed in accordance with the latest technology and
recognized safety rules. However, life and limb of the user or third parties may be endangered and the
machine or other property may be damaged during their use.
Festo Didactic systems and components must only be used:

• for their intended purpose
• when in perfect working condition.
WARNING
Malfunctions which could impair safety must be eliminated immediately!
CAUTION
Improper repairs or modifications may result in unforeseeable operating states. Do not

carry out repairs on the device.

5 Work and safety instructions
5.1 General remarks

• Trainees should work with the circuits only under the supervision of an instructor.
• Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices (RCDs).
• Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
• Malfunctions which might impair safety must not be generated when the device is operated for training
purposes.
• Wear your personal protective equipment (safety goggles, safety shoes) when working on the circuits.
5.2 Mechanical system

• Switch off the power supply.
– Switch off both the working power and control power before working on the circuit.
– Only reach into the setup when it is at a complete standstill.
– Be aware of potential overtravel times of actuators.
• Mount all of the components securely on the profile plate.
• Make sure limit switches are not operated from the front.
• Risk of injury during troubleshooting.
Use a tool to operate the limit switches, for example a screwdriver.
• Set all components up so that it’s easy to activate the switches and interrupters.
• Follow the instructions regarding positioning of the components.

Work and safety instructions Mixing Learning System
5.3 Electrical system

• Risk of fatal injury in case of interrupted PE conductor!
– The protective conductor (yellow-green) must not be interrupted, either inside or
outside of the device.
– The insulation of the protective conductor must never be damaged or removed.
• Risk of death from series connection of power supply units!
Contact voltages of greater than 25 V AC or 60 V DC are not permissible.
Coming into contact with voltages of greater than 50 V AC or 120 V DC may be fatal.
– Do not connect voltage sources in series.
• Risk of death due to electric shock!
Protect the outputs of the power supply units (output sockets/terminals) and cables connected to them
from direct contact.
– Only use cables with adequate insulation and electric strength.
– Use safety sockets with fully shrouded contact points.
• Disconnect from all sources of electric power!
– Switch off the power supply before working on the circuit.
– Please note that electrical energy may be stored in individual components.
Information on this issue is available in the datasheets and operating instructions included
with the components.
– Caution!
Capacitors inside the device may still be charged even after being
disconnected from all sources of voltage.
• Devices with a grounding terminal must always be grounded.
– If a ground connection (green/yellow laboratory socket) is available, it must always be connected
to protective ground. The protective grounding must always be connected first (before voltage) and
disconnected last (after voltage).
– Some devices have high leakage current. These devices must be additionally grounded with
a protective earth conductor.
• Use safety extra-low voltages only: max. 24 V DC.
• The power supply unit must be operated only with a power supply with a grounding conductor.
• Establishing and disconnecting electrical connections
– Electrical connections may be established only in the absence of voltage.
– Electrical connections may be disconnected only in the absence of voltage.

Mixing Learning System Work and safety instructions
• Maximum permissible current loads for cables and devices must not be exceeded.
– Always compare the current ratings of the device, the cable and the fuse to ensure that they match.
– In the event that these are not the same, use a separate upstream fuse in order to
provide appropriate overcurrent protection.
• Use only connecting cables with safety plugs for electrical connections.
• When laying connecting cables, make sure they are not kinked or pinched.
• Do not lay cables over hot surfaces.
– Hot surfaces are indicated by a corresponding warning symbol.
• Make sure that connecting cables are not subjected to continuous tensile loads.
• The device is not equipped with a built-in fuse unless otherwise specified in the technical data.
• Pull the plug only when disconnecting connecting cables; never pull the cable.
• Hazard-free operation of the device is no longer possible in the case of:
– Visible damage
– Malfunction
– Incorrect storage
– Incorrect transport.
– Switch off the power supply immediately.

– Protect the device against an inadvertent restart.
5.4 Pneumatics
• Depressurize the system.
– Switch off the compressed air supply before working on the circuit.
– Use pressure gauges to check whether the entire circuit is pressure-free.
– Please note that energy may be stored in reservoirs.
Information on this issue is available in the datasheets and operating instructions included
with the components.
• Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
• Do not switch on the compressed air until all the tubing connectors have been joined and secured.
• Do not disconnect tubing while under pressure.
• Do not attempt to seal or plug pneumatic tubing or plug connectors with your hands or fingers.
• Risk of injury when switching on compressed air!
Cylinders can advance and retract automatically.

Work and safety instructions Mixing Learning System
• Risk of accident due to advancing cylinders.

– Always position pneumatic cylinders so that the piston rod’s working space is unobstructed
over the entire stroke range.
– Make sure that the piston rod cannot collide with any rigid components of the setup.
• Risk of accident due to pneumatic tubing slipping off!
– Use shortest possible barbed tubing connectors.
– If pneumatic tubing slips off:
Switch off the compressed air supply immediately.
• Pneumatic circuit setup:
Connect the devices with plastic tubing with an outside diameter of 4 or 6 mm. Push the pneumatic
tubing into the push-in connector as far as it will go.
• Switch off the compressed air supply before dismantling the circuit.
• Dismantling the pneumatic circuit
Press the blue release ring down so that the pneumatic tubing can be pulled out.
• Noise due to escaping compressed air
– Noise caused by escaping compressed air may damage your hearing. Reduce noise by using
pneumatic mufflers, or wear hearing protection if noise cannot be avoided.
– All of the exhaust ports of the components included in the equipment set are equipped with
mufflers. Do not remove these mufflers.
5.5 Process technology

Always fill the tanks when the power is switched off!
Switch off the 24 V DC and 230 V AC power supply!
• Use tap water of drinking water quality (recommended) to ensure longer maintenance-free operation of
the stations (valves, pump, etc.).
• The maximum operating temperature of the containers of +65°C must not be exceeded.
• Only start up the heater when the heating element is completely immersed in the liquid.
• The maximum operating pressure for the liquid in the pipes must not exceed 0.5 bar.
• Do not allow the pump to run dry. The pump must not be used with seawater, contaminated liquids or
viscous media.
• Drain the liquid in the stations/system before making changes in the piping layout.
• The liquid in the station can be drained by opening the drain valves!
• No liquid should be left in the system for a long period of time, as bacteria such as Legionella can form
in it.

6 Technical data
6.1 General data
Parameter Value
Operating pressure (compressed air) 600 kPa (6 bar)
Max. operating pressure in piping (water) 50 kPa (0.5 bar)
Operating voltage 24 V DC, 4 A, ≤ 100 W output power, SELV/PELV limited

power supply (LPS)
Digital inputs/outputs Max. 24 V DC

Inputs: 7 Max. 0.5 A per output
Outputs: 5 Max. 4 A total
Analog inputs/outputs
Inputs: 1
Outputs: 1
Signal range of the final control Pump (0...24 V DC) Voltage 0...10 V
elements
Operating range of the flow section 0...9 L/min
Measuring range of the flow sensor 0...10 L/min
Signal of the flow rate sensor Voltage 0...10 V
Electrical connection 24-pin IEEE-488 socket (SysLink)

15-pin ISO 4903 socket (Sub-D)
Pneumatic connection Plastic tubing with 6 mm outside diameter
Compressed air consumption at 600 kPa (continuous cycle) 5 l/min
Process connections Flexible piping system DN10 (∅a 15mm)
Volumetric flow rate of the pump ~ 10 l/min
Tank volume storage tanks/main tank max. 3 l / 10 l
Dimensions of the station 700 x 700 x 870 mm
Dimensions of the profile plate 700 x 700 x 32 mm
Weight 51 kg
Subject to change

Technical data Mixing Learning System
6.2 Pin allocation table
6.2.1 Digital terminal
I/O Reference Designation Terminal SysLink SysLink

designation Pin Wire color
I0 -BF1 Limit value >3l/min Flow rate sensor BF1 9 13 Gray-pink
I1 -BG2 Filling level, upper limit value of tank VE1 10 14 Red-blue
I2 -BG3 Filling level, lower limit value of tank VE1 11 15 White-green
I3 -BG4 Filling level, lower limit value of tank VE2 12 16 Brown-green
I4 -BG5 Filling level, lower limit value of tank VE3 13 17 White-

yellow
I5 -BG6 Filling level, upper limit value of tank VE4 14 18 Brown-

yellow
I6 -BG7 Filling level, lower limit value of tank VE4 15 19 White-gray
I7 -KF10 Overflow alarm of the relay contact, collection error 16 20 Gray-brown
Q0 -MA1 Motor PL1 pump ON, conveying in mixing tank 1 1 White
Q1 -MA2 Motor PL2 pump ON, conveying to the downstream station 2 2 Brown
Q2 -MB3 5/2W valve, 2W ball valve VV1 OPEN 3 3 Green
Q3 -MB4 5/2W valve, 2W ball valve VV2 OPEN 4 4 Yellow
Q4 -MB5 5/2W valve, 2W ball valve VV3 OPEN 5 5 Gray
Q5 6 6 Pink
Q6 7 7 Blue
Q7 8 8 Red
24 V A 24 V power supply for outputs 24 VA 9+10 Black
24 V B 24 V power supply for inputs 24VB 21+22 White-pink
GND A 0 V power supply for outputs GND A 11 Brown-pink
GND A 0 V power supply for outputs GND A 12 Purple
GND B 0 V power supply for inputs GND B 23+24 White-blue
Note
Cable jumpers are connected from emergency off to bit 1.5 on all preferred PLC versions.

Mixing Learning System Technical data
6.2.2 Analog terminal
I/O Reference Designation Terminal Sub-D Sub-D

designation PIN Color
UE1 -BF1 Analog input 0-10V, flow sensor BF1 0...10 l/min 1 8 Red
UE2 2 7 Blue
UE3 3 15 White-
yellow
UE4 4 14 Brown-green
IE1 5 5 Gray
IE2 6 4 Yellow
IE3 7 13 White-gray
IE4 8 12 Red-blue
UA1 -MA1 Analog output 0-10V, pump PL1 control range 0...100% 9 1 White
UA2 10 2 Brown
IA1 11 10 Gray-pink
IA2 12 9 Black
24 V B 24 V power supply for inputs VB
GND B 0 V power supply for inputs GB 6 Pink
24 V A 24 V power supply for outputs VA
GND A 0 V power supply for outputs GA 3 Green

Technical data Mixing Learning System
6.2.3 Control panel
I/O Reference Designation Terminal SysLink SysLink

designation Pin Wire color
I0 -SF1 START button 13 Gray-pink
I1 -SF2 STOP button (NC contact) 14 Red-blue
I2 -SF3 AUTO/MAN key switch 15 White-green
I3 -SF4 RESET button 16 Brown-green
I4 I4 Communication input I4 17 White-

yellow
I5 I5 EMERGENCY STOP (NC contact) 18 Brown-

yellow
I6 I6 Communication input I6, downstream station process ready 19 White-gray
I7 I7 Communication input I7 20 Gray-brown
Q0 -PF1 Indicator light START 1 White
Q1 -PF2 Indicator light RESET 2 Brown
Q2 -PF3 Indicator light function Q1 3 Green
Q3 -PF4 Indicator light function Q2 4 Yellow
Q4 Q4 Communication output Q4, station ready for process 5 Gray
Q5 Q5 Communication output Q5 6 Pink
Q6 Q6 Communication output Q6 7 Blue
Q7 Q7 Communication output Q7 8 Red
24 V A 24 V power supply for outputs 9+10 Black
24 V B 24 V power supply for inputs 21+22 White-pink
GND A 0 V power supply for outputs 11 Brown-pink
GND A 0 V power supply for outputs 12 Purple
GND B 0 V power supply for inputs 23+24 White-blue
Note
Communication input I5 is used as an EMERGENCY-STOP signal input in PLC EduTrainers.
The inputs and outputs of the control panel are located on the second byte of the EduTrainer.

7 Transport/unpacking/scope of delivery
7.1 Transport
The MPS PA systems and stations are delivered in a crate on a pallet. The packaging material is designed so
that it can be reused as long as it has not been damaged during transport. Please keep the original
packaging and use it if you need to transport the MPS PA system or station again.
The crate may only be transported with a suitable pallet jack or forklift. The crate must be secured against
tipping over and falling.
– Report transport damage without delay to the freight forwarder and Festo Didactic.
7.2 Unpacking
Carefully remove the padding material from the crate when unpacking the station. When unpacking the
system or station, make sure that none of its assemblies have been damaged.
Examine the system or station for possible damage after unpacking.
– Report any damage without delay to the freight forwarder and Festo Didactic.
7.3 Scope of delivery

Check delivered items against the delivery note and the purchase order.
– Report any discrepancies without delay to Festo Didactic.

8 Setup
8.1 The Mixing Learning System

The Mixing Learning System consists of the MPS PA Mixing station and the most important control
components for teaching learning content.
Figure 1: Front view Mixing Learning System
The Mixing Learning System consists of the following main components:

• MPS PA Mixing station with 19″ frame incl. 24 V DC power supply, control panel, and communication
panels 1x I/O data cable with SysLink plugs to IEEE 488, crossed (order no. 167106) and accessories
• Trolley (order no. 541139)
• EasyPort USB 19″ (order no. 8021637) incl. connecting cable (length 1 m)
• FluidLab-PA closed loop (order no. 544304)
• USB device server
• EduTrainer Universal MPS PA: A4 rack with SIMATIC S7-1500 (order no. 8065600)
• 1x I/O data cable with SysLink connectors to IEEE 488, crossed (order no. 167106)
• 1x analog cable, parallel (order no. 529141)
• Safety laboratory cable, 3 m (order no. 571817)
• Control console with SIMATIC Touch Panel TP700 (order no. 8079869)

Mixing Learning System Setup
8.2 The Mixing Station

The Mixing station combines a controlled system with digital and analog sensors and actuators. The flow
rate system is operated via a PLC with a control function. The process runs after selecting a recipe with a
defined mixing ratio (e.g., 80% - 10% - 10%). Depending on the selected recipe, the mixture is fed from
three dosing tanks into the main tank by the mixing pump.
The finished mixture can then be pumped to the downstream station with a pump.
The following control functions can be edited:

• Flow rate system with PID controller (main function)
6
3
7
1 9
Figure 2: Mixing station (similar to figure)

Setup Mixing Learning System
8.2.1 Main components

The following components are included in the scope of delivery. The data sheets can be found in numerical
order as a PDF data sheet collection.
Datasheets Designation Order no Quantity
8079872 Flow sensor, magnetic-inductive (6) 8079872 1
691225 Variable area flow sensor 691225
170712 Pump (9) 170712 2
689201 Tank, square (3) 548595 1
689200 Tank, round (7) 689200 3
690588 Sensor, capacitive 549824 4
691282 Float switch, lateral installation 691282 1
691383 Float switches, overflow protection (5) 691383 3
691224 2W ball valve with pneumatic quarter-turn actuator and position indicator (2) 549828 3
I/O board (5) 1
8025736 I/O terminal 8025736 1
8025737 Analog terminal 8025737 1
541150 Motor controller 541150 1
150768 Starting current limiter 150768 1
BEEL0426 H-rail relay, 2 changeover contacts 268327 2
17070x Pipe, straight, pipe section of 800 mm 304518 4m
17070x L-plug connector 170701 17
17070x T-plug connector 170702 8
17070x Hand lever valve 170703 8
17070x Blanking plug 170705 3
17070x Push-in bracket 90° 690590 11
9543 Ball valve DN15 9543 1
159410 Aluminum profile plate 700 x 700 159410 1
540691 Start-up valve with filter control valve 540691 1

8.2.2 Small parts included in the scope of delivery of the station
Item Designation Order no.: Quantity
1 T-plug connector for 6 mm tubing 153304 1
2 Plastic tubing, PUN 6x1 152963 5m
3 Pipe and tubing cutters 7658 1
4 Pipe section 15 mm x 800 mm 2
5 L-plug connector 170701 14
6 Push-in bracket 90° 690590 2
7 Hand lever valve 170703 1
8 Tubing D:MPS-PA-B-SCHL.15/1100 1
9 4 mm safety laboratory cables, 300 mm, black 8092632 2
10 4 mm safety laboratory cables, 300 mm, blue 8092631 2
11 4 mm safety laboratory cables, 1500 mm, black 8092659 2
12 4 mm safety laboratory cables, 1500 mm, blue 8092658 2
8.2.3 RI flow diagram
Figure 3: RI flow diagram to ISO10628 and EN 62424

8.3 Function of the flow system

A liquid is conveyed through the piping system from one of the storage tanks VE1, VE2, or VE3 with the
pump PL1 as final control element. The flow rate through the pipelines is measured by sensor BF1 at the PCE
exercise, with 'FIC BF1' as controlled variable and should be kept constant even after disturbances or
changes in the reference variable.
Figure 4: Flow system
As a disturbance variable, the manual valve VV12 can be closed in continuous automatic operation.
The flow rate is recorded as an actual value by means of an electromagnetic

flow sensor and should be kept constant even after faults or setpoint jumps.
For a purely mechanical indication of the flow rate, a flow sensor with float is
also used.
Figure 5: Rotameter

8.4 Pump
Centrifugal pumps are used to convey the liquid.

One mixing pump delivers the liquid for mixing from
the dosing tanks to the main tank. The second pump
delivers the liquid to downstream stations.
The centrifugal pump must not run dry. For this

reason, the tank or piping to and from the pump
must be filled with liquid before commissioning.
Figure 6: Pump with 24 VDC motor
The pumps must not be operated dry. To connect the pumps, please refer to the electrical circuit diagram.
8.5 Level monitoring

The following technical solutions for level monitoring are installed in the Mixing Station:
• Capacitive proximity sensors, one in the first metering tank at the top and one at the bottom.
• The second and third metering tanks have only one proximity sensor at the bottom.
• Float switch for overflow protection in every tank
Figure 7: Level monitoring with capacitive proximity sensors

8.5.1 Capacitive proximity sensors

Two capacitive proximity switches are mounted using holding brackets on a profile rail at the side of the first
metering tank and the main tank for monitoring the water level. The proximity sensors can be adjusted
mechanically on the mounting rail.
For the first dosing tank, the lower proximity switch indicates that the tank is filled with the filling quantity
for a recipe (1.6 l). The upper proximity switch indicates the maximum filling level (2.7 l) of the first dosing
tank. In the initial position, that is, with the tank full, both proximity sensors are actuated. The other two
dosing tanks have only a lower proximity switch to query whether the tank is filled with at least 0.5 l (1
recipe). The proximity switches for the main tank are set to 0 l (bottom) and 6 l (top).
8.5.2 Float switch

The float switches for installation in the cover and for side installation monitor the increasing liquid level in
the tank and serve as overflow protection. As soon as the maximum level is exceeded, the float moves
upward with both switches, the reed contact in the switch housing opens and interrupts the circuit of the
pumps. The pumps are switched off.
Figure 8: Level monitoring with float switch (lateral installation)
8.5.3 Flow sensor, magnetic-inductive

The flow sensor measures the volumetric flow rate which the pump conveys through the piping system and
is set to a measuring range of 0…10 l/min (output signal of 0...10 V). The medium flows through a magnetic
field. It generates a voltage signal which is directly proportional to the volumetric flow.
Figure 9: Electromagnetic flow sensor BF1 (PCE exercise 'FIC BF1')

8.6 2-way ball valve with pneumatic quarter-turn actuator

The process valves VV1, VV2, and VV3 consist of a 2-way ball valve and are opened and closed by a
pneumatic quarter-turn actuator. The actuating device consists of a brass ball valve (1) with quarter-turn
actuator of type COPAR (4), rack and pinion principle with flanged-on 5/2-way NAMUR valve (3) with
solenoid coil (2) and position indicator (6). The outlet of the lower tanks into the mixing tank can be opened
by switching the 2W ball valves.
Figure 10: 2W ball valve with pneumatic quarter-turn actuator (similar to figure)
Legend
1 2W ball valve, brass

2 Solenoid coil
3 5/2 way NAMUR valve for pilot control
4 Quarter-turn actuators of type COPAR
5 Sensor box with inductive double sensor (optional, not available!)
6 Position indicator
Caution
Loud noises are generated when the actuator is moving!
Caution
Parts rotate when the actuator is moved, there is a danger of crushing!

8.7 Compressed air supply

As a maintenance unit, a filter control valve with pressure gauge and switch-on valve for compressed air
supply is mounted on a swivel mount. The on-off valve pressurizes and exhausts the connected MPS®PA
Station. The station accessories included in the station scope of delivery include:
• Plastic tubing PUN 6x1, 5 m
• T-plug connector for 6 mm tubing
Figure 11: On-off valve with filter regulator
Caution
Loud noises are generated when operating the maintenance unit!

8.8 Electrical connection technology
8.8.1 Connection board

The connection board serves as an interface for the analog and digital input and output signals. All analog
signals are converted to 0…10 V and applied to the analog terminal. The binary signals, max. eight inputs
and eight outputs per station, are applied to the I/O terminal. This ensures compatibility with EasyPort,
SimBox, and PLC trainers.
Figure 12: I/O connection board (similar to figure)
1. Earthing terminals
2. I/O terminal (Syslink Station): connection of the inputs, for example capacitive proximity sensors, and
connection of the outputs, for example pumps.
3. Jumper: in the delivery state (jumper = "analog"), the
actuator (pump, heater, etc.) is controlled analogically (analog terminal UA1). By repositioning the
jumper from "analog" to "digital", the actuator (pump, heater, etc.) can also be controlled digitally. (I/O
terminal output A0.0)
4. Analog terminal (Syslink analog): analog connection of the controlled variable x and the manipulated
variable y.
5. Starting current limiter: limits the max. station current (e.g., starting current of pumps)
6. Motor control: analog control of the motor of pump PL1 (0...10V corresponds to 0...24V).
7. 2-fold changeover relay for binary actuation of the motor of the pump PL2
8. 2-fold changeover relay for overflow protection circuit: if a tank is overfilled, the float switch opens, the
relay drops out and interrupts the power supply to the pump motors.
9. Wiring terminals for overflow protection circuit

8.8.2 Mounting frame

The mounting frame (1) of the MPS-PA station consists of a single-line ER frame for the connection board (2)
and a 19″ frame (3) for 19″ mounting plates.
The connection board is plugged into the ER frame.
Figure 13: ER mounting frame (similar to figure)

8.8.3 19″ frame

The following components are installed in the 19″ frame of the station:
• Power supply 120 V / 230 V AC with IEC socket in accordance with IEC 60320, type C13
• 19″ power supply 24 V DC, 4 A
• EasyPort 19″ USB
• 19″ control panel with 3 pushbuttons, 1 key switch and 4 LED indicators
• 19″ communication fields with 4 inputs and outputs placed on safety sockets (in combination with the
19″ control panel)
19″ frame – sample setup for the Filtration, Mixing, or Bottling stations
Switch off the device and unplug the connection for power supply before
assembly, repair, maintenance and cleaning work.
Observe the user documentation, in particular all safety instructions. Non-

observance may result in severe personal injury or damage to property.
There is a risk of electric shock if used improperly!
With the MPS PA 204 system, a 19″ EMERGENCY-STOP panel is added as an option to the 19″ frame of the
Filtration and Reactor stations.

8.9 PLC EduTrainer Universal S7-1512C

The Siemens SIMATIC controller CPU S7-1512C-1PN is integrated in an EduTrainer® Universal.
Figure 14: PLC EduTrainer Universal with S7-1512C
The compact CPU S7-1512C-1PN has the following technical data:

• Main memory: 250 KB for programs and 1 MB for data
• Memory card 24 MB
• Interface: PROFINET IRT with 2-port switch
and the following composition of inputs and outputs:

32 digital inputs (24 V DC) / 32 digital outputs (24 V DC / 0.5 A)
5x analog inputs, 4x U/I, 1x R/RTD, 16 bit resolution / 2x analog outputs, 2x U/I, 16 bit resolution
The support system of the EduTrainer Universal, size 1 (W x H) 305 x 300 mm, can be placed on a table or in
an MPS PA station. The 19″ module with 2x SysLink connector with 8 digital inputs and 8 digital outputs
each and 1x D-Sub 15-pin connector with 4 analog inputs and 2 analog outputs establishes the signal
connections to the MPS PA station and the control panel. The emergency stop bridge allows the connection
of a safety circuit to switch off 8 digital outputs with the emergency stop board.
The S7-1512C controller is connected to the automation network with a network cable (6 m).
The sample project in combination with the TP700 Comfort control console enables the operation of the
MPS PA station (see chapter 10.4 Sequence).

8.10 Control console with operator unit TP700 Comfort

The control console is mounted on the front right of the profile plate. The 7″ operator unit TP700 Comfort
operates with a resolution of 800 x 480 pixels. The electrical connections with the operating device are
established through a flexible cable bushing. The power supply is provided via a 2-core cable from the
connection board to 24 V DC. The operator unit TP700 Comfort is connected to the controller, for example an
S7-1512C, using a network cable (6 m).
Figure 15: Control console with operator unit TP700 Comfort
8.11 EasyPort and FluidLab-PA closed-loop V5

In addition to control via PLC and operator unit, the Mixing Learning System includes an EasyPort, which is
permanently installed in the 19″ frame. With FluidLab-PA closed-loop V5, process data can be recorded and
evaluated step by step, or the fundamentals of control technology can be learned and developed. The
EasyPort is used to connect a PC to actual hardware.
Figure 16: EasyPort 19″ USB
Optionally, the binary control of the process with the digital technology module or the GRAFCET can be
created in combination with FluidSim.

8.12 USB device server

With the 2-port USB device server, you can connect your USB devices and use them via the network. An
EasyPort USB and all other USB device types become network-compatible.
Figure 17: USB device server
The USB device, that is to say the EasyPort and thus the MPS PA station, can now be placed anywhere in the
network/classroom and does not have to be connected directly to the computer. In addition, several users
can access the learning scenario one after the other.
8.13 Trolley 700
The trolley makes an MPS PA Station a compact and

mobile unit. The station is mounted on the trolley.
The EduTrainer Universal, size 1, can be inserted
and the emergency stop board attached.
Appropriate through-holes in the side and rear
panels enable orderly routing of cables.
The front side is equipped with mountings for

panels. The trolley is supplied complete with twin
castors.
Figure 18: Trolley 700
Dimensions:
• Height: 750 mm (including castors, to bottom edge of profile plate)
• Width: 700 mm
• Depth: 700 mm

9 Function
9.1 Function as individual station

Liquid (tap water) is filled directly into the three metering tanks. After selecting a recipe with a mixture, the
mixing pump is used to pump the liquids one after the other into the main tank in the mixing ratio.
To empty the tanks, the hand valve in the drain line is opened. To do this, insert a suitable piece of pipe or
hose at the end piece to drain the medium into a bucket or similar.
9.2 Operation as a downstream station

The Mixing station can be combined with the individual stations of Filtration, Reactor, and Bottling to form a
single system. Various variants are possible:
• Upstream PA stations: Filtration Station, Mixing Station, Reactor Station
• Downstream PA stations: Filtration Station, Mixing Station, Reactor Station
If the Mixing Station is the first station, the liquid is fed directly into the three metering tanks, as with the
individual station. During operation as a downstream station, the first metering tank is connected to the
upstream station via the supply pipe and a flexible tube. Before filling the first metering tank, the hand valve
in the drain line must be closed and opened in the inlet (downstream PA station). The liquid is then pumped
by the pump of the upstream PA station into the first metering tank of the Mixing Station. After the mixing
process has been completed, you can use the pump of the downstream station to pump the liquid from the
main tank to the next downstream PA station. If the downstream tank is already filled with liquid, the
pumping process cannot be started.
Communication between the MPS PA stations takes place via 4mm safety laboratory cables and the
communication fields, as with MPS-D stations. Tank overflows in the Mixing station are monitored using
float switches. The overflow protection is coupled to upstream and downstream stations using an optical
transmitter and receiver.

10 Sequence description
10.1 Sequence description of the mixing process

Liquids can be pumped from three dosing tanks into the main tank. A mixing pump fills the main tank with
the mixture. When working with a downstream station, the finished mixture can then be pumped to the next
station via the pump of the downstream PA station when the discharge valve is open. Otherwise, the liquid
is pumped back into the three smaller metering tanks.
10.2 Start-up prerequisites
10.2.1 Individual station

• Metering tanks must be filled with a liquid (lower and upper proximity switch actuated).
• Main tank is empty (lower proximity sensor, unactuated).
10.2.2 Station with downstream station

• Metering tanks must be filled with a liquid (lower and upper proximity switch actuated).
• Main tank is empty (lower proximity sensor, unactuated).
10.3 Initial position

• 2W ball valves are closed
10.4 Sequence
Select which mixture is used in the station.
Recipe VE1 VE2 PU3
Recipe A 80% 10% 10%
Recipe B 75% 10% 15%
Recipe C 75% 15% 10%

Mixing Learning System Sequence description
10.4.1 Automatic mode without downstream station

1. Select the quantity (1…2 l) and recipe A, B, or C.
2. Starting
3. Station not occupied as long as the first metering tank is not full.
4. Upper limit switch triggers when the first metering tank is full (approx. 2.7l)
5. Switch on mixing pump and open valve from tank 1 until timer recipe
6. Close valve of tank 1 and open valve of tank 2 valve until timer recipe
7. Close valve of tank 2 and open valve of tank 3 until timer recipe
8. Close the valve of tank 3, switch off the pump
9. Message recipe “Ready”
10. Continue with 1.
The STOP function switches the actuators off at any time.
10.4.2 Automatic mode with downstream station

1. Set to a fixed quantity (2l) and select recipe A, B, or C
2. Select the flow rate (1…5l/min)
3. Starting
4. Main tank not full, metering tanks not empty, and pump of the downstream station off
5. Switch on the mixing pump and open the valve of tank 1 until timer recipe
6. Close the valve of tank 1 and open the valve of tank 2 until timer recipe
7. Close the valve of tank 2 and open the valve of tank 3 until timer recipe
8. Close the valve of tank 3, switch off the pump
9. The pump of the downstream station then pumps the water into the downstream station (as soon as it
is ready) until B204 is empty.
10. Message recipe “Ready”
11. Continue with 3.

Sequence description Mixing Learning System
10.4.3 Manual mode

All actuators can be switched on in the Manual/Flow diagram menu on the control console (control elements
as switches). All analog values and the signal statuses of the sensors are displayed. In manual operation,
the station must be reported as busy so that liquid from an upstream station is not pumped into the tank. At
the same time, the STOP function is active at all times, which switches off all actuators.
Figure 19: Operating screen for manual operation
Notes
• The sequence can be interrupted at any time by pressing the EMERGENCY-STOP button or by
pressing the STOP button.
• The following applies when several stations are combined:
The individual stations are aligned in the order opposite the direction of material flow.

11 Commissioning
The stations of the MPS PA are generally

• Fully assembled
• Individually adjusted and ready for use
• Pre-commissioned
• Tested
Figure 20: Flow chart for commissioning an MPS PA station.

Commissioning Mixing Learning System
Commissioning is normally limited to visual inspection in order to ensure correct tubing connections, wiring,
and operating voltage supply.
All components, tubing connections and cabling are clearly identified, so that all of the connections can be
readily restored.
11.1 Workstation
To commission the MPS PA station with the sample programs you will need:
• the mounted and adjusted MPS PA station
• a control console with operator unit (e.g., TP700)
• a PLC EduTrainer with 16 digital inputs and outputs and 4 analog inputs, 2 analog outputs
• a power supply 24 V DC, 4 A, ≤100 W output power, SELV/PELV limited power source (LPS)
• compressed air supply: 600 kPa (6 bar)
• a PC with installed PLC programming software
• two I/O cables (SysLink) and one analog cable
11.2 Filling and emptying

1. Switch off the power supply and pull out the mains plug.
2. Check the piping and tubing connection of the components for correct seating.
3. Close the exhaust valve.
4. Switch off the compressed air supply.
5. Fill the main tank with max. 6 liters of clean tap water. The float switch (overflow protection) must not
be mechanically actuated. The float must be horizontal and cover the reed contact.
6. Check the piping of the components for tightness.
7. Remove splashing water.
8. Switch on the power supply at the 24 VDC power supply unit.
9. Check if the LEDs of the two capacitive proximity sensors indicate a signal after filling.
10. The storage tanks are emptied when the pump pumps the liquid in the mixing tank or when the hand
valve in the drain line is opened and the liquid is drained into a separate tank. To do this, insert a
suitable pipe or piece of tubing into the connection in the drain.
Note
Always empty the station completely if it is not to be used for a long period of time.

Mixing Learning System Commissioning
11.3 Power supply

• The stations are supplied with electricity from a power supply with 24 V DC voltage (max. 4 A).
• The power supply for the entire station is provided via the PLC EduTrainer, SimuBox,
or the EasyPort 19″ USB.
11.4 Compressed air supply

The service unit is connected via a coupling plug. The quick coupling socket (KD3-CK-6) is included in the
scope of delivery of the service unit:
1. Connect the plastic tubing PUN 6x1 to the coupling socket.
2. Connect the plastic tubing PUN 6x1 to your compressed air supply. If necessary, use the T-plug
connector for 6 mm tubing.
Figure 21: On-off valve with filter regulator
3. Connect the quick coupling socket to the quick coupling plug of the service unit.
4. Check the display of the pressure gauge and set a pressure of 6 bar at the filter regulator.
11.5 Actuation with PLC EduTrainer and control console
11.5.1 Cable connections between station and EduTrainer PLC

The cable connections are described and shown for an MPS PA station connected to a PLC control without
power supply in the EduTrainer Universal as MPS-PA preferred variant:
• Connect the digital I/Os of the EduTrainer (3/A) and the I/O terminal (5) XD1 of the station with I/O data
cable SysLink (7) or check the connection.
• Connect the digital I/Os of the EduTrainer (3/B) and control panel (4) with the I/O data cable SysLink
(10) or check the connection.

• Connect analog I/Os of the EduTrainer (3/C) and analog terminal XD3 (6) of the station
with analog I/O data cable (8) or check the connection.
• Connect the EduTrainer laboratory sockets to the power supply and power supply unit with laboratory
cables (9 - 4 mm safety plug red = + / blue = -) or check the connection.
• Connect your PC or operator unit with a network cable to the PLC controller (not shown) or check the
connection.
Legend
1 I/O connection board MPS-PA station
2 Power supply unit 24 V DC, 4.5 A
3 Edutrainer Universal with PLC
4 Control panel
5 I/O terminal SysLink
6 Analog terminal
7 SysLink I/O data cable, parallel (034031)
8 Analog cable, 15-pin, parallel (529141)
9 Laboratory cable with safety laboratory sockets

(red/blue)
10 SysLink I/O data cables, parallel (034031)
Figure 22: Cable connection MPS PA Station - EduTrainer Universal without power supply

11.5.2 Cable connections between control console and PLC EduTrainer

The cable connections are described for a control console with TP700 Comfort connected to a PLC
EduTrainer. On delivery, the cables in the control console are already connected. To remove the
connections, the front panel on the front of the control console must be removed and the cable through feed
opened on the back.
Procedure
• Connect the network cable from the operator unit to the PLC controller (not shown) or check the
connection.
• Check/Connect the power supply cable in the control console. The operating device is supplied via the
SysLink terminal and only switches on when the PLC EduTrainer is connected to the station and the 24 V
DC power supply unit has been switched on.
11.5.3 Establish 1-bit communication connections

The communication cables are supplied with the station and must be plugged in.
The communication connections to the other stations must be established according to the following
examples. The examples are general, but apply equally to all stations. Any deviations from this standard will
be pointed out.
Example of I/O push-in connectors between 19″ frames
Figure 23: Communication connection between 19″ frames

Procedure
• Connect the sockets Q4 and GND of the downstream station to the sockets I6 and GND of the upstream
station
Further MPS-PA stations are connected to each other according to the same principle.
Figure 24: Communication connection between 19″ frames on several MPS-PA stations
11.5.4 Load sample project
Siemens S7-1500 CPU1512C

For example, use an EduTrainer Universal with Siemens S7-1500 CPU1512C.
Programming software: Siemens STEP7 version 14 (SP1) or higher
1. Connect the PC and PLC with the network cable

2. Switch on the power supply
3. Switch on the compressed air supply
4. Unlock emergency stop switches (if present)
5. Reset the memory of the PLC
6. Set the CPU switch to the STOP position
7. Start the TIA-Portal development environment
8. Unarchive the file, e.g., MPS-PA_V2-4_CPU1512C_TP700_XXX.zap14 in directory
...\MPS-PA_Sources_V2-4\PLC&HMI\S7-1500_TP700 of the supplied CD-ROM.
9. Load the project into the PLC. Help can be found at Getting started.
10. CPU switch in RUN position

Siemens TP700 Comfort

For example, use a control console with Siemens TP700 Comfort.
Programming software: Siemens STEP7 version 14 (SP1) or higher
1. Connect the PC and HMI with the network cable

2. Switch on the power supply
3. Start the TIA-Portal development environment
4. In the de-archived project (see above), select the corresponding sub-project of the station “tpBottling”.
5. Load the project into the operator unit. Help can be found at Getting started.
11.5.5 Starting the sequence

1. Check the power supply and compressed air supply.
2. Empty/Fill the station as described in “chapter 11.2 Filling and emptying”.
3. Select the automatic operating mode with/without downstream station.
4. Select a recipe in the process type.
5. Press the Start button.
6. The station starts the sequence.
Notes
• The sequence can be stopped at any time by pressing the emergency stop button or
the STOP button.

11.5.6 Operation on the control console with operator unit TP700 Comfort
The control console is mounted on the front right of the profile plate. First, connect all the components of
the station. Check whether the PLC is in operation and the program is loaded.
Main menu
If all components are in operation, the main menu appears on the control console.
Figure 25: Main menu screen
1. First, select the language (German, English, Spanish, or French) using the four flag symbols.
2. Select one of the four operating modes: automatic, manual, controller configuration, or display of the
trend.
Note
The actuators can be switched off at any time via the “STOP” button – automatic operation is
ended.

Automatic mode
Main menu (points 1 to 2)
3. In the main menu, select the “Automatic” button.
4. Select the automatic mode as individual station “Without downstream PA station” or in combination
with other MPS-PA stations “With downstream PA station” (see chapter 10.4 Sequence).
Figure 26: Automatic operating screen
5. In the next screen, select a recipe. The metered quantities stored in the program, i.e., the number and
the filling time, are displayed.
6. In “Conf. Controller”, check the control parameters.
7. Press the “Start” button to start the recipe (see chapter 10.4 Sequence, recipe sequence).
Figure 27: Automatic control screen, individual station

Figure 28: Automatic control screen in network
Note
If the tanks VE2 or VE3 are empty or VE4 is full, the message “Station not ready - BG4 + BG5 +
Problem BG6” appears in the information field. If tank VE1 is empty, the message “Filling container
VE1” appears.
When the recipe is finished, you will receive the message "Recipe ready".
8. Use the "Back" button to return to the main menu.

Manual mode
3. In the main menu, press the “Manual” button.
4. The operating screen shows all actuators and sensors in color. Sensor “green” is actuated and emits a
signal, while sensor “red” is unactuated. Actuator “green” is in operation, while actuator “gray” is not in
operation.
Figure 29: Operating screen for manual operation
5. All actuators can be actuated on the screen. For actuators with an analog value specification, a new
screen opens for further settings.
Figure 30: Operating screen for manual operation – Reference value of the pump
6. Set the control value directly or using the arrow buttons. Read the actual value of the flow rate on the
display.
7. The “Back” button returns you to the main menu.

Controller configuration
3. In the main menu, press the “Controller configuration” button.
4. Set the values for the proportional coefficient Kp and the reset time Ti and the derivative action time Tv
using the arrow buttons or directly.
Figure 31: Operator screen for controller configuration
5. With the “Load default values” switch, you reset the control system to specified standard values.
Trend
3. In the main menu, press the “Trend” button.
4. The manipulated variable, actual value, and setpoint value of the filling quantity are displayed in the
curve diagram.
Figure 32: “Trend” operator screen with the curve diagram

11.6 Actuation with EasyPort 19″
Cable connections between station and EasyPort 19″

The cable connections are for one MPS PA station connected to EasyPort 19″ described and illustrated:
• he Connect digital I/Os of port 1 of the EasyPort and the I/O terminal (4) XD1 of the station with I/O data
cable SysLink (6) or check the connection.
• Connect the digital I/Os of port 2 of EasyPort and the control panel (9) with I/O data cable SysLink (4) or
check the connection.
• Connect the analog I/Os of port 3 of the EasyPort and analog terminal XD3 (5) of the station
with analog I/O data cable (7) or check the connection.
• Connect EasyPort for power supply and power supply unit with laboratory cables
(7 - 4 mm safety plug red = + / blue = -) or check the connection.
• Connect your PC or operator unit to EasyPort using a network cable (not shown) or check the
connection.
Legend
1 I/O connection board MPS-PA station
2 Power supply unit 24 V DC, 4.5 A
3 EasyPort 19″
4 I/O terminal SysLink
5 Analog terminal
6 SysLink I/O data cable, parallel (034031)
7 Analog cable, 15-pin, parallel (529141)
8 Laboratory cable with safety laboratory sockets

(red/blue)
9 Control panel with I/O data cable SysLink, parallel

(034031)
Figure 33: Cable connection MPS PA Station – EasyPort 19″

11.7 Adjusting sensors
11.7.1 Capacitive proximity sensor

The two capacitive proximity sensors are used for level detection in the main tank. They should be adjusted
so that you can detect the liquid in the tank without contact, but not the container surface. The liquid
changes the capacitance of a capacitor integrated in the proximity sensor.
Note
The capacitive proximity sensors are used at the positions of the lower level and the upper level.
Prerequisites
– The tank and a profile for installing the mounting brackets are mounted
– Electrical connection of the capacitive proximity sensor is established
– Power supply switched on.
Procedure
1. Mount the proximity switches with the mounting bracket so that they do not touch the tank. Distance in
each case 5 mm from the tank.
2. Fill the tank with liquid.
3. The proximity sensors are set to the following values:
– Storage tank 1: 1.6 l (bottom); 2.7 l (top)
– Storage tank 2: 0.5 l (bottom);
– Storage tank 3: 0.5 l (bottom)
– Main tank: 0 l (bottom); 6 l (top)
4. Move the sensors up or down until the switching status display (LED) switches on at the respective
volume level.
Note
The proximity sensor must be triggered by the liquid in the tank. If there is no liquid in the tank, no
signal may be present.
5. Check the positioning and adjustment of the proximity sensor by repeated filling and emptying of the
tank.

11.7.2 Float switch, cover installation

The float switch is designed for installation in a 3 l tank. The float switch opens when the maximum liquid
level in the tank is exceeded and switches off the pumps via the relay.
Prerequisites
– The tank is mounted
– Electrical connection of the float switch established
Procedure
1. The float switch is led from the inside through the cover opening in the tank and screwed from the
outside.
2. Connect the float switch. The switch must emit a signal without liquid.
3. Fill the tank and determine if the float switch interrupts the signal when the maximum fill level is
exceeded. The float must move upward.
4. Check the positioning and adjustment of the sensor by repeated filling and emptying.
Note
Make sure that the float always moves freely and does not jam due to dirt.
11.7.3 Float switch, lateral installation

The float switch is designed for installation in a 10 l tank. The float switch opens when the maximum liquid
level in the tank is exceeded and switches off the pumps via the relay.
Prerequisites
– The tank is mounted
– Electrical connection of the float switch established

Procedure
1. The float switch with cable is led from the inside through the upper left opening in the tank and screwed
from the outside. The float must be mounted to swivel upward.
2. Connect the float switch. The switch must emit a signal without liquid.
3. Fill the tank and determine if the float switch interrupts the signal when the maximum fill level is
exceeded. The float must move upward.
4. Check the positioning and adjustment of the sensor by repeated filling and emptying.
Note
Make sure that the float always moves freely and does not jam due to dirt.
11.7.4 Flow sensor, electromagnetic

The flow sensor is intended for installation in the piping. The sensor is set at the factory for a 0-10V analog
signal proportional to the flow rate and a binary switching signal for the flow rate limit value of 3 l/min.
Check the setting parameters of the sensor.
Parameter Description Factory setting User setting
SP1 Switching point 5.00 3.00
rP1 Reset point 4.90 2.50
OU1 Switching signal HNO HNO
OU2 Analog output signal I U
AEP Analog end value for volumetric flow rate (l/min) 25.00 10.00
Note
Further information can be found in the operating instructions for the flow sensor.
Prerequisites
– The sensor is mounted in the piping.
– Electrical connection of the sensor is established.
– Control is connected.
Procedure
With a flow rate of > 3 l/min, the LED 8 “SP1” must light up in the display.

12 Maintenance and troubleshooting
12.1 Maintenance
Festo Didactic systems and components are to a great extent maintenance free. The following components
should be cleaned at regular intervals with a soft, lint-free cloth or brush:
• The lenses on the optical sensors, the fiber optics and the reflectors
• The active surface of the proximity sensor
• The entire station
Note
Always use water of drinking water quality. If the MPS PA Station is not used for a longer period of
time, the water should be drained off, the remaining water should be removed from the containers
and pipes with a wet vacuum cleaner and rubbed dry with a lint-free cloth.
Observe the instructions in the data sheets!

Maintenance and troubleshooting Mixing Learning System
12.2 Error in the piping system and tanks

The following table shows errors that can be simulated through use of the manual valves or that occur due
to incorrect operation.
Location Error / What is the effect of the What causes errors? How can I detect and
Disturbance variable / error, disturbance prevent errors?
Danger potential variable, or danger?
Error in piping system and tanks
Storage tanks VE1, VE2, The pump draws in air Pump makes noises, air The piping upstream of Acoustic perception
or VE3 bubbles in the rising line the pump is not Remedy: Open ball
exhausted after valves VV1, VV2, and
emptying. VV3 to balance the tanks
Open VV1, VV2, and VV3
Open VV10 and switch
on the pump
Storage tanks VE1 Overflow When filling from the Float switch without The float switch is not
upstream station, the function or blocked movable
overflow protection is
not effective
Mixing tank VE2 Overflow When filling from the Float switch without The float switch is not
upstream station, the function or blocked movable
overflow protection is
not effective
Hand ball valve VV12 Restrict supply to mixing Longer filling time Close hand ball valve Observation of FluidLab
tank inlet VV12. PA curve
Manual valve VV9 Supply to the No supply to Valve VV9 is closed Visual inspection
downstream station downstream station
available during
pumping
Manual valve VV8 Inlet to storage tank VE1 No supply to the storage Valve VV8 is closed Visual inspection
tank during supply

Mixing Learning System Maintenance and troubleshooting
12.3 Error in the pneumatic system

The following table shows errors that can be simulated through use of the pneumatic components or that
can occur due to incorrect operation.
Error in the pneumatic system
Service unit/compressor No compressed air The 2W ball valve does Compressor off, Inspect the pressure
supply not move despite the compressed air line not gauge/manometer on
24VDC signal present at plugged in, pressure the service unit
the 5/2W solenoid valve regulator set to zero bar
or simply hand valve on
service unit switched off
Cable between service Pneumatic tubing The 2W ball valve does Kink off the hose and Unplug the compressed
unit and solenoid valves pinched not move despite the secure it with cable ties air tubing from the
24VDC signal present at solenoid valve, hold the
the Namur solenoid tubing tightly, switch the
valve signal to the solenoid
valve and check whether
air escapes

Maintenance and troubleshooting Mixing Learning System
12.4 Error in the electrical system

The following table shows errors that can be simulated through use of the electrical components or that can
occur due to incorrect operation.
Electrical faults
19" frame Power supply faulty No electrical function Unplug the IEC power Observe the light at the
back/underside cable or remove the power supply switch or
micro fuse measure the voltage
I/O terminal No switching function 24 VDC outputs do not Unplug the SysLink cable Visual inspection
switch, sensors are not from the I/O terminal
displayed by LEDs
Pump PL1 Flow rate too low Flow rate too low, On the motor controller, Display of flow rate at
increased filling time exchange ports 1 and 2 only ~ 2 l/min
of the pump
Pump PL1 Flow rate too low Flow rate too low, Turn the adjusting screw Select the tank.
increased filling time on the motor controller
counterclockwise with a
small screwdriver
SysLink I/O terminal Signal statuses faulty Switching signals are not Slide switch is in Visual inspection
displayed or are position NPN instead of with data sheet, observe
displayed incorrectly PNP representation
12.5 Mechanical faults

The following table shows errors that can be influenced mechanically or can occur as a result of incorrect
operation.
Mechanical faults
Mixing tank VE4 Filling level via Incorrect or absent Turn the sensor or adjust Visual inspection of I/O
capacitive sensors signal display the mounting bracket check
along the profile

Mixing Learning System Maintenance and troubleshooting
12.6 Error due to parameterization

The following table shows errors that can be influenced by incorrect setting of parameters or can occur as a
result of incorrect operation.
Parameter error
Pump Characteristic curve not At higher gains Kp, System performance Set the offset of the
linear oscillations occur in the reference variable in
control circuit FluidLab-PA
Flow sensor Measured value in Measurement error or Setting parameter of the Check or adjust the
FluidLab-PA does not inaccuracy sensor adjusted or reset parameters on the
agree with display on the or incorrect setting to factory setting sensor display or via the
sensor SmartBridge app
EasyPort Connection to EasyPort Connection cannot be Set the EasyPort at the EasyPort using the
established address, e.g., 2, Address buttons

13 Further information and updates
Further information and updates of the technical documentation for the Festo Didactic components and
systems are available at the following website:
www.ip.festo-didactic.com
14 Disposal
Electronic waste contains reusable materials and must not be disposed of with household
waste. Bring electronic waste to a designated municipal collection point.

15 List of figures
Figure 1: Front view Mixing Learning System __________________________________________________ 22

Figure 2: Mixing station (similar to figure) ____________________________________________________ 23
Figure 3: RI flow diagram to ISO10628 and EN 62424 ___________________________________________ 25
Figure 4: Flow system ____________________________________________________________________ 26
Figure 5: Rotameter ______________________________________________________________________ 26
Figure 6: Pump with 24 VDC motor __________________________________________________________ 27
Figure 7: Level monitoring with capacitive proximity sensors _____________________________________ 27
Figure 8: Level monitoring with float switch (lateral installation) __________________________________ 28
Figure 9: Electromagnetic flow sensor BF1 (PCE exercise 'FIC BF1') ________________________________ 28
Figure 10: 2W ball valve with pneumatic quarter-turn actuator (similar to figure)_____________________ 29
Figure 11: On-off valve with filter regulator ___________________________________________________ 30
Figure 12: I/O connection board (similar to figure) _____________________________________________ 31
Figure 13: ER mounting frame (similar to figure) _______________________________________________ 32
Figure 14: PLC EduTrainer Universal with S7-1512C ____________________________________________ 34
Figure 15: Control console with operator unit TP700 Comfort ____________________________________ 35
Figure 16: EasyPort 19″ USB _______________________________________________________________ 35
Figure 17: USB device server _______________________________________________________________ 36
Figure 18: Trolley 700 ____________________________________________________________________ 36
Figure 19: Operating screen for manual operation _____________________________________________ 40
Figure 20: Flow chart for commissioning an MPS PA station. _____________________________________ 41
Figure 21: On-off valve with filter regulator ___________________________________________________ 43
Figure 22: Cable connection MPS PA Station - EduTrainer Universal without power supply _____________ 44
Figure 23: Communication connection between 19″ frames ______________________________________ 45
Figure 24: Communication connection between 19″ frames on several MPS-PA stations _______________ 46
Figure 25: Main menu screen ______________________________________________________________ 48
Figure 26: Automatic operating screen _______________________________________________________ 49
Figure 27: Automatic control screen, individual station _________________________________________ 49
Figure 28: Automatic control screen in network ________________________________________________ 50
Figure 29: Operating screen for manual operation _____________________________________________ 51
Figure 30: Operating screen for manual operation – Reference value of the pump ____________________ 51
Figure 31: Operator screen for controller configuration _________________________________________ 52
Figure 32: “Trend” operator screen with the curve diagram ______________________________________ 52
Figure 33: Cable connection MPS PA Station – EasyPort 19″ _____________________________________ 53

Festo Didactic SE
Rechbergstraße 3
73770 Denkendorf
Germany
+49 711 3467-0 www.festo-didactic.com

+49 711 34754-88500 did@festo.com

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8079863

Mixing Learning System

© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2019

+49 711 3467-0 www.festo-didactic.com

1 General requirements for operating the devices _______________________________________________7

3 Intended use __________________________________________________________________________ 10

4 For your safety ________________________________________________________________________ 11

5 Work and safety instructions _____________________________________________________________ 13

© Festo Didactic 696686 3

8.5 Level monitoring ___________________________________________________________________ 27

4 © Festo Didactic 696686

11.6 Actuation with EasyPort 19″ _________________________________________________________ 53

12 Maintenance and troubleshooting _______________________________________________________ 57

13 Further information and updates ________________________________________________________ 62

15 List of figures ________________________________________________________________________ 63

© Festo Didactic 696686 5

6 © Festo Didactic 696686

1 General requirements for operating the devices

General requirements for safe operation of the devices:

© Festo Didactic 696686 7

Strong optical radiation.

8 © Festo Didactic 696686

General information about a hazard

Observe the user documentation, in particular all safety instructions. Non-

Warning of electric shock

Warning – laser radiation

Warning of strong optical radiation

Warning of hot surfaces

Warning of crushing hazard

Warning of drawing in due to rotating rollers

Warning of loud noises

Warning of lifting heavy loads

Warning of accidental retraction

© Festo Didactic 696686 9

Festo Didactic systems and components must only be used:

10 © Festo Didactic 696686

4 For your safety

4.1 Important information

4.2 Obligations of the operating company

4.3 Obligations of the trainees

© Festo Didactic 696686 11

4.4 Dangers when handling the components and systems

Festo Didactic systems and components must only be used:

Malfunctions which could impair safety must be eliminated immediately!

Improper repairs or modifications may result in unforeseeable operating states. Do not

12 © Festo Didactic 696686

5 Work and safety instructions

5.1 General remarks

5.2 Mechanical system

© Festo Didactic 696686 13

5.3 Electrical system

14 © Festo Didactic 696686

– Switch off the power supply immediately.

© Festo Didactic 696686 15

• Risk of accident due to advancing cylinders.

5.5 Process technology

16 © Festo Didactic 696686

6.1 General data