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DCS Learning System (PCS neo)



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Reference : 8232218



Process Workstation

Process Equipment

  • Industrial stainless-steel piping
  • Polyethylene tank – 60.6 L (16 US gal)
  • Large acrylic column with sparger tube and stainless-steel baffle – 30.4 L (8.0 US gal)
  • Small acrylic column – 7.6 L (2.0 US gal)
  • High-capacity brass centrifugal pump – 0.75 kW (1 HP), 208 V
  • Medium-capacity brass centrifugal pump – 0.75 kW (1 HP), 208 V
  • Two SIMATIC G120 variable frequency drives – 0.75 kW
  • 2-way ball valve with manual lever, flow coefficient Kv = 59 m³/h
  • Manual ball valve
  • Check valve with flow coefficient Kv = 9.482 m³/h
  • 20 stainless-steel pressure tapping points
  • Emerson pneumatically actuated ball valve (12 mm / ½"), Kv = 5.16 (Cv = 6), control range 21–90 kPa (3–13 psi)
  • Festo VPPM digital proportional pressure regulator
  • Pressure gauge – 0–690 kPa (0–100 psi)
  • Rotameter – 0–80 LPM (0–20 US gpm)
  • Festo VZWM solenoid valve – 24 V DC
  • Festo VZXF pneumatically piloted angle-seat control valve

Control Components

  • SIMATIC IPC BX-32 with SIMATIC PCS neo V6.0 license and database
  • Siemens CPU410-5H
  • SIMATIC ET 200SP HA IM155-6 PN interface module
  • SIMATIC ET 200SP HA BA 2xRJ45 bus adapter with dual RJ45 ports
  • SIMATIC ET 200SP HA DI 16x24VDC digital input module with channel diagnostics
  • SIMATIC ET 200SP HA AI 16xI 2-wire HART analog input module, 16-bit, with channel diagnostics
  • SIMATIC ET 200SP HA AQ 8xI HART analog output module, 16-bit, with channel diagnostics
  • SCALANCE XC208 managed Layer 2 industrial Ethernet switch
  • Pepperl+Fuchs PPA Ethernet-APL / Profibus PA switch
  • Siemens IPC BX-32A
  • 22” flat panel display (IFP2200)
  • Electronically configurable signal tower with 9 segments and acoustic module
  • SITOP PSU8200 stabilized power supply – 24 V / 20 A
  • SITOP PSE200U 4-channel electronic protection module

Instrumentation (Endress+Hauser)

  • PTC31B pressure switch (IO-Link®)
  • PMD75B differential pressure transmitter (high range, PROFINET over Ethernet-APL, Bluetooth®, Heartbeat Technology)
  • TH15 temperature transmitter with Pt100 RTD (HART®, Bluetooth®)
  • TH55 temperature transmitter with Type J thermocouple (HART®, Bluetooth®)
  • 5P3B15 electromagnetic flowmeter (HART®, WLAN, Heartbeat Technology)
  • FMR51 + FHX50 radar level transmitter with remote display (Bluetooth®, Heartbeat Technology)
  • PMD75B + DA63M differential pressure transmitter with 3-valve manifold for Venturi flow measurement (low range, HART®, Bluetooth®, Heartbeat Technology)
  • PMD75B differential pressure transmitter for level measurement (low range, PROFIBUS PA, Bluetooth®, Heartbeat Technology)

Gas (Air) Control

  • Festo SPAU pressure sensor with display (IO-Link®)
  • Festo VEMD mass flow meter with display and dynamic control (2–100 LPM, Modbus®)
  • Festo MS6N precision pressure regulators – 5–255 kPa (0.7–37 psi), flow rate 1098 LPM (38.8 scfm)



This training unit provides comprehensive hands-on instruction in measurement, instrumentation, and process control — from fundamental principles to advanced applications. It integrates IIoT-compatible components with a cloud-enabled Distributed Control System (DCS), enabling remote monitoring and operation.

The didactic system includes all equipment required to control water pressure, flow, and level; monitor temperature; and regulate air pressure and flow, using water and air as safe process media. It supports single-loop control as well as cascade, batch, and multivariable control strategies. The platform covers the full learning spectrum, from basic PID concepts to interacting loop dynamics and step-based process sequencing.

The mobile and robust workstation features 316 stainless steel piping, two acrylic columns, a sparger tube, a tank, and two centrifugal pumps (with different capacities) equipped with variable frequency drives. It includes manual valves (ball, plug, and check), pneumatic pilots, proportional pressure regulators, a pneumatically actuated ball valve, a pneumatically piloted angle-seat control valve, a solenoid valve, and 22 pressure tapping points. A pressure gauge and a rotameter provide flow and pressure monitoring.

The intelligent instrumentation includes a pressure switch, differential pressure transmitters for flow and level measurement, temperature transmitters, electromagnetic flowmeters, and radar level transmitters with remote display.

Electrical components are housed in a rear enclosure. Communication technologies include PROFINET, PROFIBUS, IO-Link®, HART®, Modbus® TCP, Ethernet-APL, WLAN, Bluetooth®, and Heartbeat Technology.

All components are fully integrated with SIMATIC PCS neo by Siemens and are accessible via HMI or a web browser for remote monitoring and operation. Advanced data visualization tools, along with built-in testing and simulation functions, enable learners to develop strong expertise in process automation.

A structured course provides comprehensive coverage of key learning topics with clearly defined educational objectives. It includes step-by-step laboratory exercises designed specifically for use with the system and is available in digital format via Festo LX (subscription required) or as printed lab manuals under a Campus License.

Technical Specifications

Electrical Requirements

  • Voltage: 230 V AC
  • Phase: Single-phase
  • Current: 4.5 A
  • Frequency: 50/60 Hz

Compressed Air Requirements

  • Operating pressure: 6.2 bar (90 PSI)
  • Air consumption: 28 L/min (1.0 SCFM)
  • Air quality: Dry, oil-free air (ISO 8573-1 Class 2)
  • Connection type: Push-in fitting G 1/4"

Physical Characteristics

  • Approximate dimensions (H × W × D):
    2005 mm × 2080 mm (2623 mm with screen) × 763 mm
    (104 in × 80 in [103 in with screen] × 31 in)
  • Weight: 372 kg (820 lbs)



8232218
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