Alternative & Renewable Energy Training Systems
Alternative & Renewable Energy Training Systems
Known as the standard for technical
training systems in use across virtually
every industry and around the globe,
Festo is now using its expertise to
facilitate the development, production,
installation, and maintenance of the
widest variety of Alternative and Renew-
able Energy Power Training Systems.
Alternative Energy is a natural pro-
gression for Festo. Since the post-
war technology boom of the 1950’s,
the company has been helping to train
the minds and hands of the specialists
and technicians who make the possible
practical. Festo has maintained its
leadership by combining expertise in
virtually all scientific, technological and
ii
industrial disciplines with the ability to
envision the most efficient and effective
means to educate within the training
center and classroom environments.
The result is a wide range of training
apparatus that consistently produces
awards for the company, and qualifies
technical specialists for virtually every
field of endeavor.
Systems range from those that train in
the basics and advanced applications
of electric power and controls, electro-
mechanical systems, telecommunica-
tions, manufacturing, automation and
robotics, fluid power, HVAC/R, and
more, to those that assist in the devel-
opment of upstream application skills
for researchers, designers, and product
developers.
Festo training systems are proven
and trusted worldwide by educators op-
erating in all sectors, including schools
and universities, vocational training,
government and the military, commerce
and industry, and more.
Festo supports all of their products
with state-of-the-art service centers in
the United States and Canada, and a
comprehensive network of product tech-
nicians standing by worldwide.
Alternative and renewable energy
sources are steadily climbing the lad-
der of environmental and commercial
importance as scarcity and expense re-
strict the supply of non-renewable fuels.
Festo recognizes the special nature
of Alternative and Renewable Energy,
an industry that combines factors more
unique and specialized and having more
complicated relationships than most tra-
ditional power generation and distribu-
tion fields.
While most power generation requires
the creation, management, and conver-
sion of heat energy into motion—with
most variations simply involving the
way heat is produced—alternative and
renewable sources are far more varied.
Many take advantage of the motion al-
ready found in nature; others harness
nature’s own renewable forms of heat
and energy. Capturing and converting
that motion or energy often requires
very non-traditional methods.
Accordingly, development of the Lab-
Volt alternative and renewable energy
training systems required rethinking the
traditional approaches to training, from
the need to understand the base sci-
ence to how, for example, location and
environmental issues affect an alterna-
tive/renewable energy source’s ability to
work efficiently or even acceptably.
Accustomed to breaking down pro-
cesses and procedures into elemental
blocks,Festo’s new training systems
take the esoteric and theoretical out of
the laboratory and translate it into ap-
paratus that introduce practical, under-
standable teaching methods.
Festo also recognizes the need to
nurture, through early education, an in-
terest and excitement in alternative and
renewable energy concepts and technol-
ogies in order to secure future innova-
tions in this field. Interactive, hands-on
programs for middle and high school
students foster awareness of the need
for alternative /renewable energy power
and spark the imagination, interest, and
desire to pursue this field through higher
education and beyond.
iii
New knowledge is flowing constantly in
both directions between the laboratory
and the installation. Festo is proud
to be the facilitator of that transfer,
helping the researchers develop better
and more efficient technology, helping
the designers determine the most prac-
tical means to use that technology, and
helping train technicians who will install
Table of Contents
Core Technical Systems . . . . . . . . . . . . 2
Industrial Controls . . . . . . . . . . . . . . . . 2
Mechanical Training . . . . . . . . . . . . . . . 4
Industrial Wiring . . . . . . . . . . . . . . . . . . 5
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fundamental Fluid Power . . . . . . . . . . 9
Fluid Power/Industrial Applications . . 10
® ®
LVSIM -HYD/LVSIM -PNEU . . . . . . . 11
Advanced Fluid Control Applications . 12
iv
and maintain the equipment for best
performance, longevity, and reliability.
Regardless of the operational scale of
the alternative energy sources , Festo
has distilled the essential elements
of the process down to safe, hands-on
classroom applications, developing
each training product and process to
Programmable Logic Controller . . . . . 13
PLC Applications . . . . . . . . . . . . . . . . 14
PLC Simulation Software . . . . . . . . . . 15
Electricity & Electronics . . . . . . . . . . . 16
FACET . . . . . . . . . . . . . . . . . . . . . . . . 16
Thyristors & Power Control Circuits . . 17
Magnetism & Electromagnetism . . . . 18
Motors, Generators, & Controls . . . . . 19
Power Transistors & GTO Thyristor . . 20
Synchro-Servo Training System . . . . 21
Electrical Power Transmission, Genera-
tion, Distribution . . . . . . . . . . . . . . . . . 22
yield realistic, repeatable, and logical
results. Contact your Festo repre-
sentative today to discuss your train-
ing challenges.Festo can suggest,
adapt, or customize a training system
to work perfectly within your program.
0.2-kW Electromechanical (EMS) . . . 22
Computer-Assisted 0.2-kW EMS . . . . 23
EMS Simulation Software
(LVSIM®-EMS) . . . . . . . . . . . . . . . . . . 24
Power Electronics Simulation
Software (PESIM) . . . . . . . . . . . . . . . 25
EMS Computer-Based Learning . . . . 26
Data Acquisition & Management
(LVDAM-EMS) . . . . . . . . . . . . . . . . . . 27
0.2-kW Protective Relaying . . . . . . . . 28
2-kW EMS . . . . . . . . . . . . . . . . . . . . . 29
0.2-kW Power Electronics . . . . . . . . . 30
 0.2-kW Electric Power
Transmission Line . . . . . . . . . . . . . . . 31
Control of Industrial Motors . . . . . . . . 32
Distribution Transformer . . . . . . . . . . 32
Power Line Series Compensation
Demonstrator . . . . . . . . . . . . . . . . . . . 33
Add’l EMS Equipment . . . . . . . . . . . . 34
Add’l 0.2-kW Equipment . . . . . . . . . . 35
Instrumentation Process Control
Systems . . . . . . . . . . . . . . . . . . . . . . . . 36
Instr. & Process Ctrl . . . . . . . . . . . . . 36
Process Control . . . . . . . . . . . . . . . . 38
Mobile Instr. & Process Ctrl . . . . . . . 40
Process Ctrl Stations . . . . . . . . . . . . 41
Bench-Top Trainers . . . . . . . . . . . . . 42
LVPROSIM . . . . . . . . . . . . . . . . . . . 43
Web-Based Training Systems . . . . . . 44
Industrial Training Zone (ITZ) . . . . . 44
ITZ Electrical Training . . . . . . . . . . . 45
ITZ Industrial Mechanical
Training . . . . . . . . . . . . . . . . . . . . . . 46
ITZ PLC Fundamentals . . . . . . . . . . 47
ITZ Hydraulics . . . . . . . . . . . . . . . . . 48
ITZ Pneumatics . . . . . . . . . . . . . . . . 49
Early Technology Science
Education . . . . . . . . . . . . . . . . . . . . . . . 50
Tech-Design Aerodynamics. . . . . . . 50
Tech-Design Alternative Energy . . . 51
Tech-Foundations Alt. Energy . . . . . 52
Inventions & Innovations: Design
A Windmill . . . . . . . . . . . . . . . . . . . . 53
Exploring Mechanisms. . . . . . . . . . . 54
Exploring Electricity . . . . . . . . . . . . . 55
1
Core Technical Systems
INDUSTRIAL CONTROLS TRAINING SYSTEM
Series 8036

Topic Coverage
• Basic Principles of Electric Motor
Control
• Circuit Layout and Specifications
• Basic Control Circuits
• Jogging Control Circuits
• Reduced AC Voltage Starters
• Time Relay Circuits
• Programmable Logic Controller
(PLC)
• PLC Control Circuits
• AC Drive
• DC Drive
• Sensors
• Troubleshooting

The Festo Industrial Controls Training System, Series 8036, has unique controls training capabilities, which are enhanced by its
modularity and its instructor-inserted faults. The system allows students to select and mount control devices to form typical control
circuits, and to troubleshoot them once a fault is inserted.
The Industrial Controls Training System is divided into four levels, each level being further divided into specific topics that deal with
various aspects of industrial controls equipment operation:
• Basic Controls System, Model 8036-1
• Programmable Logic Controller System, Model 8036-2
• Motor Drives System, Model 8036-3
• Sensors System, Model 8036-4
The control devices and motors in the 8036 Series are of standard industrial quality. Device designations can be added to each
module with magnetic labels. Each module is equipped with up to four faults that can be inserted by the instructor using switches
mounted behind the faceplate. Typical faults include open coils and contacts, dirty contacts, shorted connection, and crossed
wires.

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 Alternative & Renewable Energy Technologies
The modules of the Industrial Controls Training System can be
interconnected with those of other Festo training systems for
interdisciplinary training applications. Connections are made
using flexible PVC-insulated connecting leads terminated with
4-mm safety plugs. These leads allow safe connection of com-
ponents, since the live parts of their plugs are concealed and
insulated so they cannot be contacted accidentally. Leads come
in three different lengths,
each identified by a distinc-
tive color. Smaller connection
leads are also provided for
the low-voltage applications
running with 24 VDC.

Motor Drives (Stand-Alone) – Model 8036-A

The Motor Drives (Stand-Alone), Model 8036-A, is a complete,
stand-alone system that allows students to perform the same
exercises as with the system 8036-3. The system stands on
Model 8036-A a tabletop. The figure shows some components of the system
mounted in the Single-Rail Workstation (tabletop).

Motor Drives (Add-On to Models 8001 and 8006) – Model

8036-B
The Motor Drives (Add-On to Models 8001 and 8006), Model
8036-B, is an add-on to systems Models 8001 and 8006 that
allows the students to perform the same exercises as with the
system 8036-3 but using 8001 or 8006 motors and power sup-
ply. Note the components mounted in the Single-Rail Worksta-
tion on the top of the Mobile Workstation.

Model 8036-B

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Core Technical Systems
MECHANICAL TRAINING SYSTEM
Series 46101

Topic Coverage
• Belt Drives
• Chain Drives
• Gear Drives
• Lubrication
• Couplings
• Shaft Alignment
• Bearings
• Ball Screws
• Gaskets and Seals
• Clutches and Brakes
• Laser Alignment
• Vibration Analysis

Shown with optional components

The Festo Mechanical Training System, Model 46101, covers the installation, use, maintenance, and troubleshooting of me-
chanical drive components. The system is divided into five levels, and each level is further divided into specific topics which deal
with the components encountered in industry. The learning is based on practical, hands-on tasks.
The list of industrial components includes pulleys, sprockets, gears, various types of belts, single- and multi-strand chains, several
types of couplings, shafts, bearings, ball screws, clutches and brakes, and all the components required to assemble the proposed
setups.
Engineered for ease of use, the system comes with a universal steel base unit on which students prepare the setups using T-
slotted extrusion bars. This innovative design allows the base to be configured as required by the task. The universal base includes
a disconnecting switch, current meter, controls required to operate the motors, and electromagnetic clutch-brake unit. It also in-
cludes a Start/Stop push-button station for local and remote operation. The universal base can be installed on a regular table as
well as on other optional Festo benches.

4
 Alternative & Renewable Energy Technologies
INDUSTRIAL WIRING TRAINING SYSTEM
Series 46102

Topic Coverage
• Enclosures and Conduits
» Includes installing metal struts, enclo-
sures and boxes, flexible metal conduits,
liquid-tight flexible nonmetallic conduits,
electrical metallic tubing, and rigid metal
conduits.
• Electrical Power Distribution
» Includes installing a main distribution and
downstream distribution panel board, con-
duit and conductor installation, and wiring
the main distribution panel board.
• Electrical Wiring
» Includes installing safety switch handle
and motor overload reset button on the
motor control enclosure, overhead door
installation, reading electrical drawings,
and connection of the overhead door
simulator to the power lines.
• Three-Phase Motor Starters
• AC Motor Drive
• DC Motor Drive
Shown with optional components

The Festo Industrial Wiring Training System, Model 46102 faithfully reproduces an industrial environment where students can
develop their skills in the installation and wiring of industrial electrical equipment, in compliance with the National Electrical Code®
(NEC®). The system can also be used to teach trainees how to adjust and maintain industrial electrical equipment as well as en-
force the safety rules to be followed when working at industrial sites.
The Industrial Wiring Training System is divided into two levels, each level being further divided into specific topics that deal with
various aspects of industrial electrical equipment installation. The Industrial Wiring Training System – Level 1, Model 46102-20,
provides the student with complete basic training as an electrician.
The Industrial Wiring Training System – Level 2, Model 46102-30, expands on Level 1 to provide training in motor control equip-
ment installation as well as a solid introduction to the maintenance of industrial electrical equipment.
The Trainer supports up to four equipment setups at a time, allowing multiple student groups to work at a single workstation. Two or
more equipment setups can be grouped together to form complex industrial applications. Selection of equipment packages allows
the system to meet a wide range of training objectives while fully illustrated courseware guides students through various tasks. This
trainer also includes a mobile workstation featuring swiveling casters with lock mechanisms for easy motion and stable operation.
The trainer is sized to fit through standard door openings.

5
Core Technical Systems
PIPING TRAINING SYSTEM
Series 46105

Topic Coverage
• Installation of Metal Struts on the
Mobile Workstation
• Identification of Pipes, Fittings,
Valves, and Hangers
• Piping Circuit Layout and Mea-
surement
• Pipe Length Calculation
• Cutting, Reaming, and Threading
Steel Pipes
• Identification, Insulation, and
Assembly of a Steel Pipe Circuit
Using Threaded Fittings
• Assembly of a Hose Circuit Using
Barb Fittings and Clamps
• Assembly of a PVC Pipe Circuit
Using Cemented Fittings
• Assembly of a Copper Tube Circuit
Using Flare Fittings

Shown with optional components

The Piping Training System, Model 46105 is a hands-on training tool designed to train students for careers as pipe fitters and pip-
ing maintenance technicians.
The main learning objectives are the reading of piping schematics, calculation of pipe lengths, fabrication, installation, and testing
of piping circuits made of galvanized steel pipes, hoses, PVC pipes, and copper tubes.
The system can also be used to teach students how to enforce the safety rules to be followed when working at industrial sites. The
Mobile Workstation is the basis of the system. It is a versatile bench where the students set up the piping circuits. The pipes are
fixed to the Mobile Workstation using metal struts and pipe hangers. The workstation can accommodate two student groups at the
same time, and is sized to fit through standard door openings.

6
 Alternative & Renewable Energy Technologies
PUMPS TRAINING SYSTEM
Series 46106

Topic Coverage
• Single Pump Systems
• Multiple Pump Systems
• External Gear Pump
• Vane Pump
• Flexible Impeller Pump
• Progressive Cavity Pump
• Peristaltic Pump
• Pneumatic Diaphragm Pump
• Metering Pump
• Piston Pump
• Stuffing-Box Centrifugal Pump
• Multi-Stage Vertical Pump
• Magnetic Drive Centrifugal Pump
• Vibration Analysis
• Vibration Metering
• Laser Alignment

Shown with optional components

The Festo Pumps Training System familiarizes students with pump operation principles and associated maintenance tasks. The
system is divided into subsystems and learning is based on practical, hands-on tasks.
The Basic System, Model 46106-0, introduces students to maintenance tasks, such as pump installation, shaft alignment, wiring,
operation, inspection, maintenance, troubleshooting, and component replacement. It also introduces students to the measurement
of the pumping circuit parameters, pump characteristic curves, and how to use a variable speed drive.
The Multiple Pump System, Model 46106-1, introduces students to series and parallel pump configurations. Students also learn
how to replace the mechanical seal of a C-face centrifugal pump and are introduced to pump use, characteristics, and mainte-
nance through disassembly and by measuring operating parameters.
The system includes a bench, centrifugal pump with base and motor, variable speed drive, instruments, and tools. It also includes
a transparent cover that allows observation of cavitation and air ingestion in the pump. A wide variety of pumps are offered as
individual options. The pumps that can be added to the Pumps Training System correspond to the most common types found in
industry.

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Core Technical Systems
RIGGING SYSTEM
Series 46109

Topic Coverage
• Moving Machines Using Rollers
• Lifting and Handling Odd-Shaped Loads
• Moving Loads According to Center of
Gravity and Weight
• Handling Machines with Wire Rope
Pullers
• Identify Different Types of Rope, Cut
Rope Properly, and Make Knots
• Assemble a Wedge Socket on a Wire
Rope
• Install Hoist Trolleys, Chain Links, Chain
Hoist, and Electric Hoist on the Gantry
Crane
• Move a Machine from Ground Position
to a Pedestal
• Lift an Unbalanced Load

The Festo Rigging System was created to cover the fundamentals of rigging practices. Students practice the techniques that
must be developed and used to safely install and move machines. The Rigging System also features industrial-grade equipment,
as well as storage for all materials.
Moving machines is a basic requirement for any industrial plant. Usually built for special applications, machines have varying
shapes which are often asymmetrical. Machine weight, which is not evenly balanced on the machine supports, creates difficulties
for the rigger. Therefore, installation requires skilled and highly qualified riggers.
Work orders help students develop the skills required for rigging practice and are an excellent test bench for the students.

8
 Alternative & Renewable Energy Technologies
FUNDAMENTAL FLUID POWER TRAINER
Model 6059

Topic Coverage
Volume 1, Fundamentals of Fluid Power
• Getting to Know the Trainer
• Fluid Power Fundamentals
• Introduction to Fluid Power
• Compressors and Pumps
• Pressure-Control Valves
• Directional Controls
• Actuators
• Flow Measurement and Control
Volume 2, Fundamentals of Fluid Power
• Getting to Know the Trainer
• Pilot-Operated Valves
• Cam-Operated Valves
• Solenoid-Operated Valves
• Special Components
• Advanced Applications

The Fundamental Fluid Power Trainer, Model 6059, is an introductory program in fluid power concepts, devices, and circuits. The
comprehensive Fundamental Fluid Power Trainer includes two instructional trainer modules, and a correlated, two-volume set of
student manuals, plus instructor guides.
The Fundamental Fluid Power Trainer can be purchased as a complete training program (Volumes 1 and 2), or in stages by pur-
chasing Volume 1 and Volume 2 separately. Volume 1 introduces fluid power principles. Volume 2 expands on these principles
and covers new fluid power components.
Fluid power components are permanently mounted on removable trays that are stored in a lockable cabinet. Valves and
cylinders are made of clear plastic to allow students to view internal parts and better comprehend component functions.

9
Core Technical Systems
FLUID POWER TRAINING FOR INDUSTRIAL APPLICATIONS
Models 6080 and 6081

Shown with optional components

Topic Coverage
Hydraulics Pneumatics
• Hydraulics Fundamentals • Pneumatics Fundamentals
• Electrical Control of Hydraulic Systems • Electrical Control of Pneumatic Systems
• Hydraulics Applications – PLC • Pneumatics Applications – PLC
• Servo Control of Hydraulic Systems • Servo Control of Pneumatic Systems
• Sensors • Sensors

Festo offers the most comprehensive and flexible course in fluid power available. Lab-Volt’s premier training system for flu id
power technology consists of two programs: the Hydraulics Training System, Model 6080, and the Pneumatics Training System,
Model 6081. Both are innovative, modular systems that use state-of-the-art hardware and courseware to deliver job training in fluid
power.
The entire fluid power series has been designed for educational growth. Using either the Hydraulics or the Pneumatics Training
Systems, students gain a solid foundation in, and hands-on experience with, fluid power components and circuits; the principles
and concepts underlying fluid power systems and applications; and methods of troubleshooting and testing fluid systems. Each
lesson builds upon previous lessons, making this an ideal job-training program.
Most of the components used for electrical control of the Festo Hydraulics Training System are also intended to be used with the
Festo Pneumatics Training System, Model 6081, allowing interconnection of both systems to perform more complex functions.

10
 Alternative & Renewable Energy Technologies
LVSIM®-HYD & LVSIM®-PNEU
Models 6385 and 6485

Hydraulics Simulation Software LVSIM®-HYD. Pneumatics Simulation Software LVSIM®-PNEU.

Model 6385 Model 6485

Features
• Install, move, and remove hydraulic and pneumatic
components and electrical control devices.
• Modify or remove connections at any time.
• Zoom in or out to adjust the view.
• Perform measurements of flow, pressure, force,
velocity, and rotation speed.
• Access cutaway views to observe motor rotation, as
well as the extension and retraction of cylinder rods.
• Access cutaway views to observe fluid flow inside
hydraulic and pneumatic components.
• Save and restore equipment setups (including the
virtual classroom laboratory environment).

The Hydraulics (LVSIM®-HYD) and Pneumatics (LVSIM®-PNEU) Simulation Software are Windows®-based programs that cover
the same courseware as Hydraulics and Pneumatics Fundamentals (Models 6080-1 and 6081-1) and Electrical Control of Hy-
draulic and Pneumatic Systems (Models 6080-2 and 6081-2) and can be used either as a complement to the actual Hydraulics or
Pneumatics Training System or as a stand-alone product.
LVSIM®-HYD and LVSIM-PNEU® recreate the three-dimensional classroom laboratory on a computer screen, enabling students
to manipulate virtual fluid power equipment. Using the mouse, students can install virtual hydraulic and pneumatic equipment in
the laboratory, interconnect the equipment, perform lab exercises, and obtain the same results as with the actual Lab-Volt training
equipment.
Sophisticated mathematical models accurately simulate the mechanical and electrical characteristics of the hydraulic and pneu-
matic components (valves, cylinders, motors, flowmeter, and others) and electrical control devices (switches, relays, pilot lamps,
etc.) in the actual Festo Hydraulics and Pneumatics Training Systems. All components and devices contained in the LVSIM ®-
HYD and LVSIM-PNEU® software feature the same functionality and appearance as the actual equipment.

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Core Technical Systems
ADVANCED FLUID CONTROL APPLICATIONS
Models 6080-4, 6081-4, 6082, and 6085

SERVO/PROPORTIONAL CONTROL
Model 6080-4 & 6081-4
The Servo/Proportional Control module is an add-on to the Elec-
trical Control system for both Hydraulics (Model 6080-4) and
Pneumatics (Model 6081-4). Through hands-on operation of sig-
nal conditioners, pressure and position transducers, PID control-
ler, proportional directional control valve, feedback devices, and
corresponding interface hardware and courseware, students are
trained in the precise controls used in industrial applications such
as robotics, aviation, CNC machines, marine, mobile equipment,
and material handling.
All exercises require Basic and Electrical Control of Hydraulic
and/or Pneumatic Systems.
HYDRAULICS & PNEUMATICS APPLICATIONS – PLC
Model 6082
Using a PLC with either the Hydraulics or Pneumatics Training
System, students learn how to send instructions to the PLC and
download ladder programs in order to operate fluid power circuits
by means of switches, sensors, and solenoid-operated direction-
al valves.
The PLC also allows students to make a comparison with relay-
operated control circuits and design time-delay circuits, up and
down counting circuits, latch and unlatch circuits, and more.
Three PLC models are available: Allen Bradley, Omron, and Sie-
mens. Each of them can be programmed using advanced pro-
gramming software.
ELECTRONIC SENSORS SET
Model 6085
The Festo Sensors Training System, Model 6085-A, is an add-
on to Electrical Control of Hydraulic Systems, Model 6080-2 and
Electrical Control of Pneumatic Systems, Model 6081-2 and is
designed to familiarize students with the operation of various
sensor types. It is also available as a stand-alone system.
The Sensors Training System contains a selection of photoelec-
tric, inductive, and capacitive sensors representative of what can
be found in the industry. The sensors are protected against re-
verse polarity and can be used in conjunction with a Program-
mable Logic Controller to achieve advanced fluid control applica-
tions.

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 Alternative & Renewable Energy Technologies
PROGRAMMABLE LOGIC CONTROLLER (PLC)
Model 3240-2 and 3240-A
The Programmable Logic Controller (PLC), Model 3240, enables students to develop competence in op-
erating, programming, and troubleshooting modern PLC-controlled circuits. The PLC trainer is based on
e
tthe latest Allen-Bradley Micrologix™ 1200 controller, and is supported by Festo instructional material.
Programming is achieved using the Windows®-based RSLogix™ 500 software from Rockwell Automa-
P
ttion. The trainer can be used to achieve PLC control of typical industrial applications implemented with
a Mechanical Process Simulator, and of virtual industrial processes simulated by the PLC Simulation
SSoftware (P-SIM 2000). The trainer can also be used with the Festo Industrial Controls Training Sys-
ttem, Model 8036, as well as the Festo Electromechanical Systems, Models 8001 and 8006. The PLC
ttrainer includes an Allen-Bradley Micrologix™ 1200 PLC; 12 Fault switches for
ttroubleshooting; 14 dual-voltage PLC inputs; seven PLC input switches (toggle- gle-
e-
aand push button-type); 10 dual-voltage PLC outputs; expansion spacing for
Model 3240-20 the addition of an optional analog input/output module; and RS-232 DF1 full-
duplex communication link between the PLC and RSLogix. The PLC trainer is
also circuit-breaker protected. The training program consists of two courses covering basic program-
ming to advanced applications. The PLC trainer, Model 3240-A, is based on the latest Allen-Bradley
Micrologix™ 1100 controller, includes an onboard traffic light simulator, and has a built-in 10/100 Mbps
Ethernet/IP port for peer-to-peer messaging. Programming is achieved using the Windows®-based
RSLogix™ 500 software from Rockwell Automation. Model 3240-A0
Topic Coverage
Basic Principles Applications
• Familiarization with the PLC Trainer and RSLogix 500 • Introduction to the Mechanical Process Simulator
• Programming Basics • Controlling a Line Welding System with a PLC
• Online Operations • Controlling an Automatic Component Insertion Ma-
• Latching Instructions chine with a PLC
• Timer Instructions • Designing a PLC-Controlled Automated System
• Counter Instructions • Introduction to the P-SIM Simulation Software
• Sequencer Instructions • Controlling a Traffic Light System with a PLC
• Comparison Instructions • Controlling a Filling Line with a PLC
• Shift Register Instructions/The Force Function • Controlling a Batch Mixing Process

WIND TURBINE APPLICATION

Model 8075-5 Preliminary model sho
shown. Subject to change.
With the Festo Nacelle Simulator (Model 3297) and Wind Generator (Model 3213) PLC
application, students learn the basics of controlling the state and position of a wind turbine
depending on wind direction and speed. Air flow is generated using a small blower, which
can be positioned various distances from the anemometer to simulate wind force. The
nacelle is equipped with a DC motor for against-the-wind positioning and a mechanical
clutch to prevent damaging the motor shaft and to untwist the wires, if necessary. Wind di-
rection is determined by the overhead fixture that holds position even if the nacelle is turn-
ing. Different sensors can be monitored in the Nacelle Simulator. This application needs
an external 24 V Power Supply and can be controlled with any PLC with analog inputs (for
wind direction), such as Festo MicroLogix 1100 PLC Trainer, Model 3240-A.

13
Core Technical Systems
PLC APPLICATIONS
Series 8075
• Traffic Light System, Model 8075-1 – Classic training system
featuring N/S/E/W traffic control with pedestrian crossing and
traffic light synchronization.
• Electro-Pneumatic System, Model 8075-2 – Features stamp-
ing, hold and punch, and filling process.
• Electro-Mechanical System, Model 8075-3 – Features and
industrial 1800 RPM, 90 VDC motor and two magnetic limit
Model 8075-1
switches for PLC feedback.
• Electro-Mechanical System, Model 8075-4 – Features a pro-
grammable stepper motor drive and PLC triggered motion se-
quences.
• Level Process Control System, Model 8075-6 – Features a
submersible variable-speed pump and electronic level process
interface.
• Bottling Process System, Model 8075-7 – Compact application
that combines pneumatics, motion control, and PLC sequenc- Model 8075-2
ing.
• Network Interface Devices – The following network interface
devices can be added to the PLC for communications: Ad-
vanced Interface Converter (AIC+) provides an interface to DH-
485 networks from an RS-232 port, DeviceNet Interface (DNI),
and Ethernet Interface (ENI).
• RS Logix 500 Programming Software, Model 3245 – The
RSLogix 500 Programming Software Model 3245 from Rock- Model 8075-3
well Software provides the capability to program the PLC with
a personal computer. A direct communication link (DF1 full du-
plex) is used to connect the PLC to the computer, sparing the
need for any interface between them.
All systems include job sheets.

Model 8075-4 Model 8075-6 Model 8075-7

14
 Alternative & Renewable Energy Technologies
PLC SIMULATION SOFTWARE
Model 91773

The P-SIM 2000 software enables a Windows®-based computer to act

as a process simulator when demonstrating PLC operations. (Students
should already have an understanding of basic relay logic control.) A
built-in ladder logic program editor allows students to create, test and
debug industry-standard ladder logic programs to control animated
processes. The simulated PLC includes the five basic input and out-
put instructions, counters, timers, and compare function blocks. It also
incorporates logical AND/OR operations in PLC programs by means
of branching. Typical processes, such as batch mixing and material
transfer, are graphically displayed as animations, which respond to
changes to the ladder logic program in the same manner that actual
process equipment would respond. With the optional P-SIM to PLC
Interface, Model 3243, students can write programs to control the on-
screen P-SIM simulations.
P-SIM demonstrates the programming and operation of an actual pro-
grammable logic controller (PLC). The functionality of P-SIM is representative of current trends employed by PLC manufacturers.
Upon completion of the P-SIM 2000 course, students will understand and will be able to program basic relay inputs, output instruc-
tions, counters, timer circuits, compare functions, and debugging procedures.
P-SIM I/O Interface
PLC programming may be taught and practiced using the built-in ladder logic program editor; or, with the P-SIM I/O interface, any
PLC can be easily connected by using industry-standard 24 VDC I/O. The PLC is then programmed to control the simulations within
the P-SIM program.

Topic Coverage
• Familiarization with P-SIM 2000 • Comparison PLC Instructions
• Rung Editor • Silo Simulation
• Basic Input/Output PLC Instructions • Batch Mixer Simulation
• Branching • Traffic Lights Simulation
• Timer and Counter PLC Instructions • I/O Simulation

P-SIM to PLC Interface

Model 3243
The Allen-Bradley Micrologix™ 1200 PLC on the PLC Trainer,
Model 3240, can be used to control the PLC Simulation software
(P-SIM 2000), Model 91773, in order to simulate the operation of
typical industrial processes. To do this, an interface is needed: the
P-SIM to PLC Interface, Model 3243.
Model 3243

15
Electricity & Electronics
COMPUTER-BASED LEARNING FOR ELECTRONICS TRAINING (FACET®)

Four modules in the Alternative Energy Technology program derive from Festo s Computer-Based Electronics Training System
(FACET). These include: Thyristors and Power Control Circuits, Model 91011; Magnetism and Electromagnetism, Model 91020;
Motors, Generators and Controls, Model 91024; and Power Transistors and GTO Thyristor, Model 91026.
FACET is a modular program available as a manual or computer-based (Windows®) system. Each module, at minimum, requires
a FACET base unit and power supply in order to run the corresponding circuit board.
Synchro-Servo Training System
In the fields of servomechanisms and synchronous machines,Festo offers the Synchro-Servo Training System, Model 8060.
This low-power system allows the students to observe and analyze the fundamental components of servo systems and associated
electronic circuits. No longer available.

16
 Alternative & Renewable Energy Technologies
FACET® – THYRISTORS AND POWER CONTROL CIRCUITS
Model 91011

Topic Coverage
• Thyristor Component Familiarization
• Thyristor Circuit Fundamentals
• Test a Silicon-Controlled Rectifier
• SCR DC Operation
• Gate Trigger Voltage and Holding Current
• SCR Half-Wave Rectifier
• SCR Control of a Half-Wave Rectifier
• SCR Control of a Full-Wave Rectifier
• Half-Wave Phase Control
• Full-Wave Phase Control
• UJT Characteristics
• UJT Half-Wave and Full-Wave Phase Control
• Bidirectional Conduction
• The Four Triggering Modes
• Half-Wave Phase Control
• Full-Wave Phase Control
• Troubleshooting Basics
• Troubleshooting Thyristor Circuits

The Thyristors and Power Control Circuits module, Model 91011,

provides comprehensive, hands-on instruction in the fundamental
terminology, principles, and applications of thyristors and power
control circuits.
Following a carefully designed instructional program, students become
familiar with all components of the board; are able to isolate, identify,
and test a series of circuits; and perform troubleshooting exercises to
demonstrate mastery of the course objectives.
The system contains the following circuit blocks: Driver; Silicon-
Controlled Rectifier (SCR); Triac AC Power Control; SCR DC Gate
Half-Wave and Full-Wave; and SCR AC Gate and Unijunction
Transistor (UJT) Half-Wave and Full-Wave/Motor.

17
Electricity & Electronics
FACET® – MAGNETISM AND ELECTROMAGNETISM
Model 91020

Topic Coverage
• What is Magnetism?
• Magnetic Fields
• Making a Magnet
• What is an Electromagnet?
• The Solenoid
• The Relay

The Magnetism/Electromagnetism course is an extension of the

AC 1 Fundamentals training module that provides comprehensive,
hands-on instruction in the terminology, principles, and applications
of magnetism and electromagnetism. Following a carefully designed
instructional program, students will become familiar with all compo-
nents of the board, and will be able to isolate, identify and test a series
of circuits.

18
 Alternative & Renewable Energy Technologies
FACET® – MOTORS, GENERATORS, AND CONTROLS
Model 91024

Topic Coverage
• DC Motor Circuits Familiarization
• Stepper Motor and AC Motor Circuits
• Analog DC Motor Positioning
• PWM DC Motor Positioning
• Analog Speed Control of a DC Motor
• Pulsed Speed Control of a DC Motor
• Variable Frequency Control
• The Tachometer Generator
• The Stepper Motor
• The Stepper Motor Controller
• Troubleshooting
• Microprocessor Interface (Requires optional
32-bit Microprocessor module, 91017, plus
accessories.)

With the Motors, Generators, and Controls module, students configure,

operate and troubleshoot a DC motor, AC synchronous motor, phase
shifter, and stepper motor.
Following a carefully designed instructional program, students perform
troubleshooting exercises on analog and pulse width modulated
(PWM) DC motor positioning, analog and PWM DC motor speed
control, variable frequency speed control of an AC synchronous
motor, operation of a tachogenerator circuit, and speed and position
control of a stepper motor with an optional computer interface.

19
Electricity & Electronics
FACET® – POWER TRANSISTORS AND GTO THYRISTOR
Model 91026

Topic Coverage
• Introduction to the Circuit Board
• Driver and Load Circuit Blocks
• Basic Operation of Power Transistors and GTO Thy-
ristors
• Principles of Power Switching Circuits
• Bipolar Transistor and GTO Thyristor Switches
• The Power MOSFET and IGBTs

The Power Transistors and GTO Thyristor training module, enables

students to perform practical exercises that demonstrate the use of dif-
ferent types of power electronic self-commutated switches. The mod-
ule contains six different types of power electronic self-commutated
switches respectively implemented with a MOSFET, an isolated-gate
bipolar transistor (IGBT), a fast IGBT, a bipolar transistor, a Darlington
transistor, and a GTO thyristor. It also contains Driver and Load sec-
tions that help students to study the various switches. The Driver con-
sists of an opto-isolator and a driver for power transistors. The Load
consists of resistive and inductive components, as well as general-
purpose, fast, and ultra-fast free-wheeling diodes. Using these power
electronic switches, students learn the operation of power transistors
and GTO thyristors, as well as how to test their junctions. They ob-
serve switching characteristics, conduction voltage drop, and losses
of power electronic switches. Students also learn how to match free-
wheeling diodes with the various types of power electronic switches.

20
 Alternative & Renewable Energy Technologies
SYNCHRO-SERVO TRAINING
ING
G SYSTEM
Model 8060
No longer available.

Topic Coverage
• Servomechanisms
• Synchros

Digital Servo Training System

The Synchro-Servo Training System, Model 8060, provides a basic understanding of operational theory, as well as the ability to
analyze, troubleshoot, and demonstrate open- and closed-loop synchro-servo systems. System interconnections, operating signal
states, trouble symptoms, and zeroing errors are easily conveyed and identified through the front-panel interconnection jacks and
stacking leads. The front panels are clearly silk-screened with standard electrical and servomechanism symbols, representing
each module’s function. The Synchro-Servo Training System is primarily an analog positional control device. It operates on low
voltages from the power supply, which is built into the system enclosure. The control modules are automatically energized when
they are inserted into the enclosure. Solid state amplifier modules provide signal amplification, phase shift, and power gain typically
required in practical systems. Both control modules and synchro-servo modules have fault-insertion capabilities that introduce
common system or component malfunctions.
The Festo Digital Servo Training System is a compact trainer designed to familiarize students with the fundamentals of digit al
servo controls. The system features a single-axis, belt-driven positioning system, a digital servo controller, and powerful software
tools. The single-axis positioning system includes a DC brush servo motor (brushless motor optional), a belt mechanism, two limit
switches, and two optical encoders (one on the motor and one on the travel cart). Friction, loading, inclination, and backlash can
be modified to introduce new system dynamics. The mechanism can be used either for positioning or speed control (belt can be
unfastened easily from the travel cart).

21
Electric Power Transmission, Generation, Distribution
0.2-kW ELECTROMECHANICAL TRAINING SYSTEM
Model 8001

Topic Coverage
• Investigations in Electric
Power Technology
• Power Circuits (Vol. 1)
• DC Machines (Vol. 2)
• Single-Phase Transformers
and AC Machines (Vol. 3)
• Three-Phase Transformers
and AC Machines (Vol. 4)

Shown with optional components

The Festo 0.2-kW Electromechanical Training System (EMS), Model 8001, is a modern modular instructional program that
represents a new approach to teaching electric power technology by providing new opportunities for laboratory observations. The
program, presented in four subsystems and special applications, deals with the different techniques associated with the generation
and use of electrical energy. The subsystems cover the common machines, and each subsystem is offered with its courseware
presented in a student manual. The special applications deal with less common machines, and the courseware is available in
individual leaflet form for each application. Each subsystem is available as a package that consists of the equipment necessary to
perform the laboratory exercises presented in the correlated student manual. All machines have cutaway bell housings (front and
rear) to permit visual inspection of the internal construction and observation of the machine during operation.
This system was developed by educators to satisfy educational requirements that include industrial applications of electric power
technology. The design objective was to develop a low-power educational system with equipment that operates like industrial
equipment. Through careful attention to engineering detail, the Festo EMS System meets this objective, and in so doing,
provides laboratory results that are easy to understand, with data values that are easily observed.

22
 Alternative & Renewable Energy Technologies
COMPUTER-ASSISTED 0.2-kW ELECTROMECHANICAL TRAINING SYSTEM
Model 8006

Topic Coverage
• Fundamentals for Electrical
Power Technology
• Alternating Current
• Capacitors in AC Circuits
• Inductors in AC Circuits
• Power, Phasors, and Impedance
in AC Circuits
• Three-Phase Circuits
• Single-Phase Transformer
• Special Transformer Connections
• Three-Phase Transformers
• Fundamentals for Rotating Ma-
chines
• DC Motors and Generators
• Special Characteristics of DC
Motors
• AC Induction Motors Shown with optional components
• Synchronous Motors
• Three-Phase Synchronous Gen-
erators (Alternators)

The Computer-Assisted 0.2-kW Electromechanical Training System, Model 8006, is a modern modular program that provides new
opportunities for laboratory observations in the study of electric power technology.
The system is based on the same modular approach as the 8001 Training System. However, instead of using pointer measuring
instruments, it uses a computer-based system for measuring, observing, and analyzing electrical and mechanical parameters in
electric power systems and power electronics circuits. The system’s modular approach also allows instructors to start their EMS
laboratory with basic courseware and equipment and to add new modules over time without duplication of equipment.
The computer-based system, referred to as the Festo Data Acquisition and Management for Electromechanical Systems
(LVDAM-EMS), Model 9062, allows training in various areas, such as electric power technology, AC/DC machines, and power
electronics, using modern and versatile measuring instruments.

23
Electric Power Transmission, Generation, Distribution
ELECTROMECHANICAL SYSTEMS SIMULATION SOFTWARE (LVSIM®-EMS)
Model 8970

The Windows®-based Festo Electromechanical Systems Simulation Software (LVSIM ®-EMS), Model 8970, covers the same
course work as the Computer-Assisted 0.2-kW Electromechanical Training System, Model 8006. LVSIM®-EMS recreates a
three-dimensional virtual classroom laboratory in which students can install an EMS training system, set up equipment, and
perform exercises, just as if actual EMS equipment were being used. The virtual EMS equipment faithfully reproduces the actual
EMS equipment included in the Computer-Assisted 0.2-kW Electromechanical Training System (Model 8006). Sophisticated
mathematical models fully simulate the electrical and mechanical characteristics of all the actual EMS modules: power supply,
motors, generators, transformers, and electrical and mechanical loads. All modules contained in the LVSIM-EMS software feature
the same front panel information as the actual EMS modules. Short-circuit connections in the virtual equipment setup cause the
virtual circuit-breaker protection to trip as on the actual EMS modules.
Used either as a complement to the actual EMS laboratory equipment or as a stand-alone product, LVSIM-EMS is a cost-effective
learning tool that enables students to perform the same exercises as in the Computer-Assisted 0.2-kW Electromechanical Training
System, Model 8006, courseware. As a stand-alone package, the LVSIM-EMS software program provides hands-on activities to
familiarize students with electrical power and machines, including active, reactive and apparent power, phasors, AC/DC motors
and generators, three-phase circuits, and transformers. The LVSIM-EMS virtual equipment is so representative of the actual EMS
laboratory equipment that by using it, the students can develop hands-on abilities as they would with actual equipment.

24
 Alternative & Renewable Energy Technologies
POWER ELECTRONICS SIMULATION SOFTWARE (PESIM)
Model 8971
No longer available.
Topic Coverage
• Power Diode Single-Phase and Two-Phase
Rectifiers
• Power Diode Three-Phase Rectifiers
• The Power Thyristor
• Introduction to AC Phase Control
• Thyristor Single-Phase Bridge Rectifier/
Inverter
• Thyristor Three-Phase, Six-Pulse Converter
• Introduction to High-Speed Power Switching
• The MOSFET Buck Chopper
• The MOSFET Boost Chopper
• The MOSFET Buck/Boost Chopper
• The MOSFET Four-Quadrant Chopper
• The MOSFET Single-Phase Inverter
• The MOSFET Two-Phase Inverter
• The MOSFET Three-Phase Inverter

The Power Electronics Simulation Software (PESIM), Model 8971, is a computer simulation package that delivers quick, efficient,
and effective tools for learning power electronics circuit design and analysis.
The PESIM package consists of the following three elements:
• A schematic circuit editor that enables students to create and edit electronic circuits from a comprehensive set of components
and function blocks.
• A powerful calculation engine that uses efficient algorithms to speed simulation and prevent convergency failure.
• SIMVIEW, a waveform and post-processing tool that enables students to manipulate and observe simulations and their results.

25
Electric Power Transmission, Generation, Distribution
ELECTROMECHANICAL SYSTEMS COMPUTER-BASED LEARNING
Model 8980

Animation showing how a revolv-

Figure explaining the 90° phase shift ing magnetic field is produced in
between the voltage and current in a three-phase induction motors and
capacitor. synchronous motors.

Figure illustrating armature reaction

in a DC motor.

The Electromechanical Systems Computer-Based Learning (EMS-CBL) program, Model 8980, is a modern instructional tool that
runs under the Festo platform Tech-Lab System and Utilities. It makes learning the principles of electric power technology f aster,
easier, and more enjoyable than the more traditional, manual method. The EMS-CBL program consists of complete courses in
electric power technology delivered on a CD-ROM. It is designed for use with the Computer-Assisted 0.2-kW Electromechanical
Training System, Model 8006, or the Electromechanical Systems Simulation Software (LVSIM®-EMS), Model 8970.
Using the EMS-CBL program with LVSIM-EMS, students can follow a complete course in electric power technology at home, using
their own computers and learning at their own pace. Throughout the course, students are prompted to answer questions to verify
their understanding of the subject matter. Incorrect answers are rejected, feedback is given, and students are prompted to answer
again until they give the correct answer. This efficient, self-guided method greatly reduces the time instructors must spend on
assessing student progress while increasing the time they can spend helping students who experience difficulties with the course
material.
Instructors can assess students’ knowledge by administering periodic hands-on exams that require students to demonstrate their
knowledge on actual EMS laboratory equipment. This efficient approach to learning and instruction allows schools to offer remote
courses, an educational trend that is gaining increasing acceptance throughout the world.

26
 Alternative & Renewable Energy Technologies
DATA ACQUISITION & MANAGEMENT FOR ELECTROMECHANICAL TRAINING
SYSTEMS (LVDAM®-EMS)
Model 9062

The Data Acquisition and Management for Electromechanical Systems (LVDAM-EMS), Model 9062, is a computer-based system
for measuring, observing, and analyzing electrical and mechanical parameters in electric power systems and power electronics
circuits. It allows training in various areas, such as electric power technology, AC/DC machines, and power electronics, using
modern and versatile measuring instruments. The LVDAM-EMS system consists of a data acquisition interface (DAI) and the
Festo software Data Acquisition and Management for Electromechanical Systems (LVDAM-EMS).
Data Acquisition Interface: The Data Acquisition Interface (DAI) consists of isolation and data acquisition units. The isolation unit
converts high-level voltages and currents found in electric power systems and power electronics circuits into low-level signals, and
routes these signals to the data acquisition unit. The data acquisition unit converts the low-level signals into digital numbers (data)
that are sent to the personal computer that runs the LVDAM-EMS software.
LVDAM-EMS Software: The LVDAM-EMS software consists of a set of conventional and specialized instruments that run on
Windows®-based operating systems. Each instrument appears as a window on the computer screen. The conventional instruments
include AC/DC voltmeters and ammeters, power meters, and an eight-channel oscilloscope. The specialized instruments include
a six-channel phasor analyzer, a harmonic analyzer, a spectrum analyzer, torque, speed, and mechanical power meters, and
six user-programmable meters. The LVDAM-EMS software is also provided with data-recording and graph-plotting facilities.

27
Electric Power Transmission, Generation, Distribution
0.2-kW PROTECTIVE RELAYING TRAINING SYSTEM
Model 8007

Topic Coverage
• Synchronous Generator
Protection
• Three-Phase Power
Transformer Protection
• Induction Motor Protec-
tion

The innovative 0.2-kW Protective Relaying Training System, Model 8007, extends training in protective relaying beyond the opera-
tion and calibration of individual relays into broader circuit applications with system-level hands-on training in the following fields of
protective relaying: Generator Protection, Transformer Protection, and Induction Motor Protection. The 0.2-kW Protective Relaying
Training System consists of several modules, which can be divided into four groups:
• Common Electrical Modules – Power supply, synchronous generator, induction motor, prime mover/dynamometer, resistive
loads, voltmeters, ammeters, and others. Most of these modules are part of the Lab-Volt 0.2-kW Electromechanical System
(EMS), Model 8001 or 8006.
• Power System Modules, 3700 Series – Specially designed for training in the protective relaying area, including current trans-
formers, voltage transformers, power transformers, source impedances, a transmission grid, and others. These modules are
designed to be installed in the Lab-Volt EMS workstation.
• Protective Relays, 3800 Series – Selection of protective relays, each mounted on a metal panel, which facilitates relay instal-
lation in the Protective Relaying Control Station. Each relay panel is equipped with fault switches that allow fault insertion for
troubleshooting at the system level.
• Additional and Optional Equipment – Various modules, such as distribution busses, a ring bus, transmission lines, distribution
transformers, protective relays, and reactive loads are available and can be added to the basic 0.2-kW Protective Relaying Train-
ing System to create more elaborate hands-on exercises.

28
 Alternative & Renewable Energy Technologies
2-kW ELECTROMECHANICAL TRAINING SYSTEM
Model 8013

Topic Coverage
• Power Circuits
• DC Machines
• Transformers and AC Machines
• Advanced Experiments

The Festo 2-kW Electromechanical Training System, Model 8013, is a modular program in electric power technology. The sys-
tem consists of several modules, which can be grouped to form four subsystems which deal with the different techniques associ-
ated with the generation and use of electrical energy. All modules can be inserted into a standard Mobile Workstation, Model 8110.
The modules are constructed from heavy-gauge steel, finished in baked enamel. There are two standard module sizes: full size,
308 mm (12.1 in) high, and half size,154 mm (6.0 in) high. Symbols and diagrams specific to each module are clearly silk-screened
on the faceplates. Standard color-coded safety 4-mm jacks are used to interconnect all system components.
Each Festo 2-kW machine is permanently mounted on a mobile cart, and includes a double-extension shaft terminated with
geared-type flanges. Different machines may be joined with a hard rubber coupling device and patented locking fastener designed
to eliminate vibrations. Any combination of machines may be studied simultaneously. The machines have a specifically high inertia
to simulate large-power machines. The frames of the machines are equipped with transparent shatter-proof shields for inspection
of the interior. The insulation class of the machines is B (80E temperature rise), the service factor is continuous, and the construc-
tion is of the open type. In addition, all machines are equipped with search coils through which the magnetic flux distribution at
various locations in the machine can be observed on an oscilloscope.

29
Electric Power Transmission, Generation, Distribution
0.2-kW POWER ELECTRONICS TRAINING SYSTEM
Model 8032

Topic Coverage
• Thyristor Circuits
• PWM Chopper/Inverter Circuits
• AC Network Control Systems
• HVDC Power Systems
• Thyristor DC Motor Drives
• PWM DC Motor Drives
• Thyristor AC Motor Drives
• PWM AC Motor Drives
• Industrial AC Motor Drives

Shown with optional equipment

The 0.2-kW Power Electronics Training System, Model 8032, is a versatile and flexible teaching system, covering many topics
that can be included in any power electronics program. The 0.2-kW Power Electronics Training System uses the same modular
approach as the Festo EMS Training Systems, Models 8001 and 8006. It even shares several modules with the EMS Training
Systems. The modular design allows experiments other than those suggested in the courseware to be performed.
Although the modules operate like industrial equipment, they are designed to satisfy the special needs of students. The equipment
is easy to set up and operate. Because all of the important circuit points are readily accessible through front-panel safety banana
jacks, the interconnection between modules is simple and straightforward. Special attention has been given to the circuit protection
provided in all modules, thus making it possible to perform many experiments with virtually no risk to equipment.
As a highly modular, flexible, open-ended system, the 0.2-kW Power Electronics Training System lends itself well to a wide variety
of sophisticated applications not covered in the courseware. As a result, the equipment can also be used for comprehensive re-
search work, allowing complex power electronics systems to be set up easily and in a relatively short time.

30
 Alternative & Renewable Energy Technologies
0.2-kW ELECTRIC POWER TRANSMISSION LINE TRAINING SYSTEMS
Model 8055

Topic Coverage
• Safety and the Power Supply
• Phase Sequence
• Real Power and Reactive Power
• Power Flow and Voltage Regulation of a
Simple Transmission Line
• Phase Angle and Voltage Drop Between
Sender and Receiver
• Parameters which Affect Real and Reac-
tive Power Flow
• Parallel Lines, Transformers, and Power-
Handling Capacity
• The Alternator
• The Synchronous Motor
• The Synchronous Capacitor and Long High
Voltage Lines
• Transmission Line Networks and the
Three-Phase Regulating Autotransformer
• The Synchronous Motor Under Load
• Hunting and System Oscillation
• Power System Transients
• Additional Experiments

The 0.2-kW Electric Power Transmission Training System, Model 8055, consists of modular hardware and corresponding course-
ware. Electrical phenomena, previously studied solely by using advanced-level mathematics, can now be observed through the
effects of voltage transients and power oscillations. Voltage regulation, real and reactive power flow control, and system stability
can also be observed in Festo laboratory exercises.
This system was developed by educators to satisfy educational requirements that include industrial applications of electric power
technology. The design objective was to develop a low-power (0.2 kW) transmission line system of equipment that operates like
industrial equipment. Through careful attention to engineering detail, Lab-Volt has achieved this objective and in so doing, provides
laboratory results that are easy to understand, with data values that are easily observed. The data, when applied to formulas, pro-
vide results that verify electrical laws rather than deny them because of large operational tolerance errors.

31
Electric Power Transmission, Generation, Distribution
CONTROL OF INDUSTRIAL MOTORS TRAINING SYSTEM
Series 8045

The Control of Industrial Motors Training System is a complete

instructional program that trains students in the concepts and
applications of conventional (electromechanical) motor con-
trol through the use of block, wiring, and schematic diagrams.
It is the perfect add-on to the 8001 EMS Training System for
those who wish to extend the teaching of electromechanical
systems to the control of industrial motors. Mechanical and
electrical assembly of electromechanical control circuits is ac-
complished in the 8001 EMS Training System environment
without the use of hand tools. The student manual, included
with the training system, guides students through a large variety of electromechanical control circuits, beginning with simple con-
cepts and expanding them until the full sophistication of industrial motor control is reached. Students gain first-hand knowledge of
the reasons why certain practices are followed, as well as how circuits operate. The manual is complete with a Glossary of terms
containing the current NEMA, IEC, ANSI, and IEEE official definitions of electrical terms.

DISTRIBUTION TRANSFORMER TRAINER

Model 8361
The Distribution Transformer Trainer, Model 8361,
is a portable, hands-on trainer designed to allow
students to develop competence in completing
single- and three-phase transformer connections
similar to those performed in the field. The trainer
includes a three-phase, wye-connected primary line
with ground and neutral, and two sets of indepen-
dent secondary lines to exhibit the complexity of the
distribution network. The trainer contains two sets
of three single-phase transformers to demonstrate
three-phase banking configurations, such as wye-
wye, delta-delta, closed delta-wye, closed wye-del-
ta, open-wye, open-delta, and others. Various faults
can be inserted in the unit using fault (FLT) switches
accessed through a hinged door on the rear panel
of the trainer. Each individual transformer winding is
thermally protected and designed to accept multiple
faults.

32
 Alternative & Renewable Energy Technologies
The Distribution Transformer Trainer is available in two variants. On the first variant (Model 8361-0X), each transformer has a pri-
mary winding with a nominal voltage equal to the line-to-line voltage of the AC power network. On the second variant (Model 8361-
1X), each transformer has a primary winding with a nominal voltage equal to the line-to-neutral voltage of the AC power network,
but that can sustain the line-to-line voltage.

Topic Coverage
• Distribution Transformer Trainer
• Transformer Polarity and Terminal Markings
• Single-Phase Transformers Supplying Single-Phase Loads
• Single-Phase Paralleling
• Three-Phase Banking of Single-Phase Transformers

POWER LINE SERIES COMPENSATION DEMONSTRATOR

Model 8362
The Power Line Series Compensation Demonstrator, Model odel
8362, is specifically designed for hands-on training in the prin-
rin-
ciples of series compensation for electric power transmission
sion
lines. All equipment is provided in a single, integrated mobile
bile
console.
The unit is powered from a standard single-phase wall outlet. tlet.
It simulates two high-voltage (735 kV) three-phase transmis- mis-
sion lines: one uncompensated, the other compensated to 17%, 7%,
25%, or 34%. Line voltage, current, active power, and reactivetive
power are measured at the inputs and outputs of the lines. The
Power Line Series Compensation Demonstrator includes all the
test equipment required to perform the suggested hands-on -on
demonstrations in the accompanying manual. Input and output tput
metering, dual transmission lines, and various loads are avail-
vail-
able from the front panel of this self-contained unit. Mounted on
casters, the trainer can be easily moved.

Topic Coverage
• Power Transfer Capability of a Transmission Line
• Effects of Series Compensation on Power Transfer Capability and System Stability
• Effect of Series Compensation on Regulation of the Receiver Voltage
• Reduction of Transmission Losses on Parallel Lines Using Series Compensation

33
Electric Power Transmission, Generation, Distribution
ADDITIONAL ELECTROMECHANICAL EQUIPMENT

The modular system approach allows equipment to be added to existing EMS laboratories to offer more advanced exercises or
to cover specialized fields of study.

R
DISSECTIBLE MACHINES TRAINING SYSTEM AND MOTOR
WINDING KIT
The Model 8020 Dissectible Machines is an electromechanical
(EMS) trainer that provides hands-on instruction in the construction
and operation of rotating machines. The system fulfills educational
requirements that include industrial applications of electric power
technology. It employs training equipment that has characteristics
similar to industrial equipment.
Various machines are assembled without the use of tools from a
complete set of components, including stators, rotors, armatures,
rheostats, and capacitors. Once assembled, they can be mounted
on basic modules that lock into place on one of Lab-Volt’s EMS
Workstations.

Dissectible Machines

MAGTRAN® TRAINING SYSTEM

The Festo ® Training System, Model 8024, is designed
to teach magnetic circuit principles and the application of these
principles to basic transformers. It is suitable for a broad range
of teaching programs – from vocational schools to universities.
The MagTran® Training System consists of a set of laminated iron
bars, a vise-type nonmagnetic base that holds the bars in place,
coils, and other related components that can be assembled
in many ways. Correlated courseware contains an extensive
set of laboratory experiments that illustrate basic principles of
magnetism and electromagnetic induction.

MagTran® Training System

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 Alternative & Renewable Energy Technologies
ADDITIONAL EQUIPMENT FOR THE 0.2-kW EMS TRAINING SYSTEMS

TWO-PHASE WOUND-ROTOR INDUCTION MOTOR,

MODEL 8233
Each phase of the stator windings of the Two-Phase Wound-
Rotor Induction Motor, Model 8233, is independently terminated
and identified on the faceplate to permit operation with a two-
phase electric power source. The rotor windings are brought out
to the faceplate via external slip rings and brushes.
This machine can be used as a wound-rotor induction motor,
phase shifter, single-phase variable coupling transformer, two-
phase transformer, selsyn control, frequency converter, or
asynchronous induction generator.

THREE-PHASE BRUSHLESS AC GENERATOR,

MODEL 8243
The Three-Phase Brushless AC Generator, Model 8243, is a
synchronous generator without its conventional brush-gear for
field excitation. It comprises an AC power generator and an
exciter, which can be set in one of two modes: separately excited
(PILOT) or self-excited (AUTO). The exciter voltage is adjustable
in both modes using a rheostat control on the module faceplate.
Each phase of the stator windings is independently terminated to
permit operation in either Delta or Star (Wye) configuration.

ADDITIONAL MOTORS AND STARTERS

Festo offers many other motors and starters supplied with corresponding courseware to complete more advanced programs.
These include:
• Dahlander Two-Speed Constant Power Induction Motor,
Model 8223
• Dahlander Two-Speed Variable Torque Induction Motor,
Model 8224
• Dahlander Two-Speed Constant Torque Induction Motor,
Model 8225
• Two-Pole Squirrel-Cage Induction Motor, Model 8227
• Three-Phase Wound-Rotor Induction Motor, Model 8231
• Three-Phase Synchronous Reluctance Motor, Model 8246
• Capacitor-Run Motor, Model 8253
• Repulsion-Start Induction-Run Motor, Model 8255
• Two-Value Capacitor Motor, Model 8259
• Triple-Rate Motor, Model 8266
• High-Leakage Reactance Transformer, Model 8350
• Manual DC Motor Starter, Model 8631
• Synchronous Motor Starter, Model 8641
• Three-Phase Full-Voltage Starter, Model 8651
• Star (Wye)/Delta Starter, Model 8653
• Reduced Voltage Primary Resistor Starter, Model 8661
• Reduced Voltage Autotransformer Starter, Model 8671
• Three-Phase Rheostat, Model 8731

35
Instrumentation and Process Control Systems
INSTRUMENTATION AND PROCESS CONTROL TRAINING SYSTEM
Series 3530

Topic Coverage
• Introduction to Process Control
• Pressure Processes
• Flow Processes
• Level Processes
• PID Process Control
• Introduction to Temperature
Process Control
• Temperature Measurement
• Characterization of Tempera-
ture Process
• PID Control Temperature
Processes

Shown with optional components.

The Festo Instrumentation and Process Control Training System introduces students to process instruments and controls. The
use of the latest control equipment coupled with a wet simulator and complete training curriculum helps students gain the theoreti-
cal and practical knowledge that is mandatory for employment in the process control industry.
To maximize the educational efficiency of the system, the teaching material covers the industry standards for maintenance con-
currently with the main training objectives. The modularity of the system allows the instructor to select equipment depending on
the training objectives. Several configurations are available for a single workstation. Adding optional equipment can increase the
number of these configurations.
The Instrumentation and Process Control Training System features two workstations: the Process Workstation and the Instrumen-
tation Workstation. The equipment of the Pressure, Flow, and Level Process System is installed on both workstations. Two student
teams can work at the same time on the workstations if the Second Team Add-On, Model 3530-A, is used. One controller of the
3539 Series is required for each team. A wide choice of optional equipment is available.

36
 Alternative & Renewable Energy Technologies

Process Workstation*
The Process Workstation is a double-sided mobile
workstation with a 115-liter (30-gal) tank, a centrifu-
gal pump, a rotameter, a column (large diameter), a
drip tray (front), an instrumentation mounting pipe,
ball valves, and process supports. To have a fully
functional system, a Controller, Model 3539-XX,
is required. To configure the system for hands-on
training, the students must install the appropriate in-
struments as described in the student manuals. The
student manuals cover both the theory and practice
of measurement, control, and troubleshooting of
pressure, flow, and level processes.

*Both stations shown with optional equipment.

Instrumentation Workstation*
The Instrumentation Workstation is designed to house the Electrical Unit and the Pneumatic
Unit as well as other electrical equipment. Devices such as controllers, PLC, Color Paperless
Recorder, and Touch Screen Graphic Terminal must be installed on the Instrumentation Work-
station. This prevents such equipment from coming in contact with water.
The Electrical Unit provides power for the whole system. It includes a lockable power switch, a
variable speed drive, and a 24-VDC power supply. The design of the Electrical Unit allows cut-
ting both the electric and pneumatic power using either an emergency button or the lockable
power switch.
The teaching material includes a complete lockout/tagout procedure explaining how to lock the
power switch. This procedure is similar to the procedure used in industry to lock and unlock
electrical equipment.
Like the Process Workstation, the Instrumentation Workstation is a double-sided mobile work-
station. Two groups of students can work at the same time on the system, one group on each
side. The Instrumentation Workstation also features a storage cabinet with lockable doors and
a shelf.

37
Instrumentation and Process Control Systems
PROCESS CONTROL TRAINING SYSTEM
Model 6090

Topic Coverage
• Process Control Fundamen-
tals using the LVPROSIM
Software
• Pressure, Flow, and Level
Process Control
• Temperature Process Control
• pH Process Control

Shown with optional equipment

The Festo Process Control Training System, Series 6090, familiarizes students with the fundamentals of instrumentation and
process control. It demonstrates the control of pressure, flow, level, temperature, and pH processes. It can also demonstrate ad-
vanced process control techniques, such as second-order control, and cascade control when used with a controller featuring these
functions.
The basic trainer demonstrates PID (proportional, integral, derivative) control of flow, pressure, and level processes. It comes
with a variable-speed pump, a tank, a column, two-way valves, pressure gauges, flexible hoses, a venturi tube, an orifice plate, a
rotameter, a paddle wheel flow transmitter, and a differential pressure transmitter.
A work surface, consisting of a solid-metal perforated plate hinged to a drip tray, provides a large area (that can be laid flat or
tilted to a 45° angle) on which components can be mounted. Additional work area can be added with the expanding work surface
provided.
Mounting and removal of the components are made especially easy with push-lock fasteners that snap effortlessly into the perfo-
rations of the work surface. The components can be interconnected by means of flexible hoses equipped with garden-type fittings
that permit easy and fast component connections without the use of tools. The hose fittings contain check valves to prevent water
from running out of the hoses when they are disconnected.

38
 Alternative & Renewable Energy Technologies

Temperature Process Control Add-On, Model 6090-2 pH Process Control Add-On, Model 6090-3

Although the equipment is designed to operate atop a regular work table, an optional bench is available to provide mobility and
storage space. Mounted on four heavy-duty, swiveling, lockable castors, the bench provides a storage area for components. Op-
tional dressing panels and lockable doors are also available to fully enclose and lock the bench.
The trainer processes can be controlled by a computer-based PID Controller through the use of a personal computer (Pentium
type), the included Process Control and Simulation Software (LVPROSIM), Model 3674, and the I/O Interface, Model 9065. The
trainer processes can also be controlled using any conventional PID controller compatible with standard 4-20 mA signals or 0-5 V
signals.
To demonstrate PID control of temperature and pH processes, additional components can be added to the basic trainer. The ad-
ditional components required for temperature process control include a heating unit, a cooling unit, and temperature transmitters.
Those required for pH process control include chemical tanks, metering pumps, and a pH transmitter.
Cascade and second-order process control can also be studied on the basic trainer by having the students from two workstations
work together at a single workstation, or by adding the following components to the basic trainer: a Pressure Transmitter, a Column,
and a PID Controller.

39
Instrumentation and Process Control Systems
MOBILE INSTRUMENT & PROCESS CONTROL TRAINING SYSTEMS
Series 3500

Features
F
• Fault-insertion capabilities
• Patch-connected signal
conditioners, controllers, and
transmitters to permit alter-
nate control schemes and for
flexibility in incorporating new
technology as it is developed
• Realistic process response
times
• Multi-element and ratio control
capability
• Microprocessor-based control-
lers
• Comprehensive courseware
Model 3501 Model 3503
Pressure Process Level Process
Station Station

Model 3502 Model 3504

Temperature Process
Flow Process Station
Station

The Festo Mobile Instrumentation and Process Control Training System, Series 3500, consists of self-contained workstations
designed for hands-on training in the measurement, control, and troubleshooting of pressure, flow, level, temperature, heat ex-
change, and analytic processes. The stations can operate independently, or be interconnected into several configurations to simu-
late complex processes.
All processes are sized to be “real-world” in time lag and process response. Process dynamics can be altered by various means to
provide several degrees of stability and damping. The Flow, Level, Heat Exchanger, Multi-Process, and Analytic Process Stations
utilize water as the process media, while the Pressure and Temperature Process Stations utilize air.
All Process Stations include a microprocessor-based controller, a dual-channel, paperless, digital recorder with color display, and
alarm lamps, with all connections terminated by banana jacks on the station’s main control panel.

Compressed Air Requirement: 700 kPa (100 psi) at 0,95 l/s (2 SCFM) of dry air to each station

40
 Alternative & Renewable Energy Technologies
PROCESS CONTROL STATIONS
Models 3505, 3507, 3508, & 3550

Features
• All required gauges, switches, ma-
nometers, patch cords, hoses, and
flow elements are included
• Transparent piping and valves for
student observation of system op-
eration (where applicable)

Model 3505 Model 3507

Model 3550
Model 3508

The Multi-Process Station, Model 3505, consists of a pump, a water reservoir, a programmable AC variable frequency pump drive,
a 20-cm (8-in) diameter, 92-cm (36-in) high level column, a pneumatically operated flow control valve, needle valves, and process
piping made of clear thermoplastic (PVC). The pump can be operated either at fixed speed or variable speed.
The Heat Exchanger Station, Model 3507, consists of two pumps, a water reservoir, a 6-kW (5.7-Btu/s) electric water heater,
a shell-and-tube heat exchanger, a forced-air cooling-coil, a pneumatically operated flow control valve, a header, and needle
valves.
The Analytic Process Station, Model 3508, is intended to be coupled to the Level Process Station, Model 3503, for the study of
water quality monitoring, through the measurement of pH, conductivity, temperature, and dissolved oxygen. The station is made up
of separate heating, demineralizer, sampling, chemical, and dissolved oxygen sections.
The Calibration Bench, Model 3550, is designed for basic study of the operation and calibration of process instrumentation and is
required to calibrate the pressure gauges, pressure transmitters, D/P transmitters, temperature transmitters, I/P converters, and
strip chart recorders found on the Process Stations of the Mobile Instrumentation and Process Control Training System.

41
Instrumentation and Process Control Systems
BENCH-TOP TRAINERS
Models 3521 and 3522

The Festo Process Control Trainer, Model 3521, is a bench-

top portable trainer designed to familiarize students with the
concepts related to process control systems, from basic defini-
tions used in instrumentation and control to closed-loop control
systems. Although a temperature process is involved with this
trainer, the theory and concepts presented in the student manual
can be applied to a variety of process control applications. The
trainer includes DC sources, a PID controller, an alarm detector,
and a noise source that allow studying various types of closed-
loop control systems. A dual input voltmeter is provided to mea-
sure voltages in the process control system.
Model 3521
Topic Coverage
• Open-Loop Process Control • Proportional Controller
• Positive and Negative Feedback in Closed-Loop Process • Proportional plus Integral Controller
Control • Proportional plus Derivative Controller
• Basic Measurement Channel • Proportional plus Integral plus Derivative Controller
• Basic Measurement Channel Instrument Characteristics • Alarms in Process Control Systems
• Process Characteristics • Troubleshooting
• Two-Position Controller

T Temperature/Flow Process Training System, Model 3522, is

The
a portable, bench-top unit designed to familiarize students with
tthe fundamentals of instrumentation and process control. Ad-
vvanced concepts such as cascade and feed-forward control can
also be studied. The trainer provides a temperature process and
a
a flow process. Process control is achieved through an external
ccontroller that is compatible with either standard 4-20 mA or 0-5
Model 3522
V signals.
Topic Coverage
• Familiarization with the Trainer • Proportional plus Integral (PI) Control
• Open-Loop Process Control • Proportional plus Integral plus Derivative (PID) Control
• Closed-Loop Process Control • Open-Loop Tuning Method
• Measurement Channel Characteristics • Ultimate-Cycle Tuning Method
• Process Characteristics • Troubleshooting Temperature and Flow Processes
• Proportional (P) Control

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 Alternative & Renewable Energy Technologies
LVPROSIM SIMULATION SOFTWARE
Model 3674

Topic Coverage
• Introduction to Process Control
• Process Dynamics
• Proportional plus Integral Control Mode
• Proportional plus Derivative Control Mode
• The PID Controller
• Temperature Process Control Trainer

The Festo Process Control and Simulation Software (LVPROSIM) provides computer-based training in the control and simula-
tion of generic processes. Using this Windows®-based software, students can simulate a generic process with adjustable process
time constants, dead time, process gain, and disturbance time constant. In addition, students can use the software to simulate
process dynamics and regulation of the Festo Process Control Trainer, Model 3521. LVPROSIM offers a selection of precon-
figured experiments. An Experiment Editor allows modification of existing experiments or addition of new experiments. A series
of pre-programmed tests can be selected from the main menu. User-defined tests can also be created with the Test Editor. Both
editors can be password-protected to limit access to the instructor only.

43
Web-Based Training
INDUSTRIAL TRAINING ZONE (ITZ)

Features
• Premier training interface or-
ganizes curriculum in a logical
sequence.
• Interactive learning builds content
mastery and troubleshooting
expertise.
• Pre- and post-test certification
ensures mastery of skills.
• 3D animations illustrate in real
time how equipment works.
• Self-paced learning increases
retention and job skills.
• Video narrations guide training
step-by-step.
• Courseware is updated and
reviewed regularly to ensure ac-
curacy.

Industrial Training Zone by Festo delivers a broad range of online and CD-ROM-based fundamental and specialty industrial
training courses designed to help instructors build a more competent, qualified, and efficient workforce.
Engaging training systems feature 3D simulations, course narrations, a virtual guide, testing, and quizzes to promote learning
retention and use on the job.
Courses are available online or via CD-ROM. Each Online CoursePack™ contains one training pass (good for one student to take
one course), an online reference manual, online assessment and certification passes, and a ToolBox™ user account. Each CD
CoursePack™ contains a CD training perpetual license, course-specific CD and printed reference manual, online assessment and
certification passes, and a ToolBox™ user account.
Mechanical, Electrical, and Fluid Power training programs for both industry and mobile systems are available online or via CD-
ROM.

44
 Alternative & Renewable Energy Technologies
ITZ – ELECTRICAL TRAINING
Models 47903, 47905, 47907, and 47908

Topic Coverage
• Electrical Theory, Model 47905
• Industrial Electrical, Model 47903
• Mobile Electrical, Model 47907
• AC/DC Motors and Drives, Model
47908

Festo Industrial Electrical course delivers an interactive training experience designed to help trainees understand the fu n-
damental concepts of electrical systems. This course is popular among those who need to understand the workings of electrical
systems on the production floor.
Electrical Theory begins with the basics – the atom, charge, voltage, current, and more. The basics are followed by an in-depth,
theoretical approach to circuit analysis, basic magnetism, magnetic induction, and single- and polyphase AC circuits.
Mobile Electrical covers electrical systems of mobile equipment, including the basic electrical system common to most combustion
engine vehicles.
AC/DC Motors and Drives helps trainees understand how electrical motors and drives work with each other and other systems.
Trainees also learn about the safety considerations associated with operating electromechanical systems.

45
Web-Based Training
ITZ – INDUSTRIAL MECHANICAL TRAINING
Model 47904

Topic Coverage
• Basic Physics • Bearings
• Linear Actuators • Gears
• Clutches • Drives
• Clutch/Brake Sys- • Couplings
tems

Festo ’s Industrial Mechanical Course, Model 47904, provides an overview of the basic physics laws, schematics, and systems
design associated with mechanical power transmissions. This course delivers an interactive training experience designed to show
the various components found in a typical mechanical system and how these components function and interact with each other.
This course covers topics such as linear actuators, clutches, brakes, bearings, gears, drives and more. Instruction also includes
studying how these mechanical systems work and how to troubleshoot them.

46
 Alternative & Renewable Energy Technologies
ITZ – PROGRAMMABLE LOGIC CONTROLLER (PLC) FUNDAMENTALS
Model 47910
Topic Coverage
• PLC Hardware • PLC Devices
• Numbering Systems • Timers
• Structure • Counters
• Programming

The PLC Fundamentals course delivers an interactive training experience designed to teach the concepts and skills required to
operate these controllers. 3D simulations, quizzes, and tests assist in exploring the world of PLC fundamentals. This course also
covers the hardware, firmware, and software that make a PLC function.
Instruction also includes differentiating among various types of PLCs used for specific purposes, connecting external devices to
PLCs, and reading and writing basic PLC ladder-logic software programs. Learning to connect to PLC hardware and PLC functions
in various control systems through this ITZ course provides expertise in automation control and its components.

47
Web-Based Training
ITZ – HYDRAULICS TRAINING
Models 47901 and 47906

Topic Coverage
• Industrial Hydraulics, Model
47901
• Mobile Hydraulics, Model 47906

Festo offers online and CD-ROM-based hydraulics training for both industrial and mobile markets. The Industrial Hydraulics
course introduces the components, functions, and interactions of hydraulic systems and covers the various components found in a
typical hydraulic system. The course also covers hydraulic pumps, actuators, and pressure controls, directional, flow, and modular
control valves, maintenance practices for hydraulic systems and accessories, basic physics laws as they apply to fluid power, and
the symbols represented in hydraulic schematics.
Mobile Hydraulics covers the basics of hydrostatic transmissions, valves, and maintenance systems common to most combustion
engines, as well as the symbols and language of schematics, allowing a comprehensive understanding of hydraulic systems. Vari-
ous physics laws related to hydraulic power are explored, as well as the hydraulic components and circuits associated with these
systems.

48
 Alternative & Renewable Energy Technologies
ITZ – PNEUMATICS TRAINING
Model 47904

Topic Coverage
• Industrial Pneumatics, Model
47902
• Pneumatic Specialist, Model
47909

Festo s Industrial Pneumatics course focuses on the basic physics laws, schematics, and systems design associated with pneu-
matic systems and fluid power. Various pneumatic compressors, air dryers, actuators, and airline conductors are covered, as well
as air-transfer of energy through vacuum, distribution, and directional controls. This course also covers air preparation, distribution,
and accessories used to make pneumatic systems operate and provides an understanding of the symbols represented in pneu-
matic schematics and how to read them.
In addition to this course, a Pneumatic Specialist course has been developed in collaboration with the Fluid Power Society and
CFC-Solar to help teach the concepts related to the successful design and interaction of pneumatic systems as a Certified
Pneumatic Specialist. This preparatory course covers the topics required to pass the Pneumatic Specialist Certification test. The
computer-based presentation boasts a powerful, multi-sensory learning experience that includes video segments, animated illus-
trations of pneumatic systems, and comprehensive training from some of the foremost teachers of pneumatic certification.

49
Early Technology Science Education
TECH-DESIGN – AERODYNAMICS
Module
e 40000

Topic Coverage
• Aerodynamic forces (weight, lift, drag, and gravity) • Helicopter operations
• Airfoil theory (experiments with a wind tunnel) • Hypersonics and supersonics
• Angle of attack • Laminar/tubular flow and viscosity
• Atmosphere (temperature, pressure, and humidity) • Mass flow and the lever law
• Bernoulli’s Principle • Stability and control
• Calibration kit • Velocity
• Fundamentals of aeronautics technology • Weather center

In the Aerodynamics module, students learn about the scientific principles of aerodynamic technology. As a result, they understand
and appreciate these technological achievements and the potential for future innovations.
Students learn how moving objects are designed, developed, tested, and manufactured. They also observe and understand how
the four aerodynamic forces – weight, lift, drag, and gravity – are affected by temperature, pressure, and humidity. In fact, they
collect and measure this atmospheric data themselves. Through other experiments, students use a wind tunnel to measure the
forces of air on different shapes.
Advanced principles of aerodynamics are covered in later segments of this module. Students also design airfoils and measure the
effects of drag, lift, and velocity on their creations. This and other experiments also promote skills in examination, analysis, and
troubleshooting. In addition, students learn about careers where they can apply their newly developed knowledge and abilities.

50
 Alternative & Renewable Energy Technologies
TECH-DESIGN – ALTERNATIVE ENERGY
Module
dule 40036

Topic Coverage
• Alternative energy research and development • Hydro-energy
• Renewable and nonrenewable energy sources • Biomass energy
• Energy conversion systems • Geothermal energy
• Wind energy • Energy conservation
• Solar energy

In the Tech-Design Alternative Energy module, students explore alternative sources of energy through interactive discussions and
experiments. The knowledge and skills they develop prepare them to help preserve energy resources through personal efforts
as well as possible future careers. Hands-on experiments in this module alert students to environmental issues affecting our
energy resources. Students also develop knowledge of technology that underlies the generation and use of these types of energy.
As a result, they gain a deeper appreciation for natural resources and may, in turn, feel driven to help make the most of what is
available.
The foundation of knowledge includes energy and its use and production; renewable and nonrenewable energy sources; and
the uses of various energy types, including solar, wind, biomass, geothermal, and hydro. Students look to the future of energy
conservation and technology, as well as career opportunities. Other subjects include biomass conversion; geothermal energy
sources, and hydropower and the economics of its production. Students gain practical experience through several experiments,
including the conversion of sunlight into usable energy and the demonstration of wind energy with a wind turbine.

51
Early Technology Science Education
TECH-FOUNDATIONS – ALTERNATIVE ENERGY
Module 42701

Topic Coverage
• Energy Resources
• Energy Measurement & Calculations
• Hydroelectric Power
• Using Wind for Energy
• Solar Power

This Tech-Foundations Alternative Energy module combines scientific theory with activities in the Profi Eco Power kit by
fischertechnik® to help students experience the advantages and disadvantages of hydropower, wind power, and solar power.
Students complete activities, experiments, and worksheets that guide them through the evaluation of each type of power. They
experiment with water flow in the “Hydraulic Turbine” activity, try storing energy generated by a wind turbine, and connect solar cells
in series and parallel to compare the effects of voltage and current on the Oil Pump or the Rotating Swing.
Students build and use a hammermill, a hydraulic turbine, a wind turbine, and a solar-powered oil pump or solar-powered rotating
swing.

52
 Alternative & Renewable Energy Technologies
INVENTIONS & INNOVATIONS – DESIGN A WINDMILL
Module 42652

Topic Coverage
• Horizontal and vertical-axis
windmills
• Power generating wind turbines
• Mechanical windmills used for
grinding
• Basic features of a windmill:
tower, rotors, and blades
• Blade angle and windmill ef-
ficiency
• Blade shape and its impact on
trapping wind
• Aerodynamic designs, lift, and
drag
• Tubular and lattice tower designs
and load limits
• Wind sheer and tower design

The Festo Inventions & Innovations Series builds both foundational knowledge and problem-solving skills. Students are encour -
aged to use their imaginations and creative talents to model solutions to a wide range of problems. They learn the cyclical nature
of invention and innovation – a process that encourages students to continue to perfect their solutions.
In this module, students are given a scenario in which they must develop and design a windmill for an isolated, family-operated
farm that is not on the state electrical grid and currently obtains its energy from a diesel generator.
Since the farm is located in an area that receives steady winds all year around, windmills are an efficient, economical, and envi-
ronmentally-friendly alternative. The windmills would also be used to help with other farm work, such as grinding corn or pumping
water to feed livestock and irrigate crops.
Students are tasked with taking all criteria into consideration to design and build the prototype of a windmill that can generate
electricity, do mechanical work, or both.

53
Early Technology Science Education
EXPLORING MECHANISMS
Model 3342

Topic Coverage
• Introduction to the Trainer
• Work and Power
• Friction
• Mechanical Advantage
• Inclined Plane
• Gears and Gear Trains
• Friction-Belt Drives
• Synchronous-Belt Drives
• Chain Drive
• Pulley System

The Exploring Mechanisms module, Model 3342, introduces students to the world of mechanical power transmission. Using a
fully operational elevator, the module covers the topics of work, power, force, energy, and torque.
The module comes fully equipped with a collection of gears, belt drives, and a chain drive. Other topics include direction of
rotation and tension. Practical examples and association with real world examples set this module apart from others.
The Exploring Mechanisms trainer features a DC driving motor with control switch; assortment of gears, O-rings, chains, and
belts; a lift (elevator) with control switch and upper/lower sensors, hex keys, and a spring scale.

54
 Alternative & Renewable Energy Technologies
EXPLORING ELECTRICITY
Model 3343

Topic Coverage
• Electric Circuits
• Measuring Voltage, Current,
and Resistance
• Series Circuits
• Parallel Circuits
• Logic Circuits
• Electromechanical Relays
• Three-Way Switching Circuits
• Ohm’s Law
• Ohm’s Law for Series Circuits
• Ohm’s Law for Parallel Cir-
cuits

The Exploring Electricity module, Model 3343, plays a vital role in every area of technology. This module teaches students the
basic characteristics of simple electrical circuits.
Students build a variety of series circuits, parallel circuits, and logic circuits using electrical leads. Students also learn how to
calculate electric values and measure them with the digital multimeter.
The Exploring Electricity trainer features a built-in regulated 12 VDC source; digital multimeter; an assortment of resistors, switch-
es, relays, and indicator; and a fan used as a circuit load.

55
Notes
Notes
Notes
Notes
Festo Guadalajara
M.I. Francisco Javier Eguia Salazar
Asesor Instructor de Didactica
Anillo Periférico Poniente 10115
Parque Industrial El Colli Guadalupe
45069 Zapopan Jalisco
T. +52 (33) 1002 2020
M. +52 1 (33) 31370189
Cotizaciones y Pedidos en:
javier.eguia@festo.com
T. +52 (55) 5321 6610
http://www.festo-didactic.com/mx-es/

85218-00