FEEDBACK Industrial (Fault-Finding) Process Trainer

SKU: E6.4.2.9 Category: Tags: , ,



This trainer teaches fault diagnosis and rectification in industrial processes. Faults are introduced by the instructor via switches concealed behind a locked compartment, to which the student does not have access. These switches provide both short circuits and open circuits and can also switch in or out circuit elements to simulate a variety of fault conditions. Additional faults can be inserted into the process through the replacement of working components with faulty ones, e.g. faulty flow switches; faulty relays; faulty solenoid coils and faulty control valve electronic circuit board. The process involves initially filling a header tank with water and then cycling the level between a set upper and lower limit, whilst simultaneously creating a demand from the header tank via two on/off solenoid drain valves into a sump tank. Flow is produced by a pump and controlled by relay operated on/off solenoid valves which control:

  • the inflow of water to the header tank from the sump tank
  • the outflow of water from the header tank to the sump tank

The level of water in the header tank is monitored by float switches which open and close at the following points:

  • Header tank low (nearly empty)
  • Header tank normal operation lower limit
  • Header tank normal operation upper limit
  • Header tank overflow

Designed for students studying industrial process maintenance, it can also be used as a process trainer in its own right, using either Industrial Process Controllers or Programmable Logic Controllers (PLCs). A 34-252-1 PLC Board (supplied separately) is available for users to develop their own PLC programs.


  • Teaches Fault diagnosis
  • Faults introduced by teacher via switches housed in a lockable compartment
  • Can be externally controlled using process controllers and PLCs
  • Self-contained process
  • Wide range of faults easy to apply
  • Fully protected for safety
  • Comprehensive instructor & student manuals


  • Introduction to the system
  • Fault finding methodologies
  • Fault analysis flow charts
  • Fault finding from circuit diagrams
  • Fault identification to line replaceable unit level
  • Mechanical, electrical & electonic faults
  • Diagnostic tools
  • Maintenance procedures
  • Process control techniques
  • Fault finding processes controlled from electronic controllers
  • Interfacing to PLCs


1 34-250 Industrial (fault-finding) Process TrainerFB
1 34-252-1 * PLC Interface for 34-250FB

Additionally required: 1 PC with Windows 7 / 8.1 / 10 (x86 or x64)

Articles marked with * are not essential, we do however recommend them to carry out the experiment.