Industrial Control Troubleshooting Trainer
(CT-016)

1.Supply pump 2.Supply tank 3.Tank A 4.Tank B 5.Process tank 6.Agitator motor 7.Heater 8.Process pump 9. Solenoid valves 10.Operation panel 11.Test terminals panel 12. PC touch screen13. Indication LEDs test terminals 14. Control circuits terminals 15.Power circuits terminals

  • Operation of the training system
  • Simulation of: Basic level: 8 faults.
    • Intermediate level: 5 faults.
    • Advanced level: 2 faults.
    • Additional level: 5 faults.
  • Interpretation of process scheme.
  • Familiarization of using included terminals for measurement purposes.
  • Familiarization with mixing process.
  • Control of a typical mixing process.
  • Familiarization with different electrical components.
  • Reading wiring diagrams related to the process.
  • Acquaintance with possible hazards within the system and how to mitigate them.
  • Pumps
    • Flow rate: 20 ~ 110 L/min.
    • Maximum head: 32 m.
    • Minimum head: 19.5 m.
    • Supply: 3 phase, 230 V (∆ connection, 400 V (Y connection).
  • Motor
    • Supply: 3 phase
    • Power: ½ HP.
    • Speed: 1350 rpm.
  • solenoid valves
    • Fittings: ¾ inch.
    • Supply: 220 V.
  • Heater
    • Power: 3 KW.
    • Supply: 3 phase
    • Process tank: 30 * Φ 25 cm
  • Power contactors
    • Power: 4 Kw
  • Power contactors
    • Power:11 Kw
  • Thermal overload
    • Current: 1.8 ~ 2.5 A
  • Relays
    • 4 poles
  • Timers
    • AC supply: 220 VAC, 50-60 Hz
    • DC supply: 24 ~ 240 VDC
    • Timing: 0.5 sec ~ 10 hours
  • Level Liquid Control
    • Input: 220 V
    • Auxiliary contact: 6A
  • Fuse Holder
    • Current: 32 A
  • Industrial process troubleshooting training system (CT-016)
  • Hard copy user manual

The industrial control troubleshooting trainer exposes trainees to two main essential topics in the industry field. The first topic is the process control over processes that may exist in a typical industrial plant while the other topic is how to troubleshoot this control system. Through this trainer, trainees will also get introduced to the mixing process specifically, and how it’s being controlled industrial wise through temperature and level control. Trainees will be able to detect faults through the system, maintain and perform a variety of troubleshooting processes.

                                     
  • The trainer demonstrates a closed cycle mixing process, so that trainees can follow the consequence of the process while applying control to its components using the industrial control components.
  • The closed cycle consists of a supply tank, supply pump, two substance tanks A and B, process tank, mixing agitator, heater, process pump and solenoid valves. 
  • The process begins when the supply pump drives the substance from the supply tank to both tank A and tank B at specific quantities. Both tanks supply the process tank with substances at specific quantities to be mixed by the agitator for a specific period of time, then heated to a specific temperature by the heater. 
  • Each one of the substance tanks has electrode level sensor and solenoid valve. When the electrode level senses low level of substance, it sends a signal to the solenoid valve to operate the supply pump to drive substance to the substance tank.
  • An intake solenoid valve is located right after each substance tank to automatically supply the mix tank with a specific quantity of each substance.
  • The process pump is also provided with a solenoid valve to operate the pump to drive the mix from the process tank to the supply tank.
  • A drain solenoid valve is located at the bottom of the process tank to drain the process tank to the supply tank after finishing experimentation or in case a fault occurs during the operation.
  • The process tank has four electrode levels, the first is the bottom of the tank, the second is the maximum allowable level of substance A, the third is the maximum allowable level of substance B and the fourth is an indication for overflow.
  • An operation panel is supplied that includes, trainer ON/OFF switch, circuit breaker, emergency switch and a selection switch to select local mode to control the process manually or remote mode for automatic control.
  • The operation panel also has indication LEDs to state starting process, alarm, process ready for start, cycle is running, heater operation, drain solenoid valve operation, intake solenoid valves operation, agitator operation and process pump operation.
  • The operation panel is equipped with push buttons to reset alarm, start the process, open the drain solenoid valve and activate remote mode and mode display screen (Normal/Test)
  • The trainer is also supplied with test panel that includes a schematic diagram of the process with test terminals of each component of the process.
  • The lower panel of the trainer contains section of the power circuits measuring terminals, section of control circuits measuring terminals, and section of the indication LEDs test terminals.
  • A PC screen is mounted to the training system in order to run the software and activate the faults.
  • The software has two modes, Normal mode for process operation simulation and Test mode for activating faults.
  • The test mode has four levels of faults, basic level (8 faults), intermediate level (5 faults), advanced level (2 faults) and additional level (5 faults).
  • Within BEDO trainer, students will get acquainted with the basic principles of process control as well as the electrical interference with it.