Building the skills that keep industry moving
Industry-standard equipment pairs real-world hardware with advanced teaching resources, preparing students with practical skills they need to maintain and shape the future of industry.
Maintenance of closed loop systems
SKU# IM0004
The Industrial Maintenance Closed Loop PID Control System is a hands-on industrial training solution designed to teach fault diagnosis, system behaviour analysis, and component-level troubleshooting in a real-world flow control environment.
It includes a Siemens S7-1200 PLC, Unified HMI, turbine flow sensor, proportional control valve, analogue flow gauge, IFM temperature sensor, float switches, and a proximity sensor, simulating industrial process equipment. Learners engage with hands-on experiments involving general system use and fault simulation, and sensor validation. The system operates via a closed-loop feedback structure: the PLC adjusts both the valve and pump output using a PID algorithm to maintain a target flow rate, with real-time sensor feedback displayed on the HMI.
The product includes a full curriculum of guided worksheets focused on closed-loop control theory, component diagnostics, and fault scenarios.
This product range also has access to an online interactive learning environment to engage students and broaden their learning while working through the curriculum, with real-life scenarios and simulation.
Pictures are a representation of the product and correct at the time of uploading. Occasionally there may be changes to equipment for supplier or development reasons which may not be reflected. Please check the bill of materials before purchase to confirm the contents that you will receive.
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Target Audience
This curriculum is designed for 16 to 18-year-old engineering students in further education colleges, as well as apprentices beginning careers in industrial maintenance, automation, and related engineering fields. It is ideally suited for learners pursuing T-Levels, BTECs, or similar vocational qualifications, and for those aiming to develop practical skills in diagnosing, maintaining, and troubleshooting real-world automated systems.
Whether preparing for a role in manufacturing, utilities, or process industries, this program provides a strong foundation in industrial control systems and maintenance best practices.
Key Features
System Hardware & Design
• Siemens S7-1200 PLC with digital and analogue I/O
• Siemens Unified Basic HMI with real-time control and diagnostics
• Turbine-type flow sensor
• Proportional solenoid control valve and immersion pump
• IFM PT100 temperature sensor with transmitter
• Dual float switches (high/low) for level safety
• Inductive proximity switch on tank lid for safety interlock
• Modular, compact rig optimized for classroom or training bench use.
• CE/UL compliant components and wiring safety measures
Curriculum & Learning Outcomes
• Covers closed-loop system theory and PID control in real industrial context.
• Teaches sensor validation, feedback systems, and control loop dynamics.
• Builds skills in fault detection, diagnostics, and root cause analysis.
• Focuses on interpreting HMI/PLC data to guide decision making.
• Develops hands-on troubleshooting ability using multimeters and test routines.
Fault Simulation & Troubleshooting
• Built-in software-based faults (e.g. sensor offset, emergency stop errors)
• Hardware fault simulation via removable wiring (e.g. float switch failures)
• Faults include emergency stop, unreachable PID setpoint, temperature errors, and lid open detection.
• Fault diagnosis via HMI IO screen, alarms, and status LEDs Practical Exercises & Support
• 13+ guided worksheets covering each system component and fault type.
• “Over to You” sections to encourage independent problem-solving.
• Structured fault scenarios reflecting real-world industrial situations.
• IO diagnostics and LED indicators on PLC and field devices for live troubleshooting
• Full BOM, wire numbers, and test points included for in-depth exploration.
Educational Focus
• Aligned to UK T-Level & BTEC qualifications (Maintenance, Installation& Repair)
• Designed for Further Education students and apprentices aged 16–18.
• Teaches control system integration: sensors, PLC, HMI, actuators.
• Suitable for classroom teaching, self-guided labs, and assessment
Industrial Maintenance of Closed Loop Systems
REF: CP0539
Suitable for:
Troubleshooting & Fault Finding Closed Loop Systems
REF: CP6773
The includes a full curriculum of guided worksheets focused on closed-loop control theory, component diagnostics, and fault scenarios.
Suitable for:
Software Resources
Please visit the Resource tab on the main page to access the online learning environment –