Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis reviews ways to measure tank levels, like float switches, conductivity probes, ultrasonic, and pressure senders, plus signal kinds, fitting, and common setup issues to dodge.
Point level float switches and wiringConductivity probes for clean liquidsUltrasonic level transmitters and dead zonesHydrostatic pressure level transmittersVent, stilling well and mounting issuesLesson 2I/O signal mapping: digital inputs/outputs vs analog channels, typical wiring and earth/EMC considerations for industrial sensorsThis explains mapping signals for field gear, digital vs analog lines, usual wiring, labels, shielding, earthing, and noise protection for solid sensor work in factories.
Digital input and output channel mappingAnalog current and voltage channel mappingTerminal numbering and cable labelingShielding, grounding and earth schemesEMC noise mitigation and testingLesson 3Valve types and actuators: solenoid valves, motorized ball/needle valves, I/P and pneumatic actuators — digital vs analog controlThis compares valve kinds and movers, like solenoid, motorised ball/needle, and air or I/P types, and when to use digital or analog for position and flow checks.
On/off solenoid valve selection basicsMotorized ball and needle valve controlI/P converters and pneumatic actuatorsDigital versus analog position controlFail-safe positions and air failure modesLesson 4Pumps and motor drives: centrifugal vs positive displacement pumps, VFD basics and analog/digital I/O for start/stop and speed controlThis covers pump types and motor drives, centrifugal vs positive shift, VFD starts, including on/off, speed settings, and main analog/digital signals.
Centrifugal pump behavior and curvesPositive displacement pump characteristicsVFD power wiring and parameter basicsDigital I/O for start, stop and faultsAnalog speed reference and scalingLesson 5Flow and dosing devices: mass flow meters, volumetric flow meters, and dosing pump or valve choicesThis looks at flow and dosing gear, mass vs volume meters, and picking dosing pumps or valves, controlling them with PLC for exact, repeat fills.
Coriolis and thermal mass flow metersMagnetic and turbine volumetric metersDosing pump versus dosing valve choicePulse, analog and digital flow signalsBatch control logic and fine dosingLesson 6Reject mechanisms and actuators: pneumatic cylinders, solenoid valves, integration with conveyor controlsThis focuses on reject setups on belts, air cylinders, solenoid valves, syncing with sensors and encoders, timing, and checking rejects work.
Pneumatic cylinder sizing and strokeSolenoid valve selection for reject unitsTiming with sensors and encoder trackingAir preparation and exhaust noise controlReject confirmation and jam detectionLesson 7Level and presence detection for bottles and conveyors: photoelectric sensors, proximity sensors, capacitive sensors — wiring and signal typesThis covers bottle and belt checks with light, nearness, and touch sensors, fitting, background block, wiring, and signals for packing lines.
Photoelectric sensor modes and setupInductive proximity for metal detectionCapacitive sensors for nonmetal bottlesMounting, alignment and false trip reductionPNP/NPN outputs and cable routingLesson 8Temperature sensing in process tanks: RTDs, thermocouples and 4-20 mA transmitters — accuracy, response and mountingThis explains RTDs, thermocouples, 4-20mA temp senders, their accuracy, speed, straightness, and right fitting, shielding, tuning for tank control.
RTD principles, wiring and accuracy classesThermocouple types, ranges and cold junction4–20 mA temperature transmitters setupResponse time, immersion length and lagMounting, shielding and calibration checksLesson 9Safety devices: emergency stop circuits, safety door interlocks, safety light curtains, safety relays/PLCs, and safe torque off (STO)This covers main safety gear, e-stop and door lock circuits, light curtains, relays/PLCs, and STO for drives to cut risks.
Emergency stop categories and reset logicSafety door interlocks and guard lockingSafety light curtains and muting zonesSafety relays, safety PLCs and wiringSafe Torque Off integration on drivesLesson 10Filling head sensors and feedback devices: nozzle position sensors, valve feedback, and overfill detectionThis details sensors on fill heads, nozzle spots, valve feedback, overfill checks, and their use in locks, steps, faults.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
