Lesson 1Level check ways for tanks: float switches, conductivity, ultrasonic/pressure senders — signal kinds and setup tipsThis part checks level ways for tanks, like float switches, conductivity probes, ultrasonic, and pressure senders, and talks signal kinds, placing, and usual setup problems to skip.
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 linking: digital in/out vs analog paths, usual wiring and ground/EMC needs for factory sensorsThis part explains I/O signal linking for field tools, telling digital and analog paths apart, and details usual wiring, marking, shielding, grounding, and EMC ways for steady factory sensor work.
Digital input and output channel mappingAnalog current and voltage channel mappingTerminal numbering and cable labelingShielding, grounding and earth schemesEMC noise mitigation and testingLesson 3Valve kinds and actuators: solenoid valves, motor ball/needle valves, I/P and air actuators — digital vs analog controlThis part compares valve kinds and actuators, like solenoid valves, motor ball and needle valves, and I/P or air actuators, and explains when to use digital or analog control for place and flow rules.
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: spin vs push pumps, VFD starts and analog/digital I/O for start/stop and speed ruleThis part explains pump kinds and motor drives, comparing spin and push pumps, and starts VFD basics, covering start/stop rule, speed guides, and main analog and digital I/O 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 tools: mass flow meters, volume flow meters, and dosing pump or valve picksThis part covers flow and dosing tools, comparing mass and volume flow meters, and explains how dosing pumps or valves are picked, ruled, and joined with PLC plans for true, repeat filling work.
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 tools and actuators: air cylinders, solenoid valves, joining with mover rulesThis part looks at reject tools on movers, like air cylinders and solenoid valves, and shows syncing moves with sensors and counters, handle time slots, and check good product reject.
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 check for bottles and movers: light sensors, near sensors, touch sensors — wiring and signal kindsThis part covers level and presence check for bottles and movers using light, pull, and touch sensors, explaining placing, back stop, wiring, and usual signal kinds in pack lines.
Photoelectric sensor modes and setupInductive proximity for metal detectionCapacitive sensors for nonmetal bottlesMounting, alignment and false trip reductionPNP/NPN outputs and cable routingLesson 8Heat check in process tanks: RTDs, thermocouples and 4-20 mA senders — true, answer and placingThis part explains RTDs, thermocouples, and 4–20 mA heat senders, comparing true, answer time, and straight, and details right placing, shielding, and set for process tank heat rule.
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 tools: emergency stop paths, safety door locks, safety light sheets, safety relays/PLCs, and safe torque off (STO)This part covers main machine safety tools, how emergency stop and guard lock paths are made, how safety light sheets and relays/PLCs work, and how Safe Torque Off (STO) fits drives for risk cut.
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 back tools: nozzle place sensors, valve back, and too-much fill checkThis part details sensors on filling heads, like nozzle place check, valve open/closed back, and too-much fill ways, and shows how signals fit locks, order, and fault finds.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
