Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis section reviews level measurement methods for tanks, including float switches, conductivity probes, ultrasonic, and pressure transmitters, and discusses signal types, mounting, and common installation pitfalls to avoid.
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 analogue channels, typical wiring and earth/EMC considerations for industrial sensorsThis section explains I/O signal mapping for field devices, distinguishing digital and analogue channels, and detailing typical wiring, labelling, shielding, earthing, and EMC practices to ensure reliable industrial sensor operation.
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, motorised ball/needle valves, I/P and pneumatic actuators — digital vs analogue controlThis section compares valve types and actuators, including solenoid valves, motorised ball and needle valves, and I/P or pneumatic actuators, and explains when to use digital versus analogue control for position and flow regulation.
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 analogue/digital I/O for start/stop and speed controlThis section explains pump types and motor drives, comparing centrifugal and positive displacement pumps, and introduces VFD basics, including start/stop control, speed reference options, and key analogue 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 devices: mass flow meters, volumetric flow meters, and dosing pump or valve choicesThis section covers flow and dosing devices, comparing mass and volumetric flow meters, and explaining how dosing pumps or valves are selected, controlled, and integrated with PLC logic for accurate, repeatable filling operations.
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 section focuses on reject mechanisms on conveyors, including pneumatic cylinders and solenoid valves, and shows how to synchronise actuation with sensors and encoders, manage timing windows, and verify successful product rejection.
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 section covers level and presence detection for bottles and conveyors using photoelectric, inductive, and capacitive sensors, explaining mounting, background suppression, wiring, and common signal types used in packaging 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 section explains RTDs, thermocouples, and 4–20 mA temperature transmitters, comparing accuracy, response time, and linearity, and detailing proper mounting, shielding, and calibration for process tank temperature 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 section covers key machine safety devices, how emergency stop and guard interlock circuits are designed, how safety light curtains and relays/PLCs work, and how Safe Torque Off (STO) is applied to drives for risk reduction.
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 section details sensors used on filling heads, including nozzle position detection, valve open/closed feedback, and overfill detection methods, and shows how these signals are used for interlocks, sequencing, and fault diagnostics.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
