Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis section reviews ways to measure levels in tanks, like float switches, conductivity probes, ultrasonic, and pressure senders, and talks about signal kinds, fitting, and common setup problems 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 section explains mapping I/O signals for field devices, telling digital and analog channels apart, and details usual wiring, labels, shielding, earthing, and EMC ways to make sure factory sensors work well.
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 section compares valve types and movers, like solenoid valves, motorised ball and needle valves, and I/P or air movers, and explains when to use digital or analog control for position and flow setting.
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 section explains pump types and motor drives, comparing centrifugal and positive displacement pumps, and brings in VFD basics, including start/stop control, speed settings, 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 devices: mass flow meters, volumetric flow meters, and dosing pump or valve choicesThis section covers flow and dosing devices, comparing mass and volume flow meters, and explains how to pick, control, and fit dosing pumps or valves with PLC thinking for exact, repeatable filling jobs.
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 looks at reject setups on belts, including air cylinders and solenoid valves, and shows how to match moving with sensors and encoders, handle timing gaps, and check good 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 sensing for bottles and belts using photoelectric, inductive, and capacitive sensors, explaining fitting, background cut-off, wiring, and usual signal types in 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 section explains RTDs, thermocouples, and 4–20 mA temperature senders, comparing exactness, response time, and straightness, and details proper fitting, shielding, and setting 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 main machine safety devices, how emergency stop and guard door circuits are set up, how safety light curtains and relays/PLCs work, and how Safe Torque Off (STO) is used on 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 section details sensors on filling heads, including nozzle position sensing, valve open/closed feedback, and overfill spotting methods, and shows how these signals are used for locks, ordering, and fault checks.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
