Lesson 1Cabling basics: power cables, multi-core control cables, shielded signal cables, and conduit vs tray selectionThis lesson introduces cabling fundamentals for power, control, and signals, covering conductor sizing, insulation types, shielded cables, and selection between conduit and cable tray, with focus on segregation, bending radius, and EMC compliance.
Conductor sizing and voltage dropPower vs control cable constructionShielded signal cable and groundingSegregation of power and signal routesConduit, tray, and flexible conduit useLesson 2Terminal block selection and distribution: feed-through, fuseable, ground, and shield termination blocksThis lesson details terminal block selection and distribution, including feed-through, fused, earth, and shield terminals, their current and voltage ratings, jumpering, labelling, and layout for safe, serviceable industrial control panels.
Feed‑through terminal applicationsFuse and disconnect terminal blocksGrounding and PE terminal designShield termination and EMC controlJumpering, labeling, and groupingLesson 3Field device choices: photoelectric sensor types, cable gland and connector selection, appropriate ingress protection (IP) ratingsThis lesson discusses field device and interface selection, covering photoelectric sensor varieties, cable glands, connectors, and IP ratings, stressing environmental suitability, mounting, wiring methods, and mechanical safeguards for dependable functioning.
Diffuse, retroreflective, and through‑beam sensorsPNP vs NPN and 2‑wire vs 3‑wire sensorsCable gland sizing and strain reliefM12 and other industrial connector typesIngress protection (IP) and NEMA ratingsLesson 4Protection devices: MCCB, MCB, fuses, motor protection circuit breakers, and overload relaysThis lesson examines protection devices for feeders and motors like MCCBs, MCBs, fuses, motor protection circuit breakers, and overload relays, focusing on breaking capacity, trip characteristics, coordination, and safeguarding cables and equipment.
MCB and MCCB ratings and trip curvesFuse types, classes, and applicationsMotor protection circuit breakers (MPCBs)Thermal and electronic overload relaysSelective and backup coordination basicsLesson 5VFD selection criteria: voltage rating, current rating, overload capacity, braking, EMC filtersThis lesson explains VFD selection based on voltage and current ratings, overload capacity, braking features, and EMC filters, matching to motor specs, ambient conditions, cable lengths, and necessary control interfaces and protections.
Matching VFD voltage and currentNormal and heavy duty overload classesDynamic braking and braking resistorsInput and output EMC filter optionsCable length, dV/dt, and motor stressLesson 6Three-phase supply types and selection (208V/230V/400V/480V) and impact on motor/VFD sizingThis lesson covers common three-phase supplies (208V, 230V, 400V, 480V), their frequencies, earthing, and fault levels, and their effects on motor and VFD choice, insulation classes, and panel component spacings.
Wye vs delta and grounded systems208 V vs 230 V vs 400 V vs 480 V useFrequency and motor speed implicationsShort‑circuit level and SCCR impactVoltage tolerance and derating rulesLesson 7Motor selection and thermal ratings for 5–10 HP motors including service factors and nameplate interpretationThis lesson addresses 5–10 HP motor selection, covering voltage, enclosure types, duty cycles, nameplate reading, thermal classes, service factors, and their impact on overload settings, starting techniques, and drive coordination.
Reading motor nameplate dataInsulation and temperature rise classesService factor and allowable overloadEnclosure types and cooling methodsDuty cycle and starting requirementsLesson 8Control power supplies: AC vs DC control, sizing 24VDC supplies, redundancy and filteringThis lesson compares AC and DC control power, sizing 24VDC supplies for steady and inrush loads, and methods for redundancy, buffering, and filtering to enhance reliability and noise rejection in industrial panels.
AC vs DC control power advantagesCalculating 24 VDC load and inrushDerating power supplies for temperatureRedundant and parallel supply schemesEMI filtering and surge protectionLesson 9Auxiliary devices: contactors, control relays, timers, pushbuttons, pilot devices, stack light modulesThis lesson guides selection of auxiliary devices like contactors, control relays, timers, pushbuttons, pilot lamps, and stack lights, focusing on coil ratings, utilisation categories, mechanical endurance, and control scheme compatibility.
Contactor utilization categories and coilsControl relays and interposing relaysOn‑delay, off‑delay, and multifunction timersPushbuttons, selector switches, pilot lightsStack lights, buzzers, and signaling levels
