Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesDis section review level measurement methods fi tanks, including float switches, conductivity probes, ultrasonic, an pressure transmitters, an discuss signal types, mounting, an 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 analog channels, typical wiring and earth/EMC considerations for industrial sensorsDis section explain I/O signal mapping fi field devices, distinguishing digital an analog channels, an detailing typical wiring, labeling, shielding, grounding, an 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, motorized ball/needle valves, I/P and pneumatic actuators — digital vs analog controlDis section compare valve types an actuators, including solenoid valves, motorized ball an needle valves, an I/P or pneumatic actuators, an explain when to use digital versus analog control fi position an 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 analog/digital I/O for start/stop and speed controlDis section explain pump types an motor drives, comparing centrifugal an positive displacement pumps, an introduce VFD basics, including start/stop control, speed reference options, an key analog an 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 choicesDis section cover flow an dosing devices, comparing mass an volumetric flow meters, an explaining how dosing pumps or valves get selected, controlled, an integrated wid PLC logic fi 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 controlsDis section focus pon reject mechanisms pon conveyors, including pneumatic cylinders an solenoid valves, an show how to synchronize actuation wid sensors an encoders, manage timing windows, an 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 typesDis section cover level an presence detection fi bottles an conveyors using photoelectric, inductive, an capacitive sensors, explaining mounting, background suppression, wiring, an 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 mountingDis section explain RTDs, thermocouples, an 4–20 mA temperature transmitters, comparing accuracy, response time, an linearity, an detailing proper mounting, shielding, an calibration fi 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)Dis section cover key machine safety devices, how emergency stop an guard interlock circuits get designed, how safety light curtains an relays/PLCs work, an how Safe Torque Off (STO) get applied to drives fi 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 detectionDis section detail sensors used pon filling heads, including nozzle position detection, valve open/closed feedback, an overfill detection methods, an show how dese signals used fi interlocks, sequencing, an 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
