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 in industrial panels. It covers conductor sizing, insulation types, shielded cables, and deciding between conduit and cable trays, paying attention to segregation, bending radius, and EMC performance for reliable setups.
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 focuses on choosing terminal blocks and planning distribution in panels. It includes feed-through, fused, earth, and shield terminals, their current and voltage ratings, jumpering, labelling, and layout for safe, easy-to-maintain 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 guides selection of field devices and connections, covering photoelectric sensor types, cable glands, connectors, and IP ratings. It emphasises matching to site conditions, mounting, wiring methods, and mechanical protection for dependable operation in tough environments.
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 details protection for feeders and motors, including MCCBs, MCBs, fuses, motor protection breakers, and overload relays. It covers interrupting capacity, trip curves, coordination, and protecting cables and equipment in industrial setups.
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 selecting VFDs based on voltage and current ratings, overload capacity, braking options, and EMC filters. It includes matching to motor specs, ambient conditions, cable lengths, and needed 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 like 208V, 230V, 400V, 480V, their frequencies, earthing, and fault levels. It shows how these affect motor and VFD choices, insulation ratings, and clearances in panels common in Kenyan power systems.
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 helps select 5–10 HP motors, focusing on voltage, enclosure types, duty cycles, reading nameplates, thermal classes, service factors, and how these guide overload settings, starting methods, 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 surge loads, and methods for redundancy, buffering, and filtering to boost reliability and cut noise 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 shows how to pick auxiliary devices like contactors, relays, timers, pushbuttons, pilot lights, and stack lights. It focuses on coil ratings, usage categories, mechanical life, and fit for control circuits.
Contactor utilization categories and coilsControl relays and interposing relaysOn‑delay, off‑delay, and multifunction timersPushbuttons, selector switches, pilot lightsStack lights, buzzers, and signaling levels
