Lesson 1Cabling basics: power cables, multi-core control cables, shielded signal cables, and conduit vs tray selectionThis lesson covers the fundamentals of cabling for power, control, and signal transmission, including how to size conductors, select insulation types, use shielded cables, and decide between conduit and cable trays, while considering segregation, bending radii, and electromagnetic compatibility performance.
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 examines the choice and arrangement of terminal blocks for distribution, including feed-through, fused, ground, and shield terminals, along with their current and voltage ratings, jumper systems, labelling, and layout to ensure safe and easy-to-maintain industrial control panels.
Feed-through terminal applicationsFuse and disconnect terminal blocksGrounding and PE terminal designShield termination and EMC controlJumpering, labelling, and groupingLesson 3Field device choices: photoelectric sensor types, cable gland and connector selection, appropriate ingress protection (IP) ratingsThis lesson discusses selecting field devices and their interfaces, such as various photoelectric sensor types, cable glands, connectors, and IP ratings, with focus on environmental factors, mounting options, wiring methods, and mechanical safeguards for dependable performance.
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 explores protection devices for feeders and motors, covering MCCBs, MCBs, fuses, motor protection circuit breakers, and overload relays, with emphasis on interrupting 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 outlines the selection of VFDs based on voltage and current ratings, overload capabilities, braking features, and EMC filters, including alignment with motor specifications, 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 describes common three-phase supply systems (208, 230, 400, 480 V), their frequencies, grounding methods, and short-circuit levels, and how these influence motor and VFD choices, insulation ratings, and clearances for panel components.
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 the selection of 5–10 HP motors, concentrating on voltage, enclosure types, and duty cycles, interpreting nameplate information, thermal classifications, service factors, and their effects 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 options, describes sizing 24 VDC supplies for steady and inrush loads, and discusses redundancy, buffering, and filtering techniques to enhance reliability and resistance to 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 guides the selection of auxiliary devices like contactors, control relays, timers, pushbuttons, pilot lights, and stack lights, focusing on coil ratings, utilisation categories, mechanical lifespan, and appropriateness for various control configurations.
Contactor utilisation categories and coilsControl relays and interposing relaysOn-delay, off-delay, and multifunction timersPushbuttons, selector switches, pilot lightsStack lights, buzzers, and signalling levels
