Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis part reviews ways to measure levels in tanks, like float switches, conductivity probes, ultrasonic, and pressure senders, plus signal types, fitting, and common setup issues 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 part explains mapping I/O signals for field devices, telling digital and analog apart, and details on wiring, labels, shielding, earthing, and EMC to keep industrial sensors working 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 part compares valve types and actuators like solenoid valves, motorised ball and needle valves, I/P or air actuators, and when to use digital or analog control for position and flow.
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 part explains pump types and motor drives, comparing centrifugal and positive displacement pumps, VFD basics like start/stop, speed settings, and main analog/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 part covers flow and dosing devices, comparing mass and volume flow meters, and how to pick, control, and link dosing pumps or valves with PLC for accurate, repeatable filling.
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 part focuses on reject setups on belts, using air cylinders and solenoid valves, and how to time them with sensors and encoders, handle timing, and check rejects worked.
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 part covers detecting levels and presence for bottles and belts with photoelectric, inductive, capacitive sensors, including fitting, background cut-off, wiring, and signals for 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 part explains RTDs, thermocouples, 4-20 mA temp senders, comparing accuracy, response time, straightness, and proper fitting, shielding, calibration for tank temp 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 part covers main machine safety devices, emergency stop and guard door circuits, light curtains, relays/PLCs, and Safe Torque Off (STO) for 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 part details sensors on filling heads like nozzle position, valve open/closed feedback, overfill detection, and how signals work for locks, sequencing, 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
