Lesson 1Cabling basics: power cables, multi-core control cables, shielded signal cables, and conduit vs tray selectionThis section introduces cabling fundamentals for power, control, and signals, covering conductor sizing, insulation types, shielded cables, and selecting between conduit and tray, with focus on segregation, bending radius, and EMC 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 section covers terminal block selection and distribution, including feed-through, fuse, ground, and shield terminals, current and voltage ratings, jumpering, labelling, and layout for safe, maintainable 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 section addresses selection of field devices and interfaces, including photoelectric sensor types, cable glands, connectors, and IP ratings, emphasising environment, mounting, wiring practices, and mechanical protection for reliable operation.
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 section covers protection devices for feeders and motors, including MCCBs, MCBs, fuses, motor protection breakers, and overload relays, focusing on interrupting capacity, trip curves, coordination, and protection of 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 section details how to select VFDs by voltage and current rating, overload capacity, braking options, and EMC filters, including matching to motor data, ambient conditions, cable length, and required 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 section explains common three-phase supply systems (208, 230, 400, 480 V), their frequency, earthing, and short-circuit levels, and how these affect motor and VFD selection, insulation ratings, and panel component clearances.
Wye vs delta and earthed 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 section covers selection of 5–10 HP motors, focusing on voltage, enclosure, and duty, interpreting nameplate data, thermal classes, service factor, and how these influence overload settings, starting methods, and coordination with drives.
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 section compares AC and DC control power, explains how to size 24 VDC supplies for steady and inrush loads, and covers redundancy, buffering, and filtering methods to improve reliability and noise immunity 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 section explains how to choose auxiliary devices such as contactors, control relays, timers, pushbuttons, pilot lights, and stack lights, focusing on coil ratings, utilisation categories, mechanical life, and suitability for control schemes.
Contactor utilisation categories and coilsControl relays and interposing relaysOn-delay, off-delay, and multifunction timersPushbuttons, selector switches, pilot lightsStack lights, buzzers, and signalling levels
