Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis section reviews tank level measurement options, such as float switches, conductivity probes, ultrasonic, and pressure transmitters, covering signal kinds, fitting, and usual 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 section covers I/O signal mapping for field gear, splitting digital and analog channels, and spells out standard wiring, tags, shielding, earthing, and EMC steps for solid factory sensor work.
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 section compares valve types and actuators, like solenoid valves, motorised ball and needle valves, and I/P or air actuators, and covers when to pick digital over analog control for position and flow adjustment.
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 section explains pump types and motor drives, pitting centrifugal against positive displacement pumps, and covers VFD essentials, including 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 section handles flow and dosing gear, comparing mass and volume flow meters, and how dosing pumps or valves are chosen, run, and tied into PLC code for precise, repeatable filling jobs.
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 section looks at reject setups on belts, with air cylinders and solenoid valves, and how to sync moves with sensors and encoders, handle timing slots, and check successful rejects.
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 section covers bottle and belt detection using photoelectric, inductive, and capacitive sensors, explaining mounting, background cut-off, wiring, and common signals in 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 section explains RTDs, thermocouples, and 4–20 mA temp transmitters, comparing precision, response speed, and straightness, plus right mounting, shielding, and 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 section covers main machine safety gear, emergency stop and guard interlock wiring, light curtains and relays/PLCs, and Safe Torque Off (STO) use on 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 section details sensors on filling heads, like nozzle position, valve open/closed feedback, and overfill spotting, and how these signals aid interlocks, steps, and 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
