Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesDis part review level measurement for tanks, including float switches, conductivity probes, ultrasonic, and pressure transmitters, and yarn about signal types, how to mount dem, and common installation wahala 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 sensorsDis part explain I/O signal mapping for field devices, separate digital and analog channels, and detail normal wiring, labeling, shielding, grounding, and EMC ways to make sure industrial sensors work fine.
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 controlDis part compare valve types and actuators, like solenoid valves, motorized ball and needle valves, I/P or pneumatic actuators, and explain 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 controlDis part explain pump types and motor drives, compare centrifugal and positive displacement pumps, and introduce VFD basics, including start/stop, speed reference, and key 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 choicesDis part cover flow and dosing devices, compare mass and volumetric flow meters, and explain how dosing pumps or valves dey picked, controlled, and joined with PLC logic for correct, 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 controlsDis part focus on reject mechanisms on conveyors, including pneumatic cylinders and solenoid valves, and show how to sync actuation with sensors and encoders, manage timing, and check successful rejection.
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 typesDis part cover level and presence detection for bottles and conveyors using photoelectric, inductive, capacitive sensors, explain mounting, background suppression, wiring, and signal types for packaging 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 mountingDis part explain RTDs, thermocouples, 4-20 mA temperature transmitters, compare accuracy, response time, linearity, and detail mounting, shielding, calibration for process tank temperature 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)Dis part cover key machine safety devices, how emergency stop and guard interlock circuits dey designed, safety light curtains and relays/PLCs work, and Safe Torque Off (STO) for drives to cut risk.
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 detectionDis part detail sensors on filling heads, like nozzle position, valve feedback, overfill detection, and show how dis signals dey used for interlocks, sequencing, fault diagnostics.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
