Lesson 1Level measurement methods for tanks: float switches, conductivity, ultrasonic/pressure transmitters — signal types and installation notesThis reviews ways to measure tank levels, like float switches, conductivity probes, ultrasonic, and pressure senders, plus signal kinds, fitting, and common setup mistakes to skip.
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 explains mapping I/O signals for field devices, telling digital from analog channels, and usual wiring, labels, shields, grounds, and EMC ways for sure 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 compares valve kinds and movers, like solenoid valves, motor ball and needle valves, I/P or air movers, and when to use digital or analog control for place and flow check.
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 explains pump types and motor drives, comparing centrifugal and positive push pumps, VFD starts, with start/stop, speed set, 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 covers flow and dosing tools, comparing mass and volume flow meters, and how to pick, control, join dosing pumps or valves with PLC thinking for true, repeat fills.
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 looks at reject tools on belts, like air cylinders and solenoid valves, and how to match moves with sensors and counters, time slots, and check good 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 covers bottle and belt checks with light, near, and touch sensors, explaining fitting, back stop, wiring, and usual signals in pack 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 explains RTDs, thermocouples, 4-20 mA temp senders, comparing true, quick, straight, and right fitting, shield, check 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 covers main machine safety tools, how stop and door lock circuits work, light curtains and relays/PLCs, and Safe Torque Off 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 details sensors on fill heads, like nozzle place check, valve open/close back, overfill find, and how signals aid locks, steps, fault finds.
Nozzle up/down and in-position sensingValve open/closed limit feedback optionsOverfill detection strategies and devicesSignal debouncing and plausibility checksDiagnostics, alarms and maintenance tests
