Lesson 1Cabling basics: power cables, multi-core control cables, shielded signal cables, and conduit vs tray selectionThis lesson introduces basic cabling for power, control, and signals, covering conductor sizing, insulation types, shielded cables, and deciding between conduit and tray, with focus on segregation, bending radius, and electromagnetic compatibility in Zambian industrial environments.
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 lesson discusses choosing terminal blocks and their distribution, including feed-through, fuse, ground, and shield terminals, with details on current and voltage ratings, jumpering, labelling, and layout for safe and easy-to-maintain industrial control panels in Zambia.
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 lesson addresses picking field devices and interfaces, such as photoelectric sensor types, cable glands, connectors, and IP ratings, stressing environmental factors, mounting, wiring methods, and mechanical protection for dependable operation in Zambian conditions.
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 lesson examines protection devices for feeders and motors, including MCCBs, MCBs, fuses, motor protection breakers, and overload relays, highlighting interrupting capacity, trip curves, coordination, and safeguarding cables and equipment in Zambian setups.
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 lesson details selecting VFDs based on voltage and current ratings, overload capacity, braking options, and EMC filters, including matching to motor specs, ambient conditions, cable length, and necessary control interfaces and protections for Zambian industries.
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 lesson explains common three-phase supply systems (208, 230, 400, 480 V), their frequency, grounding, and short-circuit levels, and how these influence motor and VFD selection, insulation ratings, and panel component clearances in Zambian power contexts.
Wye vs delta and grounded 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 lesson covers choosing 5–10 HP motors, focusing on voltage, enclosure, and duty, interpreting nameplate data, thermal classes, service factor, and their effects on overload settings, starting methods, and coordination with drives in Zambian applications.
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 lesson compares AC and DC control power, explains sizing 24 VDC supplies for steady and inrush loads, and discusses redundancy, buffering, and filtering to boost reliability and noise resistance in industrial panels across Zambia.
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 lesson explains selecting auxiliary devices like contactors, control relays, timers, pushbuttons, pilot lights, and stack lights, focusing on coil ratings, utilisation categories, mechanical life, and fit for control schemes in Zambian factories.
Contactor utilisation categories and coilsControl relays and interposing relaysOn-delay, off-delay, and multifunction timersPushbuttons, selector switches, pilot lightsStack lights, buzzers, and signalling levels
