Electrical Control Systems Course

Lesson 1 • Electrical Theory Essentials

Covers voltage, current, resistance, and Ohm's Law as applied to control circuits. Establishes the quantitative foundation needed for all subsequent circuit analysis.

Lesson 2 • Reading Electrical Diagrams

Teaches ladder diagram and schematic conventions used in industrial control documentation. Students interpret symbols and trace circuit paths before building any physical circuits.

Lesson 3 • Control System Overview

Introduces open-loop and closed-loop control architectures and their industrial roles. Connects electrical theory to real-world machine control scenarios.

Lesson 1 • Relays and Contactors

Explains electromagnetic relay and contactor construction, ratings, and coil energisation. Students distinguish control-circuit relays from power-circuit contactors.

Lesson 2 • Overload and Protection Devices

Covers thermal and electronic overload relays, fuses, and circuit breakers used in motor protection. Proper sizing prevents nuisance tripping and equipment damage.

Lesson 3 • Switches and Pushbuttons

Examines normally open, normally closed, and selector switch configurations. Students test continuity and verify switching action using a multimeter.

Lesson 4 • Timers and Counters

Explains on-delay, off-delay, and one-shot timer functions alongside preset counters. Students configure and test timing sequences in simple control circuits.

Lesson 1 • Motor Protection and Overload Setting

Applies overload relay sizing rules based on motor nameplate full-load amperage. Students set and test overload trip points on live motor circuits.

Lesson 2 • Full-Voltage Motor Starting

Covers across-the-line starter construction, wiring, and operation for three-phase motors. Students connect a complete starter circuit and verify correct motor rotation.

Lesson 3 • Control Circuit Interlocking

Teaches electrical and mechanical interlocking methods to prevent hazardous simultaneous operations. Interlocks are applied to forward/reverse and multi-motor circuits.

Lesson 1 • Pressure and Flow Sensors

Explains pressure switch, pressure transducer, and flow switch operation in process control. Students configure setpoints and verify switching action under live conditions.

Lesson 2 • Temperature Sensing Devices

Introduces thermocouples, RTDs, and thermistors with their signal conditioning requirements. Students connect a thermocouple to a temperature controller and set alarm limits.

Lesson 3 • Proximity and Limit Sensors

Covers inductive, capacitive, and optical proximity sensors alongside mechanical limit switches. Students wire NPN and PNP sensor outputs to control circuit inputs.

Lesson 1 • PLC I/O Wiring and Field Devices

Teaches correct wiring of discrete inputs, discrete outputs, and analogue modules to field devices. Students wire sensors and actuators to a PLC and verify I/O status in the software.

Lesson 2 • Program Download and Online Monitoring

Guides students through project creation, program download, and online monitoring of tag states. Students troubleshoot logic errors by observing rung status during live operation.

Lesson 3 • PLC Architecture and Hardware

Explains CPU, power supply, I/O rack, and communication modules in a modular PLC system. Students identify hardware components and map physical I/O addresses.

Lesson 4 • Timer and Counter Instructions

Covers TON, TOF, and RTO timer instructions alongside CTU and CTD counter instructions. Students program timed sequences and count-based control logic.

Lesson 1 • Sequencer Instructions

Explains SQO and SQL sequencer instructions for controlling multi-step machine cycles. Students program a conveyor indexing sequence using a sequencer output instruction.

Lesson 2 • Data Handling and Move Instructions

Covers MOV, COP, and FLL instructions for transferring and initialising data in memory. Students build recipe-style programs that load parameter sets from data tables.

Lesson 3 • Comparison and Maths Instructions

Uses EQU, GRT, LES, ADD, SUB, MUL, and DIV instructions to perform process calculations. Students scale analogue sensor values and trigger outputs based on computed results.

Lesson 4 • Analogue PID Control Basics

Introduces the PID instruction for closed-loop process control of temperature or pressure. Students tune proportional, integral, and derivative gains on a simulated process loop.

Lesson 1 • PLC Integration with VFDs

Programs PLC analogue output and network commands to control drive speed and direction. Students build a closed-loop speed regulation system using PLC, drive, and encoder feedback.

Lesson 2 • VFD Parameter Configuration

Covers motor nameplate entry, acceleration/deceleration ramps, and frequency limits in drive parameters. Students commission a drive using keypad programming and verify motor operation.

Lesson 3 • Drive Protection and Fault Management

Addresses overcurrent, overvoltage, and thermal fault codes with corrective actions. Students read fault history logs and apply systematic fault-clearing procedures.

Lesson 4 • Drive Control Wiring Methods

Teaches hardwired digital inputs, analogue speed reference, and serial communication control modes. Students wire a drive for both local keypad and remote PLC analogue speed control.

Lesson 1 • Fault Documentation and Root Cause Analysis

Teaches work order completion, fault trend analysis, and root cause identification techniques. Documented findings drive corrective actions that prevent recurring failures.

Lesson 2 • PLC Diagnostic Tools

Uses online monitoring, I/O forcing, and fault log review to isolate PLC-related failures. Students distinguish between field wiring faults and program logic errors.

Lesson 3 • Preventive Maintenance Practices

Establishes inspection intervals, connection torque checks, and component replacement schedules. Proactive maintenance reduces unplanned downtime and extends equipment service life.

Lesson 4 • Systematic Troubleshooting Methodology

Introduces a structured fault-isolation process: observe, define, identify causes, test, and verify. A repeatable method reduces diagnostic time and prevents misdiagnosis.