Automation Technician Course

Lesson 1 • Atomic Structure and Electron Flow

Explains how atomic structure drives electrical conductivity and current flow. Establishes the physical basis for all subsequent circuit analysis.

Lesson 2 • Series and Parallel Circuits

Analyses current and voltage distribution in series and parallel configurations. Prepares students to trace faults in multi-branch control circuits.

Lesson 3 • Capacitance and Inductance Basics

Introduces energy storage in capacitors and inductors and their transient behaviour. Supports understanding of filtering and timing circuits in automation.

Lesson 4 • Voltage, Current, and Resistance

Defines the three fundamental electrical quantities and their units. Connects each quantity to measurable behaviour in automation wiring.

Lesson 1 • Clamp Meters and Power Analysers

Explains non-contact current measurement and power quality analysis. Enables safe measurement on live industrial circuits without breaking the loop.

Lesson 2 • Signal Tracing and Data Logging

Introduces systematic signal tracing methods and portable data loggers. Builds diagnostic habits essential for intermittent fault resolution.

Lesson 3 • Oscilloscope Fundamentals

Teaches time-domain signal capture, triggering, and waveform interpretation. Connects to diagnosing sensor signals and drive outputs in automation systems.

Lesson 4 • Insulation and Continuity Testing

Covers megohmmeter use for insulation resistance and cable integrity testing. Ensures wiring meets safety standards before energising automation panels.

Lesson 1 • Conductor Types and Sizing

Covers wire gauge systems, insulation ratings, and ampacity tables. Ensures correct conductor selection for automation control and power circuits.

Lesson 2 • Electrical Safety and Lockout/Tagout

Establishes arc flash awareness, PPE selection, and lockout/tagout procedures. Mandatory safety foundation before students work on live or energised systems.

Lesson 3 • Control Panel Layout and Assembly

Covers DIN-rail mounting, component spacing, and heat dissipation planning. Produces panels that are safe, accessible, and compliant with enclosure standards.

Lesson 4 • Conduit, Trunking, and Cable Management

Explains conduit fill calculations, trunking installation, and cable routing best practices. Supports organised, maintainable panel and field wiring layouts.

Lesson 1 • Temperature Sensors and Transmitters

Explains thermocouple types, RTD characteristics, and 4–20 mA transmitter wiring. Enables accurate temperature measurement in process automation loops.

Lesson 2 • Sensor Calibration and Verification

Teaches loop calibration, trim procedures, and documentation practices. Ensures sensor accuracy meets process requirements and traceability standards.

Lesson 3 • Proximity and Position Sensors

Covers inductive, capacitive, and optical proximity sensors and their output types. Connects sensor selection to detection range and target material requirements.

Lesson 4 • Level and Limit Detection

Introduces ultrasonic, float, and radar level sensors alongside limit switches. Provides detection solutions for tank management and end-of-travel safety.

Lesson 1 • PLC I/O Wiring and Addressing

Teaches physical wiring of sensors and actuators to PLC I/O terminals and address mapping. Bridges hardware installation with software configuration.

Lesson 2 • Data Handling and Math Instructions

Covers move, compare, and arithmetic instructions for data manipulation. Enables students to implement setpoint control and scaling in PLC programmes.

Lesson 3 • Ladder Logic Programming Basics

Introduces contacts, coils, timers, and counters in ladder diagram language. Builds the programming foundation for all subsequent PLC-based control tasks.

Lesson 4 • Programme Upload, Download, and Backup

Covers communication setup, programme transfer, and version control practices. Protects automation programmes from loss and supports safe modification workflows.

Lesson 1 • VFD Operating Principles

Explains rectifier, DC bus, and inverter stages of a VFD and PWM output. Connects drive topology to motor heating, harmonics, and cable length limits.

Lesson 2 • VFD Parameter Configuration

Teaches motor data entry, acceleration/deceleration ramps, and control mode selection. Enables students to commission a drive from factory defaults to running state.

Lesson 3 • AC Motor Principles and Nameplate Data

Reviews induction motor theory, slip, and nameplate parameters. Provides the motor knowledge required for correct drive and starter selection.

Lesson 4 • Motor Starter and Contactor Circuits

Covers direct-on-line, star-delta, and soft-starter configurations and their control wiring. Prepares students to build and troubleshoot starter panels.

Lesson 1 • PROFIBUS and DeviceNet Fieldbus

Explains PROFIBUS DP and DeviceNet topology, addressing, and GSD/EDS file use. Supports configuration of legacy fieldbus devices still common in industrial plants.

Lesson 2 • HMI Integration and Data Exchange

Covers HMI tag linking, screen design basics, and alarm configuration over network protocols. Enables students to connect operator interfaces to PLC data sources.

Lesson 3 • Serial Communication Fundamentals

Covers RS-232, RS-485, and Modbus RTU framing, addressing, and wiring. Establishes the serial communication baseline for legacy and modern automation devices.

Lesson 4 • Industrial Ethernet Protocols

Covers EtherNet/IP, PROFINET, and Modbus TCP addressing and device configuration. Connects modern PLC and drive communication to plant network infrastructure.

Lesson 1 • Structured Fault Diagnosis Methods

Introduces half-split, cause-and-effect, and symptom-based diagnostic strategies. Provides a repeatable framework applicable to any automation fault scenario.

Lesson 2 • Preventive and Predictive Maintenance

Establishes scheduled inspection routines, thermal imaging, and vibration trending. Shifts maintenance strategy from reactive to condition-based to reduce downtime.

Lesson 3 • Drive and Motor Fault Resolution

Addresses common VFD fault codes, motor insulation failures, and mechanical coupling issues. Connects drive diagnostics to motor and load condition assessment.

Lesson 4 • Sensor and Field Device Faults

Covers loop current checks, sensor alignment, and field wiring fault isolation. Resolves the most common causes of false signals and missed detections.