Electrical Automation Course

Lesson 1 • Reading Electrical and Automation Diagrams

Teaches interpretation of ladder diagrams, wiring schematics, and P&ID symbols. Provides the visual literacy needed for all hands-on automation work.

Lesson 2 • Actuators and Output Devices

Covers devices that convert electrical signals into mechanical or process actions. Links sensor inputs to actuator outputs within a control loop.

Lesson 3 • Sensors and Transducers

Explains how physical variables are converted to electrical signals for control systems. Introduces sensor types used throughout automation environments.

Lesson 4 • Basic Electrical Principles Review

Covers voltage, current, resistance, and power relationships essential to automation circuits. Establishes the electrical foundation all subsequent automation topics depend on.

Lesson 1 • Ladder Logic Programming Basics

Introduces contacts, coils, timers, and counters in ladder logic. Students write and test programs that replicate relay-based control logic.

Lesson 2 • PLC I/O Wiring and Configuration

Teaches field device wiring to sourcing and sinking I/O modules. Proper wiring practices ensure reliable signal transmission and equipment protection.

Lesson 3 • PLC Architecture and Hardware

Examines CPU, I/O modules, power supply, and backplane design. Understanding hardware layout is prerequisite to correct wiring and program execution.

Lesson 4 • Data Types and Memory Addressing

Covers integer, Boolean, and floating-point data along with memory map organisation. Correct addressing prevents logic errors in all subsequent programs.

Lesson 1 • Modular and Structured Programming

Covers subroutines, function blocks, and program organisation units for reusable code. Modular design reduces development time and simplifies future modifications.

Lesson 2 • Sequencer and State Machine Programming

Implements step-based machine sequences using sequencers and state machine logic. Provides structured control of multi-step automated processes.

Lesson 3 • PLC Program Optimisation and Testing

Applies scan-time analysis, structured testing, and version control to production programs. Ensures programs meet performance and reliability standards before deployment.

Lesson 4 • IEC 61131-3 Programming Languages

Introduces Structured Text, Function Block Diagram, and Sequential Function Chart languages. Multilanguage fluency enables selection of the best tool for each task.

Lesson 1 • HMI Hardware and Software Overview

Surveys panel PC, touchscreen, and web-based HMI platforms and their software environments. Establishes hardware context before screen development begins.

Lesson 2 • Screen Layout and Navigation Design

Applies human factors principles to create intuitive screen hierarchies and navigation flows. Good layout reduces operator error and speeds response to alarms.

Lesson 3 • Alarm Management Systems

Configures alarm priorities, messages, and acknowledgment workflows per industry best practices. Effective alarm management prevents nuisance alarms and missed critical events.

Lesson 4 • Tag Binding and Data Display

Links HMI tags to PLC addresses for live data display and operator input. Accurate tag binding is the core technical task of HMI integration.

Lesson 1 • Ethernet-Based Industrial Protocols

Implements EtherNet/IP, PROFINET, and Modbus TCP for high-speed controller communication. Ethernet protocols dominate modern automation and require dedicated configuration skills.

Lesson 2 • PLC-to-PLC and Controller Integration

Sets up peer-to-peer messaging and producer-consumer models between controllers. Multi-controller coordination is essential for large automated systems.

Lesson 3 • Network Diagnostics and Cybersecurity Basics

Uses network analysers and built-in diagnostics to isolate communication faults. Introduces segmentation and patch management to protect automation networks.

Lesson 4 • Industrial Network Fundamentals

Covers OSI model layers, network topologies, and media types relevant to factory floors. Provides the conceptual framework for all protocol-specific configuration work.

Lesson 1 • VFD Installation and Wiring

Covers input/output wiring, earthing, and cable routing for reliable drive operation. Correct installation prevents EMI, nuisance trips, and premature failures.

Lesson 2 • Drive Parameter Configuration

Programs acceleration ramps, current limits, and protection settings for specific applications. Parameter mastery enables optimisation of energy use and machine performance.

Lesson 3 • AC Motor and Drive Fundamentals

Reviews induction motor operation and explains how VFDs control speed via frequency and voltage. Motor-drive fundamentals underpin all drive commissioning tasks.

Lesson 4 • Servo Systems and Positioning Control

Introduces servo amplifiers, encoders, and closed-loop position control for precision motion. Servo skills extend automation capability to high-accuracy applications.

Lesson 1 • PID Controller Theory and Configuration

Explains proportional, integral, and derivative actions and their combined effect on loop response. Correct PID configuration is the central skill of process control.

Lesson 2 • Advanced Control Strategies

Implements cascade, feedforward, and ratio control to handle complex process interactions. Advanced strategies improve performance beyond what single-loop PID achieves.

Lesson 3 • Loop Tuning Methods

Applies open-loop step tests, Ziegler-Nichols, and software-assisted methods to tune PID loops. Proper tuning minimises overshoot, oscillation, and steady-state error.

Lesson 4 • Instrumentation Calibration and Maintenance

Covers calibration procedures for transmitters, control valves, and analysers. Accurate instrumentation is prerequisite to reliable closed-loop control.

Lesson 1 • Commissioning Procedures and Testing

Executes loop checks, functional tests, and performance verification against design specifications. Structured commissioning confirms the system meets all operational requirements.

Lesson 2 • Fault Diagnosis and Corrective Maintenance

Applies structured fault-finding methods to diagnose and repair automation system failures. Systematic diagnosis minimises mean time to repair and production losses.

Lesson 3 • Preventive and Predictive Maintenance

Establishes maintenance schedules, condition monitoring, and predictive techniques for automation assets. Proactive maintenance maximises uptime and extends equipment life.

Lesson 4 • Automation System Integration Planning

Develops integration plans covering hardware layout, network architecture, and software interfaces. Thorough planning prevents costly rework during commissioning.