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CWT550: Control Wiring and Termination Course
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CWT550: Control Wiring and Termination Course

Contact Us Today: info@PiControlSolutions.com, Tel: (832) 495 6436

Duration: 2 Days Classroom or 16 hours Online
Audience:  Electrical Engineers, Control Engineers, Instrumentation Engineers, PLC Technicians, Maintenance Engineers, Electrical Technicians, and Industrial Automation Professionals.
Prerequisites: Basic understanding of electrical concepts and some industrial experience. A 3-year associate's diploma in the electrical or technical field is preferred.
Course Material: Control Wiring and Termination training slides and certificate of completion.

Course Description:

This comprehensive course provides essential knowledge and practical skills for control wiring and termination in industrial applications. The course covers fundamental electrical concepts, safety procedures, and hands-on techniques for proper wiring and termination of control systems. Participants will learn about switches, contactors, relays, motor protection methods, PLC components, and electrical diagrams. The course emphasizes safety protocols, proper grounding techniques, and protection devices essential for industrial electrical installations.

This course is designed to bridge the gap between electrical theory and practical application in industrial control systems. It provides the foundation needed to safely and effectively work with control wiring in manufacturing, process control, and automation environments.

Learning Outcomes

At the end of the course, attendees will clearly understand fundamental electrical concepts and their practical applications in control panel wiring practices. Participants will be able to safely perform industrial control wiring tasks, properly terminate electrical connections, and implement appropriate arc flash and lockout/tagout safety in wiring measures. Attendees will understand how to wire PLC input and output terminals, difference between contactor and relay wiring, and relays in control circuits, implement choosing fuses and overload relays for motor protection schemes, and work with PLC wiring and termination components effectively.

Attendees will be proficient in reading and creating wiring diagrams for control circuits explained and schematics, understand electrical symbols and their meanings, and be able to troubleshoot basic electrical problems in control systems. Participants will have comprehensive knowledge of control wiring safety procedures for electricians, grounding techniques for industrial control panels, and lightning protection devices for industrial control systems to ensure safe control panel electrical installation and maintenance practices.

Syllabus

Basic Electrical Concepts

  • Electric Current and Flow
  • Ohm's Law Applications
  • Resistance and Resistivity
  • Load and Source Concepts
  • Series and Parallel Circuits
  • Power Calculations
  • Kirchhoff's Laws
  • AC and DC Fundamentals
  • Wheatstone Bridge Applications
  • Signal Transmission Types

Switches, Contactors, and Relays

  • Types of Electrical Switches
  • Electromagnetic Switches
  • Position and Pressure Switches
  • Safety Switches and Motor Disconnects
  • Contactor Operation and Applications
  • Difference between contactor and relay wiring
  • Relay Types and Functions
  • Solid State vs Electromagnetic Relays
  • Common mistakes in control panel wiring
  • Contactor vs Relay Differences
  • Wiring diagrams for control circuits explained, and Terminal Identification
  • Selection Criteria and Ratings

Electrical Safety

  • Electrical Shock Prevention
  • Arc Flash Protection
  • Best practices for control wiring in industrial systems
  • Basic Rules of Electrical Safety
  • Lockout/Tagout Procedures
  • Grounding and Ground Fault Protection
  • Grounding techniques for industrial control panels and Ground Fault Protection
  • Equipment Grounding Requirements
  • Ground Fault Circuit Interrupters
  • Personal Protective Equipment

Lightning Danger and Protection Devices

  • Lightning Formation and Characteristics
  • Lightning Surge Types
  • Entry Paths for Lightning
  • Lightning protection devices for industrial control systems 
  • Surge Protector Selection and Application
  • Protection Device Installation
  • Grounding for Lightning Protection

Motor Protection Methods

  • Motor Overcurrent Protection
  • Fuse Selection and Sizing
  • Choosing fuses and overload relays for motor protection
  • Motor Overload Relays
  • Power and Control Circuit Separation
  • Protection Coordination

PLC Components

  • PLC Architecture Overview
  • How to wire PLC input and output terminals
  • Input/Output Systems
  • CPU Functions and Operation
  • Programming Concepts
  • Ladder Logic Basics
  • Hardware Configuration Options
  • Communication and Integration

Electrical Diagrams and Symbols

  • Schematic Diagram Reading
  • Ladder Logic Diagrams
  • Block Diagrams
  • Standard Electrical Symbols
  • Drawing Conventions
  • Troubleshooting Using Diagrams

Electrical Software Design Tools

  • CAD Software for Electrical Design
  • AutoCAD Electrical for control wiring design
  • AutoCAD Electrical Applications
  • Schematic Design Tools
  • 3D Electrical Integration
  • Documentation and BOM Generation

Regulations and Standards

  • National Electrical Code (NEC)
  • Compliance with NEC and international wiring standards (NEC)
  • IP Rating Systems
  • NEMA Enclosure Types
  • Testing Procedures and Compliance
  • International Standards
  • Safety Certifications

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