Improve Workforce Efficiency

Course #: 086051
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Industrial Math (Block X21)
• DC Principles (Block A21)

What Students Learn:

Advantages and Operating Characteristics of DC Motors that make them widely used in industrial applications; Function of each component of a DC Motor; Operation of a Single-Coil Armature Motor; Troubleshooting DC Motors; How a DC Motor Controller Operates; Identify and list applications for various types of DC Motors including Universal, Stepper, PM, Servo and Brushless Motors.

Special Notes:

• This course replaces, DC Generators and Motors, course 6687.

Course #: 086052
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Industrial Math (Block X21)
• AC Principles (Block A22)

What Students Learn:

Construction and Operation of Single- and Three-Phase AC Motors; Principles of Electromagnetic Induction; Identify and work with Starter Systems for Single- and Ploy-Phase Motors including Shaded-Pole, Split- Phase Capacitor, and Repulsion-Induction Motors; Troubleshoot Polyphase Motor Systems.

Special Notes:

• This course replaces, AC Motors Generators and Rectifiers, course 6698.

Course #: 086053
Duration: 10 hours (includes 1 test)
Prerequisites:

• Industrial DC Motors (086051)
• Industrial AC Motors (086052)

What Students Learn:

How Stepper Motors are Electronically Controlled; Steps to follow when Troubleshooting Stepper Motor Controls; Explain how AC Line Frequency sets Motor Speed; How Frequency Inverters Control Motor Speed in Three-Phase Installations; Describe how Servo Motors are Controlled; Explain how Brushless Motors Work and how their Shafts are precisely Positioned; List the steps to follow when Troubleshooting Brushless Motor Controller Systems.

Special Notes:

• This course, in conjunction with courses 006010, 006011 and 006012 covering Industrial Motor Control for PLCs, replaces Industrial Motor Control, course 6699A-C.

Course #: 006010
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Industrial Math (Block X21)
• AC Principles (Block A22)
• Industrial AC Motors (086052)

Course Objectives:

• Motor Control Standards
• Operating Characteristics of Motors ­ motor starters, NEMA and IEC Starters, reversing and multi-speed starters
• Motor Control Fundamentals
• Interpreting Control Devices and Circuits using Control Diagrams ­ automatic and manual signaling devices, capacitive and inductive switches
• Enclosures.

Special Notes:

• This new series of Motor Control study units (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: 006011
Duration: 10 hours (includes 1 test)
Prerequisites:

• Motor Control Fundamentals (for Programmable Logic Controllers) (006010)

Course Objectives:

• History and Concepts of Programmable Logic Controllers (PLCs)
• Number Systems
• The Central Processing Unit (CPU) ­ CPU scan, analog and discrete signals, types of PLC memory
• The Input/Output System (I/O)
• Special Function I/O
• Elements of a Relay Ladder Logic Program
• Operation of Timers and Counters.

Special Notes:

• This new series of Motor Control study units (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: 006012
Duration: 10 hours (includes 1 test)
Prerequisites:

• Industrial Motor Control (for Programmable Logic Controllers), Part 1 (006011)

Course Objectives:

• Programmable Logic Controllers (PLCs) Fundamentals ­ contacts, coils, ladder logic terminology and symbology, scanning and solving ladder logic programs
• Application/Troubleshooting Exercise One: The Pick- and-Place Robot
• Application/Troubleshooting Exercise Two: The Mixing Vat
• Application/Troubleshooting Exercise Three: The Paper Roll Stand
• Troubleshooting Skills using LED indicators and programming console procedures
• PLCs in Motor Speed Control
• PLC System Troubleshooting and Repair.

Special Notes:

• This new series of Motor Control study units (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: 086093
Duration: 10 hours (includes 1 test)
Course Objectives:

• Understand the relation between horsepower, speed, and torque
• Calculate the required torque and power for a specific load
• Recognize the operating characteristics of various motor type
• Select the correct motor type for various industrial applications
• Recognize various types of motor couplings and choose the right coupler for a specific application

Special Notes:

• This study unit replaces 4341

Course #: 286M04
Duration: 45 hours (includes 9 tests)
Prerequisites:

• Basic Industrial Math (Block X21)
• Practical Measurements (Block X22)

What Students Learn:

This course introduces process control system components and their operation. Students learn how a control system works and how its operating characteristics can be interpreted from schematics and ladder logic diagrams. The course explains how electronic components as well as mechanical, hydraulic, pneumatic, electrical components are used to control systems measure parameters. This information is then converted into useful data or the appropriate control system response. The course discusses the application of feedback loops in real-world control systems. The student will understand how electronic systems are combined to deliver useful data signals to computers. In conclusion, the student will learn how PLCs are used throughout industry to control complex systems.

Part 1: Lesson 1 - Introduction to Instrumentation and Control Systems · Explain how process control systems and their various control elements function · Describe how various types of thermal expansion thermometers operate are matched to suitable applications · Define the operating characteristics, components, and suitable applications for thermocouples, thermopiles, RTDs, and thermistors

Lesson 2 ­ Pressure and Level Measurement · Identify several types of mechanical and electrical pressure measuring devices, and explain how their connection and operation · Identify level measuring devices and calibrate pressure sensors, and explain how each one works

Lesson 3 ­ Flow and Position Measurement · Explain the physical properties that affect fluid flow and flowmeters · Identify several types of proximity switches and sensors, and explain how each one works · Explain the practical factors that must be considered when position sensors are installed

Lesson 4 ­ Automatic Control Systems · Explain how automatic process controllers function to maintain the operation of dynamic systems · Define several types of control strategies and how they’re used in practical automatic control systems · Describe how control strategies are used in practical automatic control systems and the purpose of controller tuning

Lesson 5 ­ Valves and Other Control-System Actuators · Identify different types of valves, regulators, dampers and actuators and explain how they operate · Explain how variable speed drives work · Describe the types of circuitry used to control the speed of electric motors

Part 2: Lesson 1 - Analyzers · Explain how analyzers obtain their samples from a process · Define various types of gas and oxygen analyzers operate and how each can be used in industry · Identify common types of humidity and solids moisture analyzers and describe how electrochemical and composition analyzers can be used to identify the various liquids that make up a combined liquid stream. · Explain how an industrial liquid can be analyzed for its density, viscosity, turbidity, and refractive index

Lesson 2 ­ Signal Transmission and Communication · Explain how various numbering systems work such as decimal, binary, octal, ASCII alphanumeric systems, and the hexadecimal numbering systems · Discuss what a communication buss is, and different types of serial communication standards such as RS-232, RS-422, RS-423 and RS-485 · Identify different types of interconnecting media such as category- rated cable, coaxial cable, and fiber optic cable, Fieldbus networks

Lesson 3 ­ Controlling Safety Systems · Describe the operation and function of safety, safety relief, relief valves, rupture disc, excess flow, and fuel shut-off valves · Describe safety system hard wiring, PLC system and safe PLC systems differ from each other in operation · Explain flame detection sensors used for and hazardous environment detection in a burner control system and how system components send their signals back to a controller

Lesson 4 ­Instrumentation and Control Applications · Explain various types of control systems including cascade control systems and how they can be applied to a manufacturing process · Identify different methods of providing temperature control, accurate flows and tank level controls in an industrial process · Discuss lag/lead burner control systems, oxygen trim systems, and multi-variable control systems

Special Notes:

• This course consists of a textbook and two supplemental study guides. We recommend the course be purchased in its entirety. However, if needed, due to targeted training, study guides (Parts 1 & 2) can be purchased separately, with or without the textbook. Note that the textbook is required for the Part 1 study guide. Call Customer Service for pricing and ordering information.

Course #: 086084
Duration: 10 hours (includes 1 test)
Course Objectives:

• Basic types of control loops and their elements
• Define basic process control characteristics and terms
• Identify the five control modes found in industrial systems
• How control system components interface
• Basic components found in DCS architecture

Course #: 086085
Duration: 10 hours (includes 1 test)
Course Objectives:

• The characteristics and development of the HART protocol
• OSI layers used in HART messaging
• Distinguish between point-to-point and multidrop HART devices
• Functions of a device management system
• Seven layers of the OSI standard

Course #: 086086
Duration: 10 hours (includes 1 test)
Course Objectives:

• How Foundation Fieldbus works
• Functions and applications served with Foundation Fieldbus
• Determine existing fail-safe conditions
• Commands for opening a download
• Addressing thermal inertia

Course #: 286087
Course Objectives:

• Define what Predictive Maintenance (PDM) is and how it can be used in industry.
• Identify the various types of technologies used in PDM.
• Explain what goals should be considered for a new and a maturing PDM program.
• Discuss the scope of basic mechanical PDM.
• Explain how a time waveform and a frequency spectrum can be used to identify machine faults.

Course #: 286088
Course Objectives:

• Explain how vibration measurements are taken and the systems used to identify measurement points.
• Identify balance, looseness, and misalignment problems.
• Discuss the techniques used to diagnose rolling-element bearing faults.
• Explain how journal bearing condition monitoring and fault analysis is performed.
• Identify speed reducer faults that occur in the gear sets or the internal bearings.
• Describe how resonance can affect the operation of equipment.

Course #: 286089
Course Objectives:

• Explain the steps involved in performing balance and alignment on industrial machines.
• Discuss the use and operation of ultrasonic equipment to find problems such as electrical arcing, bearing faults, and internal and external air leaks in pneumatic systems.
• Describe the procedures used in electrical signature analysis (ESA) and how this inspection system can find motor problems.
• Explain how oil analysis can find lubricant problems and contamination.
• Describe how thermography can be used in a PDM environment.

Course #: 086064
Course Objectives:

• Explain why a safety inspection is the first inspection that should be made on a failed piece of equipment.
• Discuss how to make safety a part of all troubleshooting and repair procedures.
• Understand how to collect accurate data on trouble clues.
• Describe how to use system indicators to help you troubleshoot an electronic system problem.
• List the steps for proper basic troubleshooting, such as identifying failure trends, seeking obvious causes, and circuit board swapping.
• Describe how to perform advanced troubleshooting, such as using binary divide techniques and focusing on one of many failure possibilities.
• List the aptitude and attitude qualities needed to be a good industrial troubleshooter.

Course #: 086065
Course Objectives:

• Describe various methods of controlling the speed and direction of a DC motor.
• Explain the proper steps for troubleshooting a DC motor controller.
• List the various types of stepper motor drives and explain how to troubleshoot these systems.
• Define how DC servo systems operate and explain the normal test points for locating faults in these systems.
• List the types of adjustable frequency drives and explain how to troubleshoot their circuits.
• Describe how brushless servo systems operate and how to troubleshoot various problems with these systems.

Course #: 086066
Course Objectives:

• Identify the components of a typical limit switch and describe how to test these devices.
• Describe the operation of pressure switches.
• Identify, the components of, and troubleshooting procedures for, temperature sensing devices and level indicators.
• Describe, the operation of, and troubleshooting methods for, proximity, ultrasonic, photoelectric, fiber optic, and laser sensors.
• Define the proper troubleshooting methods for sensors that are connected to input modules.

Course #: 086067
Course Objectives:

• Describe the operation of relays and solenoids, and procedures for troubleshooting them.
• Explain how to troubleshoot across-the-line starters and contractors, including solid state controlled contactors.
• Explain the importance of arc suppression diodes and resistor and capacitor networks in output device circuits.
• Define the operation of, and repair methods for, simple numeric readouts.
• Explain how DC and AC output modules operate and how to troubleshoot them.
• Identify different types of closed loop control systems and methods to troubleshoot and repair them.
• Explain how to troubleshoot and repair human and machine interface systems.

Course #: 086068
Course Objectives:

• Discuss the principle parts and memory types of a computer motherboard.
• Identify power supply components and ratings.
• Locate the main power supply fuse and identify the type of power supply by its connectors.
• Identify the various types of computer drive systems and their cables.
• List the repair and troubleshooting procedures for computer hardware and software problems.
• Describe the operation of, and troubleshooting procedures for, optical and radio frequency identification systems.
• Explain the purpose of vision system hardware and software, and the troubleshooting procedures for them.

Course #: 086069
Course Objectives:

• Describe the methods of communication within networks.
• Explain the configurations of various types of industrial network systems.
• Identify and describe different types of network cables.
• Discuss various network protocols.
• Describe troubleshooting methods for networks.

Course #: Block B26
Duration: 36 hours (includes 6 tests)
Prerequisites:

• Analog Electronic Components (Block B23)

What Students Learn:

This troubleshooting block thoroughly covers the systems encountered in a modern plant or service facility, including the many machines controlled by personal computers (PCs). Malfunctions in modern systems are more likely to be resolved by replacing an entire module or subsystem, rather than troubleshooting specific circuit boards. Plant electricians must often interface with devices that are connected to, or controlled by, PCs or programmable logic controllers (PLCs).

The block examines the industrial components used to monitor or influence the manufacturing process. Study units specifically cover troubleshooting motor control circuits, solenoids, electronic displays, sensors, touch pads and other devices that are directly or indirectly controlled by a computer’s output and input signals. The last two units in the series cover the types of problems encountered by Instrumentation, PC, and Network technicians, relating to cables, connectors, power supplies and interference generated by other electrical equipment.

Components:

• 086064 Industrial Electronic Troubleshooting
• 086065 Electronic Troubleshooting of Industrial Motor Controllers
• 086066 Troubleshooting Sensing Devices and Systems
• 086067 Troubleshooting Industrial Control Systems and Output Devices
• 086068 Troubleshooting Industrial Computer Systems and Software
• 086069 Industrial Computer Networks