Improve Workforce Efficiency

Course #: 086051
Duration: 10 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
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 new course replaces, DC Generators and Motors, course 6687.

Course #: VB12XX
Duration: 0.77 hours
What Students Learn: An in-depth explanation is given to describing the structure of rotating machinery components, including magnetic fields, armature, wiring, along with the various rotating machinery configurations. The information is organized so that it correlates to the most current rotating machinery or electrical curriculums and training programs.
Components: Basic Parts and Fundamentals (VB1201); Principles of Operation (VB1202); Major Types (VB1203);

Course #: 086052
Duration: 10 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21);
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 new course replaces, AC Motors, Generators and Rectifiers, course 6698.

Course #: 086053
Duration: 10 hours
Course Prerequisites: Industrial DC Motors (086051); Industrial AC Motors (086052); AC Principles (Block A22); Basic Industrial Math (Block X21);
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 new course, in conjunction with courses 006010, 006011 and 006012 covering Industrial Motor Control for PLCs, replaces Industrial Motor Control, course 6699A-C.

Course #: 086E01
Duration: 25 hours
Course Prerequisites: DC Principles (Block A21); AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn: Lesson 1 - Principles of Grounding

• Understanding National Electric Code Grounding Requirements (article 250); Grounding for Safety; Fault Detection; Grounding Electrode Systems and Types.
  Lesson 2 - Grounding Systems:
• Grounding Electrode Conductor (AC and DC) Material, Types and Sizing; Circuit Grounding; System Grounding; Grounded Conductor Installation, Sizing and Identification; Main Bonding Jumper Locations, Sizing and Connections.
  Lesson 3 - Equipment and Enclosure Bonding and Grounding: Part 1:
• Understanding Effective Ground Paths; Equipment Grounding Conductor Types, Installation, and Sizing; Equipment Grounding Conductor Raceways, Connections and Boxes; Using Earth as an Equipment Grounding Conductor; Bonding Service Equipment; Working with Bonding Jumpers.
  Lesson 4 - Equipment and Enclosure Bonding and Grounding: Part 2:
• Grounding Panelboards, Receptacles, Towers and Computers; Ground-Fault Protective Equipment; GFCIs.
  Lesson 5 - High Voltage Grounding Applications:
• System and Circuit Grounding for 1kV and Over; Separately Derived Systems; Dedicated Five-Wire Systems; Grounding Two or More Buildings; Calculating Fault Currents and Grounding Conductor Withstand Ratings.
  
  Special Notes:
• This course consists of a textbook and supplemental study guide.
• This study unit is primarily appropriate for plant electricians and industrial maintenance training.

Course #: 4040
Duration: 10 hours
Course Prerequisites: AC Principles (Block A22);
What Students Learn: Essential Transformer Properties; Operation Under Load and Without Load; Losses; Voltage Regulation; Rating; Types of Core and Windings; Insulation; Bushings; Tap Changers; Polarity; Single-Phase and Polyphase Transformers; Delta, Star, Open-Delta, and Scott Connections; Special Transformers, Autotransformers, Reactors, Step-Voltage Regulators; Instrument Transformers; Maintenance of Transformers; Design of Small Low-Voltage Transformers.

Course #: 4341
Duration: 10 hours
Course Prerequisites: Industrial DC Motors (086051); Industrial AC Motors (086052); AC Principles (Block A22);
What Students Learn: Motor Torque; Inertia of Loads; Motor Types and Characteristics; Power-Supply Factors; Types of Drives; Braking of Motors; Intermittent Service; Mechanical Connecting Devices; Motor-Driven Power Pumps; Fans and Blowers; Reciprocating, Rotary, and Centrifugal Compressors.

Course #: VS22XX
Duration: 2.42 hours
What Students Learn: This series is designed for new electrical maintenance workers who have little or no knowledge of motor controls. Some knowledge of electricity and electrical principals is recommended. All of the terms used in the series are explained and defined in the workbook, so the learners are not required to have an electrical vocabulary to understand the courses.
The series covers the fundamentals of motor controls to include the subjects of basic controls, overload and time delay relays, schematic symbols, wiring diagrams; starting methods for squirrel cage, wye-delta, synchronous, and wound rotor controls; installing and troubleshooting techniques. The emphasis is to teach the specific skills required to understand basic motor controls. This series is intended to be used as an enhancement to your industrial maintenance program.
Components: Basic Motor Controls and Relays (VS2201); Overload Relays (VS2202); Time Delay Relays (VS2203); Schematic Symbols (VS2204); Schematic and Wiring Diagrams (VS2205); Starting Methods for Squirrel Cage Motors (VS2206); Wye Delta, Synchronous, and Wound Rotor Controls (VS2207); Installing and Troubleshooting Control Systems (VS2208);

Course #: 006010
Duration: 10 hours
Course Prerequisites: Industrial AC Motors (086052); AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn: 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 texts (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: 006011
Duration: 10 hours
Course Prerequisites: Motor Control Fundamentals (for Programmable Logic Controllers) (006010);
What Students Learn: 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 texts (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: 006012
Duration: 10 hours
Course Prerequisites: Industrial Motor Control (for Programmable Logic Controllers), Part 1 (006011);
What Students Learn: 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 texts (006010-11-12) provides current electronics technology not covered in Industrial Motor Control (6699A-C).

Course #: Block B23
Duration: 42 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn: This seven unit block provides a detailed theory into the workings of common electronic components and circuits. Different types of diodes, transistors, switching devices and tubes are covered. The trainee learns to perform circuit measurement tests and troubleshooting techniques for each component.
Components: Basic Semiconductor Components: Diodes (086019); Basic Semiconductor Components: Transistors (086020); Switching Devices (086021); Electronic Sensors (086022); Special Rectifiers: Electron Tubes (086023); Optoelectronic and Fiber Optic Components (086024); Electronics Hardware (086040);
Special Notes: This updated course replaces Electronic Components, Block B03. Each study unit contains a progress examination.

Course #: 086020
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Learn how transistors control the flow of electricity in a circuit.
• Describe the construction of bipolar transistors.
• Explain how the operation of bipolar transistors resembles that of the diode.
• Discuss how biopolar transistors can control and amplify current in a circuit.
• Describe the construction and operation of JFETs and MOSFETs.
• How to use an ohmmeter to perform basic tests on bipolar transistors.
• Perform basic troubleshooting measurements and calculations on circuits that contain amplifying devices.
  

Course #: 086021
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Learn how a switch changes:
  - voltage levels and current levels.
  - the DC polarity of the delivered voltage.
  - the direction of direct current.
  - from one delivered frequency to another.
• Describe how the above functions can be performed by mechanical switches or by electronic circuitry.
• List the advantages and disadvantages of various switch types and how they function..
• Analyze basic relay ladder diagrams.
• Explain how a diode can be used as a switch.
• Name some of the problems of diode switching.
• Describe how very rapid electronic switching is accomplished.
• Explain the circumstances in which a mechanical switch may be preferable to a rapid electronic switch.
  

Course #: 086022
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Learn how certain electronic components are used as sensors and as parts in control mechanisms.
• Explain what sensors and transducers do.
• Describe important thermoelectric effects.
• Learn how these types of transducers operate and the effects they cause; electromagnetic, electroacoustical. piezoelectric, photoelectric, and electromechanical.
• Explain the importance of a bridge circuit in certain types of electronic instrumentation.
• Describe how certain nonlinear resistors are used in circuits.
• Explain how certain components can be used as protection devices for circuits.
• Define the scientific terms stress and strain.
  

Course #: 086023
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Learn how electron tubes work and how to troubleshoot tubes when necessary.
• Identify the four different methods of obtaining electronic emission.
• Explain how vacuum tubes and gas-filled tubes operate.
• Learn how the following special purpose tubes work: Cathode Ray Tubes (CRTs), Transmitter Tubes, Image Orthicon Tubes, Vidicon Tubes.
• Describe how a triode uses a control grid to control electron flow.
• Explain why a screen grid is used in a tetrode.
• Describe the function of a suppressor grid in a pentode.
• Describe how electron beams are controlled in a cathode ray tube (CRT).
• Understand half-wave and full-wave rectification.
• How to select a diode for replacement in a circuit.
• Troubleshoot a half-wave rectifier power supply.
  

Course #: 086024
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• An introduction to the high technology field of optoelectronics.
• Discuss the theory and applications of the components used in this field; compact discs, bar code readers, lasers, light emitting diodes (LEDs) and light activated diodes (LADs).
• Explain why electronics and optics are natural partners.
• Identify the modern theories of light and the relationship to optoelectronic applications.
• Describe the basic theory of light communications.
• Learn how a fiber optic communications system works.
• Describe the operation of electron microscopes and their advantage over optical microscopes.
• Explain how fluorescent light and other light sources operate.
  

Course #: 086040
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Learn the uses and applications of these components that are critical to the repair and maintenance of an analog circuit or system: fasteners, connectors, jacks, component sockets, cables, strain gages, relays, wires, heat shrink tubing, batteries and UPSs.
• How to construct a circuit board for a personal computer.
• Learn correct and safe soldering techniques.
• Understand surface mount technology.
  

Course #: Block B26
Duration: 36 hours
Course 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: Industrial Electronic Troubleshooting (086064); Electronic Troubleshooting of Industrial Motor Controllers (086065); Industrial Computer Networks (086069); Troubleshooting Sensing Devices and Systems (086066); Troubleshooting Industrial Control Systems and Output Devices (086067); Troubleshooting Industrial Computer Systems and Software (086068);
Special Notes: This new course replaces Troubleshooting Electronic Equipment and Systems, Block B06. Each study unit contains a progress exam.

Course #: 086064
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
In a modern industrial plant, thousands (or even tens of thousands) of components work together to make a product. Many machines can now operate for long periods of time without requiring service. This is mainly due to excellent engineering and advances in metallurgy, the construction of electronic components, and the composition of lubricants. As long as proper maintenance work is performed, a machine may last for a very long time. However, it is inevitable that, at some point, one of those thousands of components will fail. A component failure will result in an equipment shutdown or a faulty product. At this time, workers with troubleshooting experience become invaluable.
A number of different skills are required to troubleshoot a machine or a piece of equipment effectively. In this study unit, students will learn about some of the more abstract troubleshooting procedures. These procedures will require the troubleshooter to collect information and focus on the failed component, not just connect a meter to make measurements.
Objectives
When a student completes this study unit, he and she will be able to:

• 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.

Contents
Introduction; Using Safe Work Practices; Basic Troubleshooting Procedures; Collecting Trouble Symptom Data; Advanced Troubleshooting Procedures.

Course #: 086065
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
Industrial motor controllers are widely used in industry. You are probably familiar with some of the simple devices, such as multispeed and reversing AC across the line starters or contractors, used for controlling motors. In this study unit, we will cover the more complex solid state controllers used to control a motor's position and speed.
This study unit will begin by discussing how to troubleshoot simple DC motor controllers and stepper motor control systems. These systems are often used when the speed or position of a small motor must be controlled. Although small DC motors are covered in this unit, you can apply what you learn to larger DC motors since these motors simply have larger components.
This unit will also examine the electronic troubleshooting of servo systems. This section begins with the typical industrial DC servo system where a precision DC motor can be controlled to an exact location and speed. It then covers the troubleshooting of the newer DC brushless systems.
In the final section of this study unit, it will look at the troubleshooting of AC inverter drive systems. These drive systems control AC motors.
Objectives
When a student completes this study unit, he and she will be able to:

• 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.

Contents
Troubleshooting DC Motor Controllers; Troubleshooting Stepper Motors; Troubleshooting DC Servo Motors; Troubleshooting Adjustable Frequency AC Drives; Troubleshooting DC Brushless Servo Systems.

Course #: 086066
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
Sensors are a very important part of any industrial control system. Sensors are provided to the input devices that send signals to these components responsible for monitoring and controlling an industrial system. Input devices indicate when an output device can be safely turned on and how long they should remain on.
In the past, the most popular input device was the limit switch. Although limit switches are still used, non-contact sensors, such as proximity sensors and photoelectric sensors, are becoming more common in industrial applications. Likewise, thermocouples were once popular for sensing temperature. However, modern systems may employ many different types of thermocouples, resistance temperature devices (RTDs), or even semiconductor temperature sensors. Some input devices rely on fiber optics and lasers to perform tasks. These devices and others may rely on their own small IC microchip planted within the sensor. Microchip equipped sensors can be placed on a simple four wire system along with hundreds of other sensors, allowing for a networked grouping of input and output devices.
Students will learn about different types of industrial input devices. In addition, trainees will study some troubleshooting procedures that will prove useful when one of these devices has failed.
Objectives
When a student complete this study unit, he and she will be able to:

• 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.

Contents:
Troubleshooting Industrial Contact Sensors; Troubleshooting Proximity and Ultrasonic Sensors; Photoelectric Sensors; Industrial Sensor Input / Output Troubleshooting.

Course #: 086067
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
The purpose of an industrial output device is to perform controlled work. These devices may be used to start a motor or to control the supply of pressurized air or hydraulic fluid to the actuators of a machine or a robot. In every automated industry, some type of output device controls the functions of a machine.
This study unit focuses on various forms of output devices, output modules, closed-loop systems, and human and machine interfaces. These devices and systems make up the majority of today's industrial systems. This study unit also covers troubleshooting procedures for these systems.
Objectives
When a student completes this study unit, he and she will be able to:

• 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 ouput-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.

Contents
Troubleshooting Output Devices; Troubleshooting Output Modules; Troubleshooting Closed-Loop Systems; Troubleshooting Human and Machine Interfaces.

Course #: 086068
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
On today's factory floor, there are a wide variety of control systems. In the past, control systems were dedicated controllers, such as a motor's speed controller or a programmable logic controller (PLC). However, the type of dedicated controller is changing. The personal computer (PC) now controls or monitors many industrial processes. The personal computers that workers encounter may be standard models or specifically designed for industrial environments.
In addition to PCs, other equipment is used to identify each part of a manufactured product and the machines that created these parts. Bar code readers or scanners, and radio frequency tag systems perform these identification tasks. Vision systems listed above also identify component parts in an industrial environment. These systems employ a camera to closely analyze a component's features. All the systems require software to run the control or monitoring operations.
Objectives
When a student completes this study unit, he and she will be able to:

• 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.

Contents
Industrial Computer Components; Industrial PC Components; Repairing Industrial Computers; Computer-based Identification Systems; Industrial Computer Software.

Course #: 086069
Duration: 6 hours
Course Prerequisites: Analog Electronic Components (Block B23);
What Students Learn: Preview
In industry today, the use of networks is rapidly growing. Only a few years ago, industrial networking was just in an experimental stage. Today, however, most systems are equipped with standard Ethernet connections and preconfigured network operating systems. Many forms of equipment, such as motor drives and PLCs, are able to share a network controlled by one or more large personal computers.
This study unit provides students with an introduction to industrial networks. Trainees will become familiar with the terminology and learn about the components used in these systems. Trainees will realize that industrial networking is an exciting and fast growing field.
Objectives
When a student complete this study unit, he and she will be able to:

• 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.

Contents
Fundamentals of Industrial Communication Systems; Network Configurations; Network Systems; Network Operating Systems, Model, and Protocols; Troubleshooting Network Systems.