Course Title: Electrical Control Equipment

Delivery Medium: Video Tapes

Course Overview: This comprehensive training program consists of six lessons that train participants to understand the operation and troubleshoot circuit breakers, limit switches, overload relays, motor starters, and electrical control circuits.

Intended Audience: This program is excellent for the training of electricians and electronic technicians as well as for the multi-craft training needs of process and manufacturing facilities.

Associated Course Lessons

Lesson Title: Lesson 1- Fuses and Circuit Breakers

Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, electrical print reading, and electrical safety. A knowledge of the proper use of hand tools and electrical test instruments is also required.

Lesson Description: This lesson covers fuses and molded case circuit breakers. The lesson shows and explains how to pull, test, and install fuses as well as how to replace and test molded case circuit breakers.

Lesson Outcome: Upon completion of this lesson, participants will be able to remove fuses, perform continuity checks, and install fuses; select and install circuit breakers; perform routine maintenance on a circuit breaker panel; test the operation of a ground fault circuit breaker; and interpret test results using a characteristic tripping curve.

Lesson Title: Lesson 2- Limit Switches Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, electrical safety, electrical print reading, and the proper use of electrical test instruments.

Lesson Description: This lesson shows and explains how various types of control switches operate and their functions in control circuits. It also presents procedures for adjusting limit switches and torque switches, and for trouble-shooting some typical limit switch problems.

Lesson Outcome: Upon completion of this lesson, participants will be able to adjust lever-actuated limit switches, torque switches, and geared limit switches as well as be able to troubleshoot typical limit switch problems. Upon completion of this lesson, participants will be able to adjust lever-actuated limit switches, torque switches, and geared limit switches as well as be able to troubleshoot typical limit switch problems. Upon completion of this lesson, participants will be able to adjust lever-actuated limit switches, torque switches, and geared limit switches as well as be able to troubleshoot typical limit switch problems.

Lesson Title: Lesson 3- Switches, Coils, and Overloads

Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, electrical safety, electrical print reading, and proper use of electrical test instruments

Lesson Description: This lesson describes the design and operation of manual control switches, coils, and overload relays. The lesson also shows and explains how to verify a circuit de-energized, how to check continuity through push-button and rotary switches, and how to remove and install control components such as contact blocks and overload relays.

Lesson Outcome: Upon successful completion of this lesson participants will be able to describe the function of manual switches and explain the concept of poles and throws; describe the operation of momentary and maintained push-button switches; explain how one push-button switch can be used to control more than one circuit; explain how combinations of push-buttons can be used to control a single circuit; describe how selector switches work; describe rotary switches and explain how to read a switch connection diagram; perform a continuity check on a rotary switch; verify a circuit de-energized; perform a continuity check on a push-button switch; remove and replace a defective push-button contact block; explain how a coil works; check coils for overheating and breaks in the wire windings; explain how an overload relay protects a motor; describe how a bimetallic thermal overload relay works; describe how a melting alloy overload relay works; explain heat storage characteristics of thermal overload relays; describe magnetic and electronic overload relays; describe the common problems of thermal overload relays; remove a thermal overload relay from the motor starter; select the correct heating element for a thermal overload relay; and install a thermal overload relay in a starter.

Lesson Title: Lesson 4- Magnetic Starters

Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, electrical print reading, electrical safety, electrical connections, and the proper use of electrical test instruments.

Lesson Description: This lesson shows and explains how to maintain and test magnetic motor starters. The lesson also presents the basic parts and principals of operation of a typical magnetic and a reversing magnetic motor starter. Procedures for troubleshooting magnetic motor starters and testing the interlocks in reversing magnetic motor starters are also provided.

Lesson Outcome: Upon successful completion of this lesson, participants will be able to describe the benefits of magnetic motor starters; describe a magnetic motor starter and its uses; explain how a magnetic motor starter works; describe the electro-magnet; explain how the contactor works; describe the contacts; identify the troubleshooting steps; perform a visual inspection; perform a test on the armature; perform a continuity check on the coil; perform a continuity check on the contacts; execute the disassembly of the motor starter; perform a check on the electro-magnet; perform a check on the armature and contactor; perform a check on the contacts; explain what an interlock is used for; describe how a mechanical interlock works; perform a continuity check on a mechanical interlock; describe how an electrical interlock works; and perform a continuity check on an electrical interlock.

Lesson Title: Lesson 5- Troubleshooting Electrical Control Circuits

Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, electrical print reading, and the proper use of electrical test instrument. An understanding of the operation of control circuits and components, such as switches, relays, fuses, circuit breakers and motor starters is recommended.

Lesson Description: This lesson demonstrates the basic procedures for troubleshooting electrical control circuits. Participants will learn and understand the safety considerations involved in troubleshooting electrical control circuits including the use of personal protective equipment. This lesson presents the steps in the troubleshooting sequence. It explains the benefits of equipment materials. This lesson shows how to measure resistance of a circuit, as well as how to conduct continuity checks. This lesson also covers basic replacement procedures.

Lesson Outcome: Upon successful completion of this lesson, participants will be able to develop a logical and orderly strategy for troubleshooting an electrical control circuit; describe safe work practices; describe the use of personal protective equipment; Identify and report safety hazards in their facility; identify troubleshooting equipment; list steps in the troubleshooting sequence; describe correct procedures for gathering information about the malfunction; explain how to verify the symptoms of a malfunctioning circuit; explain how to verify a de-energized circuit; describe how to conduct a visual inspection; describe how to conduct a non-visual inspection; explain the significance of schematic diagrams when troubleshooting; explain the benefits of manufacturer's literature; describe the importance of how to prepare for measuring resistance; check continuity of an electrical control circuit; describe troubleshooting techniques as applied in a troubleshooting simulation; describe alternative troubleshooting techniques; describe replacement procedures following resistance check and voltage check.

Lesson Title: Lesson 6- Inverters- Operation and Maintenance

Lesson Prerequisite: This lesson is designed for participants familiar with AC/DC theory, AC motor theory, electrical safety, electrical print reading, and proper use of electrical test instruments

Lesson Description: This lesson explains the design and operation of inverter drives, and describes control features provided by inverter drive systems. The lesson also provides procedures for inspecting and maintaining inverter drives, and gives explanations of common error messages.

Lesson Outcome: Upon successful completion of this lesson, participants will be able to describe the function of inverter drives; describe the parts of an inverter drive; describe the principle of operation of PAM inverters; describe the principle of operation of PWM inverters; describe the operation of an induction motor; explain the formula for synchronous speed; explain how to calculate slip percentage and how inverters compensate for slip; explain why an inverter drive keeps a constant volts-to-Hertz ratio; describe the three types of inverter drives; describe open-loop and closed-loop control and how flux vector control drives work; explain how using an inverter in a variable torque application can conserve energy; describe how a drive can be used for soft-starting; describe how an inverter drive can be used to stop a motor; describe environmental conditions that adversely affect inverter drives; describe the safety precautions for working with drives; perform a routine inspection of an inverter drive; explain how an inverter's display can aid in troubleshooting; give examples of error messages associated with electrical problems; give examples of error messages associated with motor problems; and describe a drive overtemperature fault.

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