Improve Workforce Efficiency

Course #: Block A21
Duration: 30 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn: In this block consisting of six study units, the trainee will learn the basics of electrical theory. These units introduce electrical terms, symbols, and the operation of simple circuits. Ohm's law receives extensive coverage including practical troubleshooting examples used to industry. A new unit specific to capacitors and inductors provides more in-depth coverage. Up-to-date information on conductors, insulation, and specialty batteries forms a revised study unit. Study units covering magnetism, electromagnetism, motors, and generators are included with industry related examples.
Components: Nature of Electricity (086001); Circuit Analysis and Ohm's Law (086002); Capacitors and Inductors (086003); Magnetism and Electromagnetism (086004); Conductors, Insulators, and Batteries (086005); DC Motors and Generator Theory (086006);
Special Notes: This updated course replaces DC Principles, Block A01. Each study unit contains a progress examination.

Course #: 086001
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Explain the operation of a simple circuit.
• Define the terms: conductor, insulator, and resistor.
• Demonstrate that unlike charges attract and like charges repel.
• List the dangers and benefits of static electricity.
• Define the terms: volt, ampere, and ohm.
• Describe common notations and prefixes used to identify electrical and electronic values.
• Identify carbon resistors, potentiometers, and rheostats, and explain how they work.
• Identify the common electrical symbols used in schematic diagrams.
• Explain the difference between a series and parallel circuit.
  

Course #: 086002
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Find the total resistance in series, parallel, and series-parallel circuits.
• Use Ohm's law to calculate the current, voltage, or resistance in circuits.
• Calculate the amount of power supplied and dissipated in a DC circuit.
• List the steps for finding current, voltage, and resistance with a digital or analog meter.
  

Course #: 086003
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Explain how a capacitor holds a charge.
• Describe common types of capacitors.
• Identify common capacitor ratings.
• Calculate the total capacitance of a circuit containing capacitors in series or in parallel.
• Calculate the time constant of a resistance-capacitance or RC circuit.
• Explain how inductors are constructed.
• Describe the system used to rate inductors.
• Describe how an inductor regulates the flow of current in a DC circuit.
• Calculate the total inductance of series or parallel connected inductors.
• Calculate the time constant for a resistance-inductance or RL circuit.
  

Course #: 086004
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Identify the north and south poles of permanent magnets and electromagnets.
• Name magnetic and nonmagnetic materials.
• Describe how to magnetize a piece of steel by induction.
• Explain the difference between simple, compound, and closed magnetic circuits.
• Locate the direction of magnetic lines of force around a conductor (if the direction of current is known).
• Use the right-hand rule to locate the poles of a solenoid.
• Describe the operation of simple electromagnetic relays, buzzers, and stepping switches.
• Explain how a DC motor operates.
• Give a simplified explanation for generator action and motor action with electromagnetic induction.
  

Course #: 086005
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Describe the various types of conductors and discuss their conductivity.
• Explain the American Wire Gage System of sizing copper conductors.
• Determine the size of conductor needed for an application.
• Identify the various types of insulating materials and their temperature ratings.
• Explain the difference between a dry cell and a storage battery.
• How to connect cells together to obtain more voltage, more current, or more of both voltage and current.
• Describe the proper safety precautions used when working with storage batteries.
• Describe how to properly clean and care for storage batteries.
• Discuss the instruments used for testing storage batteries.
• Explain how NiCad, lithium, and other types of special batteries operate, and describe their ratings.
  

Course #: 086006
Duration: 5 hours
Course Prerequisites: Basic Industrial Math (Block X21);
What Students Learn:

• Identify a series-, shunt-, and compound-wound motor and discuss their application.
• Explain how a permanent-magnet and stepper motor operate.
• List the steps to reversing a DC motor's direction.
• Discuss how the speed of a DC motor can be controlled.
• Explain the basic principle for generating a direct current.
• Name the factors that affect the strength of the induced voltage.
• Describe the purpose of a commutator and brush assembly.
• Discuss the difference between the field connections of series-, shunt-, and compound-wound machines.
• Give the reason for shifting brushes.
• Discuss the use of commutating poles and compensating windings for better generator operation.
• List the various types of machine losses.
  

Course #: 086800
Duration: 0 hours
Course Prerequisites: DC Principles (Block A21);
What Students Learn: Electronics Workbench is an electronics lab in a computer. A powerful software tool that simulates the behavior of analog circuits, digital circuits, and the corresponding test equipment. Students perform experiments faster, in a safe, user friendly environment.
Sophisticated troubleshooting options allow trainees to make practical evaluations of the theory they have been learning. High quality, visual circuit paths are recreated. The simulator lets students design, build, and verify circuits significantly faster than on a real test bench. As self-paced study, students can experiment with "what if" scenarios. Circuits can be created with any number of faults or malfunctions for students to diagnose, isolate, and repair.
Realistic test instruments used in working applications include the digital multimeter, oscilloscope, function generator, word generator, logic analyzer, logic converter, and bode plotter. A "bottomless" bin of real world components for both digital and analog circuits include over 125 74xx and 74xxx chips, resistors, diodes, capacitors, a wide variety of logic gates, scrs', triacs, npn, and pnp transistors and many more.

Special Notes:

• The Electronics Workbench is available in Microsoft Windows 95 and 98 platforms. Electronics Workbench versions 3, 4 and 5 are supported by the ICS electrical and electronics block courseware and the laboratory exercise manuals.
• Single user copies and site licenses are available. Contact your Training Consultant for pricing information.

Course #: 387009C
Duration: 10 hours
Course Prerequisites: Electronics Workbench. (086800); DC Principles (Block A21);
What Students Learn: Basic lab exercises and elementary troubleshooting problems using the Electronics Workbench (Versions 3.0, 4.0, and 5.0) are contained in this manual. Practice exercises using electrical notations, prefixes, Ohm's law, series and parallel connections, and basic circuit construction are included. The manual includes the basic operational instructions for the Workbench software and Windows.

Special Notes: The manual contains a file disk of practice circuits.

Course #: Block A22
Duration: 40 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn: Alternating current is the form of current most often used to furnish electrical energy. Students receive a complete introduction to AC terminology and basic AC circuit configurations. Individual study units on the uses of capacitors and inductors in AC circuits underlines the importance of these components in AC theory. The generation, control, and distribution of AC power are highlighted in study units on alternators, transformers, and energy distribution. How electricity is generated at a power plant and sent to consumers is covered. The student will also be introduced to basic electronics through a study unit on rectification and basic electronic components.
Components: Alternating Current (086007); Alternating Current Circuits (086008); Inductors in AC Circuits (086009); Capacitors in AC Circuits (086010); Transformers (086011); Alternators (086012); Electrical Energy Distribution (086013); Rectification and Basic Electronic Devices (086014);
Special Notes: This updated course replaces AC Principles and Components, Block A02. Each study unit contains a progress examination.

Course #: 086007
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Draw a graph of an AC voltage and describe how AC voltage is created.
• Explain AC cycle terms: "alternation," "peak," "positive," and "negative."
• Define the time period of an AC voltage as expressed in degrees.
• List the characteristic values of an AC cycle and describe the relationship between the values.
• Define phase angle and describe how it relates to reactive circuits.
• Calculate power for single-phase and three-phase circuits.
• Describe how a 220 VAC single-phase circuit operates.
• Illustrate the phase relationship of three-phase wave forms.
• Determine real power by reading a power factor meter.
• Describe delta and wye three-phase circuit connections.
  

Course #: 086008
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Identify electric circuits in terms of their circuit characteristics.
• List several circuit characteristics that are used to describe a circuit for a particular load application.
• Connect electrical components in series and parallel circuits.
• Control loads from one or two switch points.
• Describe how delta- and wye-connected three phase circuits are different.
• Explain how grounding a circuit increases its safety.
• Recognize the difference between control circuits and power circuits.
  

Course #: 086009
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Explain how an inductor is made and how it operates in a DC and AC circuit.
• Describe inductive reactance and impedance, and how AC frequency effects inductance.
• Use Ohm's law in an AC circuit that includes an inductor.
• Calculate the impedance of a series RL circuit.
• Calculate the impedance of a parallel RL circuit.
  

Course #: 086010
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Describe how a capacitor stores a charge and how series connected and parallel connected capacitance values are calculated.
• Discuss capacitive reactance and use Ohm's Law in AC circuits that contain a capacitor.
• Calculate the impedance of a series RC circuit.
• Explain how changing the frequency of an AC signal changes capacitive reactance.
  

Course #: 086011
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Explain what the main components of a transformer are.
• Tell how mutual inductance makes it possible to change an AC voltage from one value to another when using a transformer.
• Determine the turns ratio of a transformer when the primary and secondary voltages are known.
• Calculate primary or secondary voltages or current when either one of these and the turns ratio are known.
• Explain why transformers are laminated.
• Connect three single-phase transformers for three-phase operation.
• Calculate line current (if phase current is known) in delta-connected transformers.
• Explain the operating principles of an auto transformer.
  

Course #: 086012
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Explain how single- and three-phase alternators operate.
• List and describe the major components of an alternator.
• Discuss alternator ratings in terms of power, voltage, speed, and temperature.
• State the steps required for starting, stopping, and operating alternators.
• Describe the similarities and differences of the three main types of alternators.
  

Course #: 086013
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Explain the difference between feeder and branch circuits.
• Describe the different types of systems available for distributing power within a plant.
• Recognize and identify utilization equipment.
• Discuss the use of transformers in energy distribution.
• Identify by name and describe the uses of various types of raceways.
• Distinguish between panel boards and switchboards.
• Describe the electrical system of a power utility.
• Describe how electricity is generated at a power station or utility.
  

Course #: 086014
Duration: 5 hours
Course Prerequisites: DC Principles (Block A21); Basic Industrial Math (Block X21);
What Students Learn:

• Explain how diodes are used as rectifiers.
• Discuss the basic operation of a diode and a triode electron tube.
• Connect a PN junction for forward and reverse bias.
• Explain how a transistor operates as an amplifier.
• Recognize transistor input and output circuits.
• Compare rectifier circuits with and without filter circuits.
• Describe the operation of an SCR and a triac.
• Calculate the ripple frequency of a half-wave and full-wave single-phase and three-phase rectifier.
  

Course #: 387012C
Duration: 10 hours
Course Prerequisites: Electronics Workbench. (086800); DC Principles (Block A21); AC Principles (Block A22);
What Students Learn: This lab manual, designed for use with the Electronics Workbench simulation software (Versions 3.0, 4.0, and 5.0), contains lab exercises and troubleshooting problems that reinforce the theory learned in AC Principles. Problems dealing with impedances of RC and RL circuits, rectification of AC voltages, and series and parallel resonant circuits are part of the learning experience.
The manual contains the basic operational instructions for the Workbench software and Windows.

Special Notes: The manual contains a file disk of practice circuits.

Course #: Block A23
Duration: 15 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn: In this three unit block, trainees learn how to use electrical test instruments and measuring techniques. The instruments covered are multimeters, volt-ohm-milliameters (VOMs) and oscilloscopes. Students will learn how to measure voltage, resistance, and current valves is a circuit. Troubleshooting tests on both AC and DC systems including PLC input and output problems are emphasized.
Components: Basic Test Equipment (086025); Troubleshooting with Volt-Ohm-Milliamp Meters (VOMs) (086026); Using Basic Oscilloscopes (086027);
Special Notes: This updated course replaces Electrical Measurements and Instruments, Block A03. Each study unit contains a progress examination.

Course #: 086025
Duration: 5 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn:

• How to use the multimeter (also known as a volt-ohm-milliameter or VOM).
• Define the terms voltage, current and resistance, and explain their relationship in a circuit.
• Discuss how voltage, current and resistance is measured with a multimeter.
• Identify the schematic symbols used to represent various reactive devices.
• Describe the major features of analog and digital VOMs.
• Explain how to use both analog and digital VOMs to measure voltage, resistance and current in a circuit.
• Learn about the special probes used with a digital VOM.
• Discuss the important safety precautions you must take when using a multimeter.
  

Course #: 086026
Duration: 5 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn:

• Review the functions of a multimeter.
• Name the safe practices you should use when troubleshooting with a VOM.
• How to measure circuit resistance.
• Learn the purpose of, and how to perform, tests for continuity and short circuits.
• Perform resistance tests on resistors, fuses, solenoids, relays, switches, transformers, motors and semiconductors.
• How to take basic current measurements on power supplies, AC feeder lines and other such circuit areas.
• Measure current by using a direct series connection or by using a clamp-type ammeter.
• How to take basic voltage measurements on both AC and DC systems.
• Measure the output voltage of a DC power supply and the voltage of an AC feeder line.
• Measure voltage at disconnect switches, circuit breakers, contactors and transformers.
• Perform voltage tests on circuit boards, PLC systems and motor circuits.
  

Course #: 086027
Duration: 5 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21);
What Students Learn:

• An introduction to the basic controls and functions of an oscilloscope.
• Describe the component parts and features of a standard, dual-trace oscilloscope.
• How to use the front panel controls.
• How to connect an oscilloscope to a circuit.
• Learn how to perform low-voltage measurements on circuit boards.
• Measure the voltage output of a power supply and AC ripple.
• Describe how to perform measurements in SCR and TRIAC circuits.
• Test both DC and AC servo motor controller circuits and heater controller circuits.
• Perform basic scope measurements on digital circuits.
• Learn how to use an oscilloscope to troubleshoot industrial systems.
  

Course #: 387014C
Duration: 10 hours
Course Prerequisites: Electronics Workbench. (086800); Analog Circuit Measurement (Block A23);
What Students Learn: Students will complete lab exercises and troubleshooting problems using the Electronics Workbench software (Versions 3.0, 4.0 and 5.0). This lab manual will provide experience using the many simulated instruments that are part of the software package. Troubleshooting simulations using the digital multimeter, oscilloscope, function generator, and bode plotter are included in these exercises. The manual includes the basic operational instructions for the Workbench software and Windows.

Special Notes: The manual contains a file disk of practice circuits.

Course #: VB15XX
Duration: 0.8 hours
What Students Learn: A multimeter is to an electrician and electronic technician what a spreadsheet is to an accountant and a stethescope is to a doctor; the most necessary of tools. Entry level students and trainees will see how to use both DIGITAL (Fluke 77) and ANALOG (Simpson) multimeters. They will be shown how to properly make connections so as to make safe and accurate readings. Vivid, close-up videography shows detail not easily seen and makes learning how to use the multimeter easier than ever imagined.
Components: An Introduction (VB1501); Continuity and Resistance (VB1502); Voltage and Current (VB1503);

Course #: Block A24
Duration: 60 hours
What Students Learn: The twelve study units in this block provide the student with the skills and knowledge needed to install basic industrial electrical equipment. In addition to learning the symbols for the various types of equipment, the student will learn how to safely install conductors and electrical fittings. The types of equipment discussed includes outlet boxes, panels, raceways, conduits, switches, fuses, circuit breakers, plugs, receptacles, and lampholders. The student will also learn how to calculate electrical loads, lay out circuits, and troubleshoot control circuits.
Components: Conductors and Insulators in Industry (086070); Working with Conduit (086071); Electrical Boxes (086072); Industrial Enclosures and Raceways (086073); Connecting Electrical Equipment, Part 1 (086074); Connecting Electrical Equipment, Part 2 (086075); Industrial Fuses (086076); Industrial Circuit Breakers (086077); Plugs, Receptacles, and Lampholders (086078); Industrial Switches (086079); Industrial Relay Ladder Logic (086080); Industrial Relays, Contractors, and Solenoids (086081);
Special Notes: This updated course replaces Electrical Equipment, Block A04. Each study unit contains a progress exam.

Course #: 086070
Duration: 5 hours
What Students Learn: Preview
As an industrial electrician, students will work with various types of conductors and insulators. For instance, you may install a new service and have to pull conductors through conduit. Electricians will have to select the right size, type, and color of conductor to properly perform the installation. In another instance, you may troubleshoot a problem with an industrial circuit and find a faulty conductor. Your knowledge of the types of conductors and insulators can help you perform this task quickly and efficiently.
This study unit provides electricians with information on conductors and insulators that you will find in industry. This study unit covers a range of conductors from the standard plastic coated, copper conductors to the large, high-temperature conductors. Students will learn about the different types of insulators and how the type of insulator can influence the maximum temperature and current-carrying capability of the conductor. At the end of this study unit, students will learn how to troubleshoot and repair conductor and insulator problems.
Objectives
When students complete this study unit, he and she will be able to

• Identify the physical properties of various conductors.
• Describe the electrical properties of common conductor materials.
• Explain why conductors contain resistance, which causes voltage drops.
• Identify the common types of insulation materials that are used on industrial conductors.
• Explain how to repair faulty insulation on industrial conductors.
• Describe how to troubleshoot and repair conductor and insulation problems.

Contents
Physical Properties and Characteristics: Conductor Terminology; Wire Sizes; Wire Tables; Mil-Foot and the Effect of Temperature; Electrical Properties and Characteristics: Conductivity; Wire Resistance; Voltage Drop; Types of Industrial Insulation: The Definition of an Insulator; Natural Insulators; Synthetic Insulators; High-Temperature Insulators; Shrink Tubing; Tapes; Other Forms of Insulators; Problems with Conductors and Insulators: Effects of Too Much Current or Heat; Effects of Abrasion; Effects of Poor Conductor and Insulator Installation ;Effects of Aging on Conductors.

Course #: 086071
Duration: 5 hours
What Students Learn: Preview
This study unit focuses on what an electrician needs to know about conduit. First, you will study the characteristics of common types of conduit. Next, students will learn how to work with conduit. The course covers the types of fittings, conduit cutting and threading, and supporting conduit from walls and ceilings. When installing conduit, an electrician frequently has to make bends in the conduit. These bends must be made properly, using the right tools and techniques described in this study unit. Finally, you will study examples of large conduit installations and how to size and pull conductors through conduit.
Objectives
When a student completes this study unit, he and she will be able to:

• Define the characteristics of different types of conduit.
• Describe how to install various types of conduit fittings and support.
• Explain how to properly cut and thread conduit using manual and machine methods.
• Identify and use the proper tools for bending conduit.
• List the equipment used in installing large conduit and its conductors.
• Determine conduit sizing when given a particular wiring assignment.

Contents
Conduit Types and Characteristics: Rigid Metal Conduit Systems; Electrical Metallic Tubing (EMT);Intermediate Metallic Conduit (IMC);Flexible Metal Conduit; Other Types of Conduit; Conduit Procedures: EMT Conduit Fittings; Rigid and IMT Fittings; Cutting, Reaming, and Threading Conduit; Bonding Conduit; Supporting Conduit; Conduit Nipples and Elbows; Using Insulating Bushings; Bending Conduit: The Right Way ;Manually Operated Benders; Hydraulic Benders ;Radius of the Bend; Bending for a Given Rise; Back-to-Back Bends; Re-bending; Offsets; Saddle Bends; Conduit Run Requirements; Large Conduit Installations: Where Large Conduit Installations are Performed; Conduit Hangers; Using Pull Boxes; Installing Large Conduit Systems; Mating Conductors and Conduit: Derating for More Than Three Conductors; Basic Conductor Ampacity; Derating for More than Three Conductors; Derating for Ambient Temperature; Conductor cross sectional Area; Conductor Fill; Selection of Conduit Size; Combinations of Wire Sizes in Conduit; Fishing Wire through Conduit; Feeding Conductors into Conduit.

Course #: 086072
Duration: 5 hours
What Students Learn: Preview
This study unit teaches electricians about a very important part of any electrical distribution or control cable wiring system. This important part is the electrical box. The electrical box may be a small component, such as a box for a light switch or receptacle. Or, the box may be a large junction box with many conductors entering and leaving the box.
This study unit provides you with information on the types of electrical boxes their covers, and discusses boxes for pulling and splicing. Students will learn how to select the proper sized box for a situation. You will also learn about the proper ways of installing electrical boxes.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe the role of electrical boxes in an installation.
• Explain why circuits are interrupted.
• Explain when and where electrical boxes are used in installations.
• Describe how to properly install electrical boxes.
• Identify the types of electrical pulling and splicing boxes.
• Explain how to properly install conductors in a system with electrical boxes.

Contents
Equipment Defined: When Wiring is Interrupted; Material Standards; Common Wiring Terms; Wiring Symbols; The Parts of an Electrical System; Electrical Boxes and Covers: Outlet Boxes; Where Outlet Boxes are Used; Boxes and Their Associated Fittings; Types of Outlet Boxes; Non-Metallic Outlet Boxes; Outlet Box Knockouts; Brackets; Fittings for Outlet Boxes; Flush Plates and Covers; Industrial Electrical Boxes; Boxes used for Pulling and Splicing: Junction Boxes; Special Boxes; Conduit Bodies; Straight Pull Boxes; Right-Angle Pull Boxes; Knockouts and Circuit Grounding; Installing an Outlet Box: The Volume of the Box; Locating an Outlet Box; Mounting an Outlet Box; Lighting Fixtures and Exhaust Fans; Cleaning an Outlet Box; Wiring an Outlet Box.

Course #: 086073
Duration: 5 hours
What Students Learn: Preview
Whenever a person walks through an industrial plant, you will notice many large electrical enclosures that serve as control cabinets. These enclosures house panelboards to which many control components, protection devices, recorders, and other equipment, connect. As an industrial electrician, it is important for students to know how industrial enclosures and the panelboards they contain are constructed, secured, and connected to the devices throughout the plant.
This study unit provides electricians with the information you will need to construct and install an industrial enclosure, and to connect the panelboard to the field devices through one or more kinds of raceways. Many different types of installations are encountered in industry, and you will be introduced to several of them. Students will also learn about raceway installation and grounding.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe the basic construction of industrial control cabinets and similar enclosures.
• Explain how to connect conduit to enclosures.
• List the proper procedures for installing a disconnect switch or main breaker in an enclosure and the procedures for connecting conductors to the switch.
• Explain how to properly ground the enclosure.
• Describe how to properly install wireways, such as wiring troughs.
• Explain how plugs and receptacles can be used to prefabricate a system.

Contents
Industrial Enclosures: Basic Enclosures; Types of Enclosures; Enclosures with Disconnects; Large Control Enclosures; Installing the Disconnect Switches: Installing the Door Handle Hardware; Installing the Rods and Rollers; Installing the Disconnect Switch Assembly ;Connecting the Wiring to the Switch and Panel; Industrial Control Panelboard Layout: General Locations; DIN Rail; Locating Terminal Blocks; Wiring the Control Panel; Connecting Conduit to Enclosures: Layout; Creating Holes in Enclosures; Using Manual Hole Punches; Using Hydraulic Hole Punches; Installing Conduit Fittings; Using Insulating Bushings; Installing Raceways: NEC rules for Metal Wireways; Raceway Cutouts; Supporting Metal Wireway or Trough; Raceway to Machine Connections; Grounding Wireways and Troughs.

Course #: 086074
Duration: 5 hours
What Students Learn: Preview
Industrial systems are complex systems having many interconnections. All components work together to keep the system functioning properly. Every component must communicate with a main control panelboard or a main system controller, which, in turn, communicates with the other components of the system. Even a remote device like a single photoeye located on a distant conveyor plays an important role in a systems operation. That photoeye may communicate with the conveyor system controller and possibly the main assembly line controller.
This study unit provides trainees with information on how intermediate or main junction boxes are connected to the main system by means of raceway. Then, you will learn how devices are connected into a wireway, to a junction box, or to another location, using raceway or cabling and strain relief fittings. The next section discusses how connections are made inside control-panelboard enclosures. Students will be introduced to terminal block connections. You will also learn about connections to devices such as fuse holders, circuit breakers, and motor starters. The final section of this study unit covers connections to remote operator stations and remote control stations.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe the use of flexible conduit, strain relief fittings, plug connections, and terminal blocks in industrial equipment.
• Discuss why there are often two raceways run in parallel in an industrial system.
• Explain when to run rigid conduit, EMT conduit, wireway, or open cords in a system.
• Describe how to make basic connections in industrial control-panelboard enclosures.
• Explain the different classes of remote station and operator station wiring.
• Discuss why various types of cables and conductors must be kept separated.
• Explain how to properly connect communications and controller cables in an industrial control cabinet.

Contents
Connecting Devices to Intermediate Boxes: A General Layout; The AC Wireway; Strain Relief Connections; Larger Systems; Using Receptacles and Plugs; Using Flexible Conduit; The DC Wireway; External Devices; Connections to Terminal Blocks; Connecting Devices to Raceways: Using Rigid Conduit; Using EMT Conduit; Using Flexible Conduit; Using Strain Relief Fittings; Connections in the Control Cabinet: Terminal Block Connections; Connections to Motor Starters and Circuit Breakers; Connections to Fuses; Connecting Signal Cables for Electronic Equipment; Remote Operator Stations: Voltage Levels in Modern Remote Operator Stations; Grounding of Remote Operator Stations; Separating Signal and Control Cables; Broadband and Communication Circuits.

Course #: 086075
Duration: 5 hours
What Students Learn: Preview
As an industrial electrician, you will spend a lot of time selecting electrical connectors and making electrical connections. You may perform these activities as part of a new installation or as a repair task. A good electrical connection is critical. A poorly made connection may cause a failure, which can cost thousands of dollars because of downtime in a plant, and possible injury caused by electrical shock.
In this study unit, students will learn how to make good electrical connections using the proper type of electrical connector. This study unit covers solderless terminals, wire nuts, and butt splices. You will learn about larger compression-type connectors and about connections made to smaller devices.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe types of solderless connectors.
• Explain the use of hand-operated and hydraulic crimping tools to make good electrical connections.
• Identify the proper size of wire nut or butt splice for splicing conductors.
• Describe how to make good connections with wire nuts and butt splices.
• Explain how to use large compression connectors, including solderless lugs and split-bolt connectors.
• Describe the installation of wires on terminal blocks, plugs and receptacles, and push-pin style terminals.

Contents
Solderless Connectors: Types of Solderless Connectors; Sizes of Solderless Connectors; Installation Tools; Installation of Solderless Terminals; Using Wire Nuts and Butt Splices: Types of Splice Systems; Butt Splices; Installing Wire Nuts; Installing Butt Splices; Compression Connectors: Installing Compression Terminals; Installing Compression Terminal Lugs; Installing Split-Bolt Connectors; Terminal Block and Plug / Receptacle Connections: Terminal Block Connections; Plate-Type Electrical Connections; Plug and Receptacle Pins; Push-Pin Connections.

Course #: 086076
Duration: 5 hours
What Students Learn: Preview
All electrical and electronic circuits, from the small ones in our homes to the large ones in industry, need to have circuit protection. This protection guards against too much current flowing in the circuit. Too much current in a circuit can cause serious damage. There are two different methods of protecting a circuit: fuses or circuit breakers. This study unit focuses on fuses.
First, this study unit discusses the need for overcurrent protection in modern industrial circuits. There are many reasons why the system wiring, control circuits, and load devices must be protected. Next, fuse ratings and specifications are covered. This section discusses the selection of the correct type and size of fuse in a system.
The following section focuses on typical fuse holders. There are a wide range of fuse holders, from fuses soldered onto a circuit board to those that are clamped into large disconnect switches. Many problems can occur on a fuse holder. This study unit shows how to address the problem until the fuse holder can be replaced. Finally, the unit ends with a discussion of how to safely test and replace fuses in their fuse holders.
Objectives
When a student completes this study unit, he and she will be able to:

• Discuss the purpose of fuses in industrial electrical and electronic circuits.
• Explain the numbering and lettering system for classifying a fuses shape, size, or circuit protection capabilities.
• Identify various types of fuse holders.
• Locate common failure points on different fuse holders.
• Explain how to properly test and replace a fuse.
• Describe common methods for repairing fuse holders.

Contents
The Purposes of Fuses: Protecting Electrical Wiring; Protecting Circuit Devices; Protecting Control Circuits; Protecting Output Devices; Fuse Ratings and Classifications: Current and Voltage Ratings; Time and Temperature Considerations; Interrupt Current Rating; Fuse Categories and Classifications; Sizes and Shapes of Fuses; Fuse Classifications: Glass and Ceramic Fuse Types; Class RK5 Fuses ;Class RK1 Fuses; Class CC Fuses; Class L Fuses; Class J Fuses; One Time Fuses; Class G Fuses; Class T Fuses; Midget Fuses; Specialty Fuses; Using Fuse Catalogs; Fuse Holders: Holders for Small Glass and Ceramic Fuses; Larger Fuse Holders; Blade Fuse Holders; Open Fuse Installation; Changing Fuses and Maintaining Fuse Holders: Removing Power; Testing the Fuses; Checking for a Short Circuit; Checking Fuse Holder Contacts; Cleaning Fuse Holder Contacts; Maintaining Fuse Holders.

Course #: 086077
Duration: 5 hours
What Students Learn: Preview
As an electrician, one of the most common devices you will see is a overcurrent protection device (OCD). This may be a fuse or a circuit breaker, and every industrial cabinet will usually contain at least one OCD.
The Industrial Fuses study unit covered the various types of fuses. Here the second kind of protective device, the circuit breaker will be examined.
Most people are familiar with the molded-case circuit breakers used in our homes. The home load center will normally contain a main circuit breaker that protects the entire load center for the home, and smaller circuit breakers that protect the various branch circuits.
An industrial control panel is not much different from a home's load center. A large circuit breaker or fuse system is usually located at the main disconnect that supplies the control panel. Each circuit will then contain a smaller circuit breaker or fuse system to protect the branch circuits inside and outside the panel.
This study unit will look at the types of circuit breakers that are commonly used in industry; how they are designed and how they work. We will also look at typical branch circuits for single-phase and three-phase loads. Finally, the study unit will discuss ground fault circuit breakers and outlets, and how to safely work with circuit breakers.
Objectives
When a student completes this study unit, he and she will be able to:

• Explain the thermal and magnetic operation of a circuit breaker.
• Explain how a combination circuit breaker operates.
• Identify an electronic circuit breaker and its operation.
• List the various types of industrial circuit breakers.
• Describe the various types of circuit that single-pole and multiple-pole circuit breakers will be used in.
• Explain how to troubleshoot a circuit in which a circuit breaker has tripped.
• Describe the operation of a ground fault circuit breaker.

Contents
The Operation of a Circuit Breaker: An Automatic Switch; Thermal Circuit Breaker Operation; Magnetic Circuit Breaker Operation; Combination Circuit Breaker Operation; Circuit Breaker Accessories; Electronic Circuit Breakers; Current-Limiting Circuit Breakers; Circuit Breaker Time of Operation; Current Ratings and Interruption Current; Types of Industrial Circuit Breakers: Small Single Phase Breakers; Molded-Case Circuit Breakers; Adjustable Current and Time Delay Circuit Breakers; Air Circuit Breakers; Circuit Breaker Circuits: Protecting Single-Phase Circuits; Protecting Three-Phase Circuits; Alarm Circuit Contacts; Circuit Breaker Auxiliary Circuits; Working with Circuit Breakers: Finding A Replacement Circuit Breaker; Installing Circuit Breakers; Resetting Circuit Breakers; Checking Circuit Breakers; Causes for False Trips; Earth Leakage (Ground Fault) Circuit Interrupters: Terms used for Earth Leakage or Ground Fault Protection Devices; Tripping Current; GFCI Operation; Types of GFCIs; Testing GFCI Circuit Breakers and Outlets.

Course #: 086078
Duration: 5 hours
What Students Learn: Preview
Industrial equipment is rarely connected to a control system or to other equipment using direct wiring methods. Instead the power and signal cables are often hooked to the equipment using plugs and receptacles. Trainees will find a wide variety of plugs and receptacles used in industry.
In many cases, an entire work cell or area of a plant is designed and built in a factory, separate from where the equipment will be installed. The machines will interconnect to each other and to the main control system using one of a number of plug and receptacle systems. This study unit will introduce you to those industrial plug and receptacles.
This study unit will begin with information on the common 120 VAC plug and duplex receptacle systems used in both residential and industrial locations. Next students will see the various types of plugs and receptacles used in single phase and three-phase AC power systems. Information on various types of signal plugs and receptacles that are used in industry is covered. Finally, this study unit will conclude with information on various types of lampholders.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe various types of convenience receptacles and their special features.
• Explain how to properly wire a convenience receptacle.
• Describe the operation and installation of a ground-fault circuit interrupter receptacle.
• Identify various types of straight-blade plugs and their installation.
• Discuss how locking receptacles and plugs are different from straight-blade devices.
• Explain how to pick the proper locking plug and receptacle for various currents, voltages, and circuit types.
• Discuss the use and installation of various types of industrial signal and power plugs and receptacles.
• Describe various types of industrial lamps and lamp holders.

Contents
Electrical Receptacles: Convenience Outlets Split-Wired Duplex; Receptacles Twenty-Amp Receptacles; Ground Fault Circuit Interrupter (GFCI) Receptacles; Special Types of Receptacles; Special Considerations When Installing Receptacles; Plugs for Straight-Blade Receptacles; Finding the Proper Plug for the Application; Industrial Locking Plugs and Receptacles: Common Single-Phase Plug and Receptacle Outlines; Three-Phase Locking Receptacles and Plugs; Installing Receptacles and Plugs; Installing Flange-Mounted Receptacles; Installing Drop Cords; Special Industrial Plugs and Receptacles: Pin-and-Sleeve Devices; Other Types of Plastic Receptacles and Plugs; Metal-Shell Plugs and Receptacles; Communications Connectors; Industrial Lampholders: Common Types of Lampholders; Fluorescent Lampholders; Lamp Bases; Special Lamp Bases and Lamp Shapes.

Course #: 086079
Duration: 5 hours
What Students Learn: Preview
In the maze of wiring, controls, and equipment in most industrial locations, switches are among the most overlooked devices. Yet switches can cause the most problems when they do not work properly. There are many kinds of switches. When troubleshooting, some can be diagnosed simply by looking at their contacts or actuators. But many more switches consist of intricate, sometimes solid-state circuitry, and use component properties such as inductance, capacitance, and magnetism.
These types of switches are found in the basic electrical circuits and in the control rooms of industrial facilities. They also are used in the regulation of such process-line variables as flow, level, temperature, and pressure.
This study unit will introduce electricians to the many designs and technologies of industrial switches, and provide insight into their operation and applications.
Objectives
When a student completes this study unit, he and she will be able to:

• Identify switch symbols on electrical drawings.
• Have a basic understanding of the process control hierarchy.
• Identify the various types of industrial switches.
• Identify components of various types of industrial switches.
• Discuss applications for various types of industrial switches.

Contents
Common Switch Terms: Actuator; Arcing; Maintained Contact; Momentary Contact; Normally Closed; Normally Open; Poles and Throws; Positions; Switch Current Rating; Control-Station Switches: Operator-Controlled Panel Switches; Toggle Switches; Capacitive Finger Switches; Lighted Switches; Thumbwheel Switches; Position Sensing Switches: Inductive-Positioning; Capacitive-Positioning; Actuator-Positioning; Photoelectric Sensors and Switches; Pressure, Level, Temperature, and Flow Switches: Pressure Switches; Level Switches; Temperature Switches; Flow Switches.

Course #: 086080
Duration: 5 hours
What Students Learn: Preview
Control circuitry in industrial applications is the brain behind the brawn of motorized power. Motors require one element to perform the work they are designed to do: power. How they get the power is not a concern of the motor, but it is a major concern to the developers of control systems.
Industries, especially those involving sequential operations such as mills, refineries, chemical plants, manufacturing conveyor systems, and any of the processes that require certain events to happen at certain times, require well-designed control systems.
To properly provide sequential operation of these events, a control system designer must start with what is referred to as logic, or sequential events. A ladder diagram is the main tool used by control systems designers to design a control system that causes certain events to happen at certain times.
Once the design is developed, it is up to the electrician or technician to install the system and, later, to maintain it.
Objectives
When a student completes this study unit, he and she will be able to:

• Describe the fundamentals of relay ladder logic.
• Identify the different types of relays used in ladder logic.
• Identify the symbols for input and output elements used in ladder logic.
• Understand the principles such as power, current flow, rules of reading, numbering systems, and component interconnections applied in relay ladder logic.
• Interpret simple and complex ladder logic by applying the fundamentals learned.

Contents
Fundamentals of Relay Ladder Logic: Relays; Relay Applications; Motor Starters; Lighting Contactors; Control Relays; Relay Ladder Diagrams; Symbols in Relay Ladder Diagrams: Input Element Symbols of Relay Ladder Logic; Switch Symbols; Limit-Switch Symbols; Pushbutton Switch Symbols; Selector, Toggle, and Rotary Switch Symbols; Process-Switch Symbols; Foot-Switch Symbols; Relay-Contact Symbols; Supplementary Contact Symbols; Time-Delay Contact Symbols; Motor Overload Contact Symbols; Wiring and Connections; Output Element Symbols of Relay Ladder Logic; Coil, Solenoid, and Small Motor Symbols ; Meter Symbols; Pilot Lights and Alarm Symbols; Fuse and Transformer Symbols; Principles of Relay Ladder Logic: Power Supply to the Relay Ladder Logic; Logic Current Flow ; Rules of Reading Relay Ladder Logic; Numbering Systems Used in Relay Ladder Diagrams; Component Interconnections in Relay Ladder Logic; Fundamentals of Interpreting and Testing Circuit Ladder Diagrams: Interpreting Simple Ladder Diagrams; Single Start / Stop Pushbutton Control Relay with Running Lamp Circuit; Dual-Start-/ Stop Pushbutton Control Relay with Running Lamp Circuit; Motor Starter Power Schematic and Control Circuitry Ladder Diagram; Interpreting Complex Ladder Diagrams; Reversing Motor Starter Power Schematic and Control Circuitry Ladder Diagram; Ladder Logic Diagrams with Multiple Rungs and Rung Reference Numbers.

Course #: 086081
Duration: 5 hours
What Students Learn: Preview
In the Industrial Relay Ladder Logic study unit, we learned that an electromagnetic relay is an electromechanical switch made up of an electromagnet and a set or sets of contacts.
An electromagnet is created by passing electrical current through a wire, causing a magnetic field to form around the outside of the wire. A ferrous metal, which is a metal that contains iron and can be magnetized, will be pulled toward the magnetic field being emitted by the energized coil. If the ferrous metal is shaped into a rod or plunger and is inserted in the middle of the coil, the magnetic field will pull it into the coil's core, and the rod or plunger will try to align itself in the center of the field. If the bar or plunger is mechanically connected to a contact bar, the device is a relay, starter, or contactor. If the plunger in a coil is mechanically connected to a valve or other operating mechanism, the device is a solenoid.
The magnetic field will pull the contact or mechanical device with it, and cause a movable contact to either make contact or break contact with a stationary contact (in the case of a relay), or cause a mechanical action (in the case of a solenoid).
This study unit will delve deeper into the various types of industrial control relays, magnetic starters, contactors, and solenoids, covering their operating principles, construction, components, and applications.
Objectives
When a student completes this study unit, he and she will be able to:

• Distinguish between types of control relays, contactors, magnetic starters, and solenoids.
• Describe how each type operates.
• Identify the part of each type.
• Identify specific applications for each type.

Contents
Types of Industrial Control Relays, Magnetic Starters / Contactors, Solenoids and their Operating Principles: Control Relays; Magnetic Starters and Contactors; Solenoids; Components of Industrial Control Relays, Magnetic Starters, Contactors, and Solenoids: Control Relays; Magnetic Starters and Contactors; Solenoids; Applications of Industrial Control Relays, Magnetic Starters, Contactors, and Solenoids: Control Relays; Time-Delay on Plug-in Control Relays; Magnetic Starters and Contactors.

Course #: 5177EM
Duration: 60 hours
Course Prerequisites: AC Principles (Block A22); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
What Students Learn: This course provides students with the ability to understand what the National Electrical Code (NEC) requires, how to read the Code and to apply the rules.
The purpose of this Code is the practical safeguarding of persons and property from hazards arising from the use of electricity. The Code is one of the electrical standards accepted by OSHA.
Definitions and Explanation of Code; History of the Code and the NFPA; Code Changes; Understanding the terms and theories; Layout of the NEC; Understanding a Code Section; How to use and find information in the NEC.
Understanding the Scope and Attitude of the Code; NEC NFPA 70; Article 90 Purpose, Scope, Enforcement, Explanation, and Safety Summary.
Wiring Design and Protection; Wiring Methods and Materials; Use and Identification of Grounded Conductors; Branch circuits, feeders, service calculations, overcurrent protection, grounding and bonding; Equipment for General Use; Special Occupancies; Special Equipment; Special Conditions; Communication Systems; Construction Specifications; Tables; Diagrams and Examples.

Special Notes:

• The 1999 NEC course package consists of: the 1999 National Electrical Code text book (stock number 8786TB); a study guide (stock number 006023); course
  supplement, Understanding the NEC (stock number TB0309); and a NEC graded project, which is optional for course study (stock number 006017).
• The project calls for the student to design a residential wiring plan. The project guide is shipped with all course orders. Being graded, it is considered as the sixth test in the course. If the company program coordinator and/or the student determine that the project is not essential to the training program, be sure to notify the Customer Service department to adjust the student record with an excused or omit grade for stock number 006017.

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 #: 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 #: 086019
Duration: 6 hours
Course Prerequisites: Analog Circuit Measurement (Block A23); Basic Industrial Math (Block X21);
What Students Learn:

• Describe how diodes work in a rectifier and how to determine if they are working properly.
• Explain how different types of diodes function.
• List a variety of diode uses in electronic systems.
• List the characteristics that make a particular diode useful in a given situation.
• Know how a diode works with other components in an electronic circuit.
• Perform basic measurements in diode circuits, that will assist in troubleshooting tests.
• Select a proper diode for replacement in a circuit.
  

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.