Automation Integration Technology - Industrial Maintenance Training Program

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls

Sensors and Components Power Distribution Ladder Diagrams Motor Controls

This four day intensive program covers the most critical and fundamental skills that everyone in your maintenance department needs to know. They are available individually, as a group or as a complete money-saving series. Each topic is covered with short videos, followed by an in class review, troubleshooting and hands on exercises, and application discussions, question and answer sessions. Each student will receive a seven function Digital Multimeter and a set of reference notes complete with all of the onscreen graphics in a binder. Upon successful completion of all topics, a course completion certificate will be issued with the students name.

Day 1
Electrical Switching, Timing, and Control Devices Solve Even the Trickiest Component Failures Instrumentation: Discrete and Sensory Bench Test & Calibrate Components Cut Installation Time & Costs

Day 2
Understanding 3 Phase Power and Plant Distribution Save Time During Troubleshooting, Learn to Read Layout, Wiring, and Ladder Diagrams Preventive Maintenance & Troubleshooting Control Circuits Get Back On-Line Fast, Cut Production Losses

Day 3
Introduction to Motor Control Operations & Protection A Must-Have for All Your Motors Sizing the Protection of Motors & Control Circuits Keep Everything Up to Code, Prevent Electrical Fires

Day 4
AC Motor Controls & Troubleshooting Cut AC Motor Troubleshooting Time in Half DC Motor Controls & Troubleshooting Troubleshoot and Avoid DC Motor Failure Introduction to Variable Frequency Drives Installation and Troubleshooting

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

What our students say: Great basic course, nice refresher, good materials, excellent instruction. Ray Rathbone, Senior Maintenance Technician, HJ Heinz, Pennsauken, NJ Preparation was excellent, videos worked well with the written material. Dave Kulak, Maintenance Manager, HJ Heinz, Pennsauken, NJ Information was very well given. John DiGiorgio, Maintenance Supervisor, HJ Heinz, Pennsauken, NJ Youve made my job much easier, helped our electrical department, and lowered the overall machine downtime in our facilities. Nick Meheula, Plant Maintenance, Oahu Transit Services A very complete program. Its exactly what I expected. Dale Frazier, Electronic Systems Technician, City of Columbus, OH We really like your training programs. My staff review the notes. Dale Lancaster, Maintenance Manager, Color Box, Inc. Your programs have not only given my staff a better understanding of electrical controls, but also reduced our troubleshooting time. I would recommend them to other companies. Rodney Nylin, Technical Training Coord., Abbott Laboratories The information in these training programs is accurate, to the point, and easy to understand. Jerry Roshong, Project Engineer, J.M. Smucker Company Your programs are convenient to schedule. We can train all three of our shifts in a very convenient and economical way. Rick Pruden, Electrical Engineer, Bundy Corporation These troubleshooting programs are essential not only to electricians, but also to our mechanics. Joe Meccia, Production Maintenance, Current, Inc. I have passed your info on to other companies and friends. I was happy to find this program, it's hard to find good quality training. Ed Godin, VP Manufacturing, Falcon Plastics, Inc. I've had the opportunity to evaluate many training materials and I've found the AIT programs to be the best I've seen. Bob Desoto, Continuing Education Professor, University of California-Fullerton You covered a huge amount of detail well. It was very easy to understand. Jeff Camp, Senior Systems Engineer, United Control

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Electrical Switching, Timing, and Control Devices

WHAT YOU WILL LEARN: This topic covers the most common switches, timers, and control devices found in your plant. You have hundreds (probably thousands) of these devices in your plant. At a cost of $25 to $250 per component, this program will quickly pay for itself. We show how these devices work, how they are wired, and how to troubleshoot them. This program also provides the first step in learning ladder diagrams. Solve Even the Trickiest Component Failures
Poles, throws, breaksthere are dozens of different combinationspick the right one for your application and know how to wire it Avoid costly wiring mistakesread multiposition selector switches in ladder diagrams Troubleshoot tricky pushbutton problemsdont replace the whole thing when it might just be the contact blocks Read the action and timing diagrams of ON-delay and OFF-delay timers so that when something goes wrong, youll know exactly which component to replace Use time-delayed and instantaneous timer contactsknow the difference and protect your equipment Avoid intermittent problemsmake sure control relays are receiving the proper steady voltage Troubleshooting relays can be a nightmarefollow our detailed troubleshooting method and save time Many control devices share componentslearn how to cut your spare parts inventory to a minimum

Course Contents: Basic ladder diagrams, Information provider switches, SPST, SPDT, DPST, and DPDT switches Proper component wiring connections, Control device troubleshooting: static & dynamic checks Static and dynamic component checks Understanding drum switch operation & its use in the reversal of motors Use and application of control relays (standard & latching), Troubleshooting delay circuits ON-delay & OFF-delay timer action, timing control, & troubleshooting

TECH TIP
Did you know that incorrect reference wiring and connections cause most of the problems in troubleshooting timer circuits?

TECH TIPS

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Instrumentation: Discrete and Sensory

WHAT YOU WILL LEARN:
This program shows how to calibrate and bench test the most common components found in your plant. You can be sure that your people will know how to test and calibrate these components before installation to avoid costly mistakes and delays. This program also explains how valves operate, how to wire them, and how they work. Now everyone will be able to quickly identify the real problem and avoid wasting time replacing unnecessary components.

Bench Test & Calibrate Components Cut Installation Time & Costs
Similar devices share componentscut your spare parts inventory to a minimum Choose the correct photoelectric sensor for your application Apply, install, and troubleshoot limit, photoelectric, and proximity switches Should you use an inductive or capacitive proxthey look the same, but if you pick the wrong one it wontdetect Wire and understand the inner workings of 2, 3, and 4-way valves Cut your installation timebench test and calibrate pressure devices before installation Clogged ports or a bad solenoidlearn to spot the difference and avoid replacing unnecessary components Intermittent malfunctions in limit switches can take forever to track downlearn a step-by-step method for identifying and solving the problem quickly

Course Contents: Limit switches, use, application, installation, and wiring Proximity sensors, operation and use, inductive and capacitive Photoelectric sensors, selection, installation, wiring, and troubleshooting Discrete process-sensing control devices: pressure, flow, level & temperature sensors: wiring connections, setup, (bench test), installation, circuit troubleshooting Discrete solenoid-operated control valve operation & application: 2-way, 3-way & 4-way4 and 5 ports How to properly read solenoid valve schematics, Troubleshooting solenoid control valves

TECH TIP
Did you know that a 25% reduction in target size will reduce the effective sensing distance of a proximity switch by almost 50%?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Understanding Electrical Diagrams & Control Circuits

WHAT YOU WILL LEARN:
All maintenance personnel must know how to read and write ladder diagramsit's an essential skill. Plus, it's a prerequisite to using PLCs (programmable controllers). This topic explains the components of a control circuit and moves on to more complex circuits. Use this course to learn the fundamentals of control circuits and then go on to Preventive Maintenance & Troubleshooting Control Circuits on the following page to learn troubleshooting. These two programs are our most popular companion programs.

Save Time During Troubleshooting, Learn to Read Layout, Wiring, and Ladder Diagrams
Protect your peoplefollow our four basic rules of ladder diagrams to implement a safe circuit Add interlocking, memory, and cross-referencing to complex control circuits Layout a control panelfrom scratch to finishjust by following the wiring and layout diagrams Implement motor control and magnetic starter circuit diagrams Prevent faulty operation and equipment damageuse mechanical, push button, and electrical interlocks Design and read ladder, wiring, and layout diagrams Save installation timefollow our method to layout a control system using proper component placement and wiring guidelines Avoid confusiondocument and cross-reference devices properly so that everyone will understand the ladder diagram and know how to troubleshoot it

Course Contents: Control circuit components & representation, Power continuity AND-OR-NOT circuit logic: understanding & application Electrical diagrams: ladder, wiring (motor circuits) & layout, Proper reading, referencing, interpretation, design & implementation of electrical control diagrams Control circuit examples & implementation, Adding interlocking memory to a control circuit Types of control circuit interlocking: mechanical, push button & electrical Magnetic starter wiring diagrams, Interpretation of more complex ladder diagrams Layout & connection diagrams, Component placement & wiring

TECH TIP
Did you know that reading ladder diagrams incorrectly is one of the biggest causes of troubleshooting delays?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Understanding 3 Phase Power and Plant Distribution

WHAT YOU WILL LEARN:
This topic will give everyone in your plant a solid understanding of the basics of power generation and distribution. Everyone who works with, or around, electrical equipment needs to know the basics as well as how to protect themselves and your equipment. This topic will be useful to cross train your mechanics in the basics of electricity and cut your power bills at the same time.

Now Everyone Will Understand the Basics of Power in the Plant

Cut your power bills and extend the life of your equipment by using power factor correction Choose the safest methods for power distribution Understand why motors and their voltages are designed the way they are Configure wye and delta branch and feeder circuits to provide a balanced power system Learn which voltage connection to avoid to prevent equipment damage Determine phase-to-phase and phase-to-neutral voltages and currents Before you can protect your circuits everyone has to understand them Distribute power through your plant via switchgear and busways Rectify AC power into DC power Make sure you place correction capacitors in the right place or else your motor overload heaters won't work right and you'll burn out your motors Provide a safe ground busfor safety and proper equipment operation

Course Contents: Bringing power inside the plant Power generation, Wye & delta power systems, Balanced power circuits Phase-to-neutral & phase-to-phase voltages and currents in wye & delta systems Transformers, Wye & delta transformers and connections Plant power distribution, Switchgear, busways, motor control centers Rectification of 3 power into DC power, Power factor and correction Areas of proper power factor correction in a motor circuit

TECH TIP
Did you know that you must compensate for power factor when using an AC squirrel-cage motor?

TIPS

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Preventive Maintenance & Troubleshooting Control Circuits

WHAT YOU WILL LEARN: This program covers the most basic, fundamental, and important troubleshooting skills needed in the plant. It's not enough to know what the different components doyour people need a quick way of identifying and solving control circuit problems. For example, the main problem with a short circuit isn't the short itself it's the fact that things aren't running. The combination of this topic with the two previous provide for a complete control circuit toolkit. Use these topics to make sure everyone understands control circuits and can troubleshoot them. Get Back On-Line Fast, Cut Production Losses
Follow our systematic approach to troubleshooting electrical systems both at the power source and the control circuit Find short circuits and faulty components quicklyget back up and running fast Install power and phase monitors to detect dangerous conditions before causing costly motor damage Use our four fundamental guidelines to implement an effective preventive maintenance program Perform dynamic and static preventive maintenance inspections Troubleshoot control circuit logic using ladder and wiring diagrams Learn how a phase imbalance will make your motors run hotsolve the problem and prevent insulation breakdown Learn why thermal overloads aren't enough to protect your equipment against damage from phase loss

Course Contents: Preventive maintenance: approaches, guidelines & scheduling Preventive maintenance checks: dynamic & static inspections Engineering preventive maintenance into control circuits & into the plant's electrical power distribution with power & phase monitors Preventing & detecting phase imbalance, phase loss & phase reversal Troubleshooting electrical systems at the power source & at the control circuit Troubleshooting using ladder diagrams & wiring diagrams (motor circuits) Troubleshooting the logic section & the power section of the control circuit Finding faulty components, Finding a short circuit

TECH TIP
Did you know that a cross-firing problem in a double pole-double break contact component is often overlooked during troubleshooting?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Introduction to Motor Control Operations & Protection

WHAT YOU WILL LEARN:
This topic gives everyone the practical motor control knowledge they need as well as explains the different causes of motor failures and the ways to prevent them. Whether you're using AC or DC motors, this program will give everyone in your plant the skills to protect your equipment. This tpic, combined with Sizing the Protection of Motors & Control Circuits, provides the best reference for safe motor operation in your plant.

A Must-Have for All Your Motors

Learn to prevent the seven most common causes of heat-related motor failure Hundreds of different starter configurations are availableidentify and learn to quickly replace and rewire the ones used in your facility Avoid safety hazardschoose the right contactors and starters for your application Class 10, 20, 30 heaterswhich one offers the right protection for your motor application Learn why and when troubleshooting 2-wire control can be dangerous When a starter is wired incorrectly anything can happenmake sure it's done right the first time Implement proper arc suppression to protect against shorts and fire hazards Make sense out of NEMA standards Fuses, breakers, and overloads look simple, but they each offer a different type of protectionmake sure everyone understands their function and uses them properly Learn how spending a few extra dollars can add invaluable backup motor protection

Course Contents: Understanding, application, installation & wiring of contactors, and manual & magnetic motor starters Types of motor starters: full-voltage, combination, reversing, two-speed & reduced-voltage Arc suppression & protection in contactors & starters Motor & circuit protection: fuses (single & double element), circuit breakers (magnetic & thermal), & overloads (eutectic, bimetal & solid-state) Understanding motor protection curves, overload conditions & proper sizing of heater elements Use of double-element fuses as motor backup protection, Controlling motor operations & plugging Understanding electrical & wiring control diagrams, 2-wire & 3-wire control: application & uses Low-voltage release & low-voltage protection, Causes of motor failure: symptoms & prevention

TECH TIP
Did you know that thermal overloads can be affected by ambient temperature?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

Sizing the Protection of Motors & Control Circuits

WHAT YOU WILL LEARN: Some skills, such as reading motor nameplates, may be basic but are still important. The information in this program is extremely important because if someone makes a mistake, not only will you not be up to code, but a dangerous situation could occur. After watching this program, you'll not only be able to prevent future problems, but also spot and solve problems that may have been lurking in your plant for years. Keep Everything Up to Code, Prevent Electrical Fires
Use our six-step method to implement and maintain a safe motor branch circuit Time-delay or non time-delay fuseswhich one should you use to provide the best protection When it comes to nameplates, reading them isn't enougheveryone needs to understand what they mean and know how to use this valuable information The motor dictates circuit design, protection, and componentsknow how to get the requirements from Article 430 and make your job easier Select proper circuit protection components according to code Choose safe conductors and protection devices Overloads and short circuitsare you protected against both Select the right size fuse to protect a branch circuitwe'll show you how Choose the right NEMA starter for your motor Finally, a clear explanation of Article 430 and what it means to your motor control operations

Course Contents: Introduction to the National Electric Code (NEC), Article 430 of the NEC: motor, motor controller & motor circuit protection, Safety & Article 430 Sizing the proper protection for feeder & branch circuits Choosing proper conductors for feeder & branch circuits Understanding & protection of locked-rotor amperage in motor circuits & overload situations Understanding motor nameplate information according to code

TECH TIP
Did you know that according to code, an overload heater must be rated at 125% of the motor's full-load amperage (FLA)?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

AC Motor Controls & Troubleshooting

WHAT YOU WILL LEARN: Everyone needs to know the basics when it comes to AC motor controls. This program teaches you the basics. More importantly, it shows you how to quickly identify the root cause of a problem. Our View-It-and-Do-It method will show you how to check the windings for open conditions, isolate a problem to either the circuit or the motor, and much more. We even cover the tell tale symptoms of premature motor failure. Cut AC Motor Troubleshooting Time in Half
Troubleshoot solid-state starters by quickly detecting misfirings of SCRs Before someone can troubleshoot a 1 or 3 motor they need to understand how they operatewe'll show you how Troubleshoot the different reversing methods and circuits used with AC motors The motor may be working, but is it working properlylearn to identify the hidden problems that can cause your motor to fail Troubleshoot across-the-line start motors as well as the 5 types of reduced-voltage start motors Is the fault at the motor or is it the circuitlearn how to quickly troubleshoot using the ladder diagram Solve the trickiest reduced-voltage start problem Understand how variable speed drives work and where to look to solve problems Quickly troubleshoot multispeed motors and their circuitslearn how to double check the connections Cut troubleshooting time by looking for the most likely causes of motor failure first

Course Contents: 1 & 3 AC motor components & operation, Types of 1 motors: split-phase & capacitor motors Starting & accelerating 1 & 3 AC motors, Selecting motor starters: across-the-line & reduced-voltage Types of reduced-voltage starts: primary resistor, auto-transformer, part winding, wye-delta & solid-state Operation of all reduced-voltage, wiring & connections, Reversing circuits for 1 & 3 AC motors Speed control: multispeed motors & variable frequency, Introduction to AC drive speed control (inverters), applications, interface and troubleshooting will also be covered Braking circuits using plugging (zero-speed) switches, Troubleshooting at the power section (branch circuit) & wiring circuit, Finding open & short circuits, Detection of serious AC motor symptoms

TECH TIP
Did you know that if you're using friction brakes to decelerate a motor, you need to calculate the required braking torque?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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Automation Integration Technology - Industrial Maintenance Training Program

DC Motor Controls & Troubleshooting

WHAT YOU WILL LEARN: Just like our program on AC motors (AC Motor Controls and Troubleshooting), this program explains the basics of DC motor controls. However, we don't just cover the basics. We also show you how to look for the signs and symptoms of a failing motor. We show you how to troubleshoot all of the DC motors found in your plant as well as how to prevent a motor from failing and shutting down a production line. Troubleshoot and Avoid DC Motor Failure
Keep the production line runninglearn to troubleshoot and control the speed of DC motors Avoid the most common mistakes made during the installation and maintenance of brushes Learn how to detect an SCR fault in the power bridge of a DC drive See how noise can affect the operation of a DC drive and learn to correct it Series, shunt, and compound motors require different troubleshooting techniqueswe'll show you the quickest ways to find faults Troubleshoot both the circuits and components used in the three most common methods of decelerating a DC motor Bring full-voltage and reduced-voltage DC motors back on-line fast Understand how DC motors are reversed so you'll be better prepared to troubleshoot them Use our proven techniques for detecting problems in a series, shunt, and compound DC motor before they break

Course Contents: Components & operation of DC motor types: series, shunt & compound Application, characteristics & uses of series, shunt & compound DC motors & their wiring connections Field winding & armature winding circuit representation, Starting DC motors using drum switches and manual & magnetic starters Speed control of DC motors, Acceleration of DC motors using variable resistance & solid-state controls SCR operation & basic troubleshooting, Introduction to DC drive speed control Deceleration circuits & methods used with DC motors: plugging, regenerative braking & friction brakes Troubleshooting series, shunt & compound DC motors Checking for open & short circuits in DC motors

TECH TIP
Did you know that a series DC motor without a load can gain enough speed to cause a dangerous runaway condition?

ECM110-Understanding and Troubleshooting Basic Electrical Motors and Controls For More Information Call 856-719-0280

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