Instrumentation 3e Level 3 Courseplanning PDF

Lesson Plans for Module 12207-16
Control Valves, Actuators, and Positioners

Module One (12207-16) introduces different types of control valves, actuators, and positioners. Due to the vari-
ety of devices in use in various industries, instrumentation trainees require a strong grounding in this subject.
They will also learn about the different control technologies used in remotely managing valves. Finally, they will
learn how to identify valve characteristics through markings and nameplate information.
Objectives Performance Tasks

Learning Objective 1 Performance Task 1 (Learning Objective 1)
• Identify and describe various types of control • Install a positioner on a control valve.
valves, actuators, and positioners. Performance Task 2 (Learning Objective 1)
a. Identify and describe the operation of various • Locate bridgewall markings on a globe valve
types of control valves. and determine the stem and packing orienta-
b. Identify and describe actuators and their key tion.
operating features.
Performance Task 3 (Learning Objective 1)
c. Identify and describe the operation of various
• Identify different actuators and positioners
positioners.
from instructor-provided drawings or during a
d. Identify and explain the importance of factors field survey.
related to valve selection.
e. Identify and describe valve markings and
nameplate information.
Teaching Time: 15.0 hours

(Six 2.5-Hour Sessions)
Session time may be adjusted to accommodate your class size, schedule, and teaching style.
Prerequisites
Core Curriculum, Instrumentation Level One, and Instrumentation Level Two.
Before You Begin
As you prepare for each session, allow sufficient time to review the course objectives, content, visual aids, in-
cluding the PowerPoint® presentation, and these lesson plans, and to gather the required equipment and materi-
als. Consider the time required for demonstrations, laboratories, field trips, and testing.
Using your access code, download the module exams and Performance Profile Sheets from www.nccerirc.com.
The passing score for submission into NCCER’s Registry is 70% or above for the module exam; performance
testing is graded pass or fail.
12207-16 Control Valves, Actuators, and Positioners Module One iii
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Safety Considerations
This module requires that trainees work with tools and potentially energized equipment. Safety must be
emphasized at all times. Trainees should be carefully observed to ensure that they wear the proper PPE, fol-
low safe practices, and give due respect to unseen hazards. Any deficiencies must be corrected to ensure
future trainee safety. All practice sessions and Performance Tasks must be completed under your direct
supervision.
Classroom Equipment Equipment and Materials for Laboratories

and Materials and Performance Testing
Whiteboard Appropriate PPE to include the Control valve with compatible
Markers following: positioner
Pencils and paper Safety glasses Appropriate mounting hardware
Instrumentation Level Three Work gloves Common hand tools
PowerPoint® Presentation Proper footwear as designated by Selection of globe valves with
DVD player or a computer with a the instructor or training facility bridgewall markings
DVD drive provider Drawings showing a variety of
LCD projector and screen Hearing protection as designated actuators and positioners in a process
Computer with internet access by the instructor or training facility environment
Review Questions answer key provider
Copies of the module examination Hard hat as designated by the
(for paper-based exams) and instructor or training facility provider
Performance Profile Sheets
Globe valve
Gate or knife valve
Ball valve
Plug valve
Butterfly valve
Needle valve
Pneumatic or electric valve actuator
Pneumatic, analog, or smart valve
positioner
Example globe valves with
bridgewall markings
Example valves with nameplates
Additional Resources
This module presents thorough resources for task training. The following resource material is suggested for
further study.
ANSI/ISA-5.1-2009. 2009. Research Triangle Park, NC: International Society of Automation.
ANSI/ISA Standard S75.01, Flow Equations for Sizing Control Valves. 2007. Research Triangle Park, NC: Inter-
national Society of Automation.
Control Valve Handbook. Fourth Edition. 2005. Fisher Emerson Process Management. Marshalltown, IA:
Fisher Controls International LLC.
http://www.documentation.emersonprocess.com/groups/public/documents/book/cvh99.pdf
Control Valves: Practical Guides for Measurement and Control (Practical Guide Series). Guy Borden, Jr. (edi-
tor). 1998. Research Triangle Park, NC: International Society of Automation.
Instrument Engineers Handbook, Volume 2: Process Control and Optimization. Béla G. Lipták (editor). Fourth
Edition. 2006. Boca Raton, FL: CRC Press.
Instrument Engineers Handbook, Volume 3: Process Software and Digital Networks. Béla G. Lipták and Halit
Eren (editors). Fourth Edition. 2012. Boca Raton, FL: CRC Press.
Instructors are also encouraged to locate additional audiovisual aids available on the internet, make personal
videos, and take still pictures related to the subject matter and add them to the PowerPoint ® presentations
throughout the program.
iv NCCER – Instrumentation Level Three 12207-16
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Session Outline for 12207-16
The Lesson Plan for this module is divided into six 2.5-hour sessions.
This time includes 10 minutes for administrative tasks and a 10-minute break per session.
Session One Session Three

Session One introduces trainees to valve types Session Three introduces valve configurations
and operation. They will learn the advantages and the criteria used in selecting them.
and disadvantages to each major type as well Although instrumentation technicians usually
as the situations in which each is used. This do not select valves on their own, they should
session covers Sections 1.0.0 through 1.1.7. have a basic understanding of the process.
Trainees will also learn to read bridgewall
1. Show the Session One PowerPoint ® markings and nameplates in order to identify
presentation. the characteristics of a particular valve. This
2. U
se the Kickoff Activity to get trainees session covers Sections 1.4.0 through 1.5.5.
engaged and give them an idea of what they how the Session Three PowerPoint ®
1. S
will learn from this module. presentation.
3. Identify the various types of control valves. 2. U
se the Kickoff Activity to help trainees
4. Describe each valve’s basic operation and its recognize common symbols used in valve,
advantages and disadvantages. actuator, and positioner situations as well
as recognize the variations that are possible
across industry.
Session Two 3. D
iscuss the factors involved in valve selection
and sizing.
Session Two introduces valve actuators and
positioners. The different technologies behind 4. Explain how to interpret globe valve flow and
each type are addressed, as is the reason for bridgewall markings in order to understand
using a given type in a particular situation. This the valve’s basic properties.
session covers Sections 1.2.0 through 1.3.5.
5. D
escribe other valve properties that can be
1. Show the Session Two PowerPoint ® determined from nameplate information.
presentation.
2. Use the Kickoff Activity to introduce trainees
to the idea of remote control and the need
for more sophisticated control methods in
certain situations.
3. Describe the operation of a valve actuator
and identify the major technologies used for
this purpose.
4. Identify the three failure modes of a valve/
actuator combination.
5. Explain the purpose of a valve positioner and
list the three main types commonly used.
12207-16 Control Valves, Actuators, and Positioners Module One v
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Sessions Four and Five Session Six

Sessions Four and Five are laboratory sessions Session Six is a review and testing session.
devoted to the practice and completion of Have the trainees complete the Module Review
Performance Tasks 1, 2, and 3. questions. Alternatively, these may be assigned
as homework at the end of Session Five. Go
1. Note that no PowerPoint ® presentations are over the answers to the Review Questions
associated with these laboratory sessions. in class prior to the exam and answer any
2. Demonstrate how to properly install a questions that the trainees may have.
positioner on a control valve. 1. Have trainees complete the module exam.
3. Demonstrate how to locate bridgewall Any outstanding performance testing must
markings on a globe valve and determine the be completed during this session as well.
stem and packing orientation. 2. Record the testing results on the Registration
4. Identify different actuators and positioners of Training Modules form and submit the
from instructor-provided drawings or during form to your Training Program Sponsor.
a field survey.
5. Have trainees practice and/or complete the
requirements of Performance Tasks 1, 2, and
3 in these hands-on sessions.
vi NCCER – Instrumentation Level Three 12207-16
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Materials Checklist for 12207-16, Control Valves, Actuators, and Positioners
Equipment and Materials

Personal protective equipment: Pneumatic or electric valve Control valve with compatible
actuator positioner
Pneumatic, analog, or smart Appropriate mounting
Safety glasses
valve positioner hardware
Example globe valves with
Work gloves Common hand tools
bridgewall markings
Proper footwear as
Example valves with Selection of globe valves with
designated by the instructor
nameplates bridgewall markings
or training facility provider
Hearing protection as Drawings showing a variety of
designated by the instructor actuators and positioners in a
or training facility provider process environment
Hard hat as designated by the
instructor or training facility
provider
Whiteboard/chalkboard
Markers/chalk
Pencils and paper
Instrumentation Level Three
PowerPoint® Presentation
Slides
DVD player or a computer with
a DVD drive
LCD projector and screen
Computer with internet access
Module Review answer key
Copies of the module
examination (for paper-based
exams) and Performance
Profile Sheets
Globe valve
Gate or knife valve
Ball valve
Plug valve
Butterfly valve
Needle valve
To the extent possible, and as required for performance testing, provide a selection of the tools listed for each
session; alternatively, photos may be used to teach tool identification.
12207-16 Control Valves, Actuators, and Positioners Module One vii
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D etectors , S econdary E lements ,
T ransducers , and T ransmitters
Module Two (12205-16) introduces the first four components of the instrumentation chain in process control
applications. Trainees will learn about sensing devices used for measuring different parameters, and transducers
used to convert information into different forms as required by the application. Information on transmitters and
the differences between traditional designs and modern smart transmitters is also provided.
Objectives Learning Objective 4

Learning Objective 1 • Identify various transmitter types and explain
• Identify and describe the first four components how they operate.
common to most process control channel a. Identify and describe the operation of force-
applications and the relevant standards and balance differential pressure pneumatic
elements. transmitters.
a. Identify the first four common instrument b. Describe the application of force-balance
and process control channel components. transmitters to temperature, pressure, level,
b. Define key terms related to instrumentation and flow measurement.
and process control. c. Identify and describe the operation of
c. Describe measurement standards and electronic transmitters.
elements.
Performance Tasks
Learning Objective 2
• Identify various detectors and explain how they
operate. • Identify various thermocouple types using a
multifunction calibrator and a calibrated heat
a. Identify and describe the operation of various
source.
temperature detection devices.
b. Identify and describe the operation of various Performance Task 2 (Learning Objective 2)
pressure detection devices. • Identify at least three instructor-chosen
c. Identify and describe the operation of various thermocouples by color code.
level detection devices. Performance Task 3 (Learning Objective 4)
d. Identify and describe the operation of various • Connect a communication device to a smart
flow detection devices. transmitter and document the existing
Learning Objective 3 settings.
• Identify various transducer types and explain
how they operate.
a. Identify and describe the operation of I/P and
P/I transducers.
b. Identify and describe the operation of
metallic and pressure strain gauges.
c. Identify and describe the operation of other
transducers.

(Ten 2.5-Hour Sessions)
Prerequisites
Core Curriculum, Instrumentation Level One, and Instrumentation Level Two
Before You Begin
As you prepare for each session, allow sufficient time to review the course objectives, content, visual aids,
including the PowerPoint® presentation, and these lesson plans, and to gather the required equipment and
materials. Consider the time required for demonstrations, laboratories, field trips, and testing.
12205-16 Detectors, Secondary Elements, Transducers, and Transmitters Module Two iii
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emphasized at all times. Trainees should be carefully observed to ensure that they wear the proper PPE,
follow safe practices, and give due respect to unseen hazards. Any deficiencies must be corrected to ensure
supervision.
Classroom Equipment and Materials Equipment and Materials

for Laboratories and
Whiteboard Bimetallic strip thermostat
Performance Testing
Markers Thermocouples
Appropriate PPE, to include the
Pencils and paper Digital multimeter
following:
Instrumentation Level Three Thermocouple extension wire
Safety glasses
PowerPoint® Presentation Pressure gauges or capsules
Work gloves
DVD player or a computer with a Capacitance level detector
DVD drive Proper footwear as designated by
Orifice plate the instructor or training facility
LCD projector and screen Venturi tube provider
Computer with internet access Pitot tube Hearing protection as designated
Review Questions answer key Magnetic flowmeter by the instructor or training facility
Copies of the module examination Ultrasonic flowmeter provider
(for paper-based exams) and Hard hat as designated by the
I/P and/or P/I transducers
Performance Profile Sheets instructor or training facility provider
Individual strain gauges
Detectors Selection of thermocouples with color
Example transducer
Transducers codes
Various pneumatic and/or analog
Amplifiers Thermocouple color code chart
transmitters
Transmitters appropriate to the provided
Smart transmitter thermocouples
Modern smart transmitter
Smart transmitter field Multifunction calibrator
containing all four functions
communicator
Example instruments with Calibrated heat source
measurement scales Smart transmitter
Field communicator
further study.
Instrumentation, Franklyn W. Kirk, Thomas A. Weedon, and Philip Kirk. Fifth Edition. 2010. Orland Park, IL:
American Technical Publishers.
Power-Plant Control and Instrumentation: The Control of Boilers and HRSG Systems, David Lindsley. 2000.
London: The Institution of Electrical Engineers.
Overview of Measurement Systems and Devices, M.T. Tham. Newcastle University. 1996–2009.
http://lorien.ncl.ac.uk/ming/procmeas/measintr.htm
The Condensed Handbook of Measurement and Control, N.E. Battikha. Third Edition, 2006. Research Triangle
Park, NC: The International Society of Automation.
Dwyer Instruments Inc. website, www.dwyer-inst.com
Emerson Electric Company website, www.emerson.com
Omega Engineering website, www.omega.com
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The Lesson Plan for this module is divided into ten 2.5-hour sessions.

Session One introduces the first four Session Three introduces specific sensors used
components in the instrument chain. These will in measuring common process parameters.
be addressed individually, although in many Temperature and pressure measurement
systems, they are combined in various ways. technologies will be examined and compared.
This session covers Sections 1.0.0 through 1.1.4. This session covers Sections 2.0.0 through
2.2.5.
how the Session One PowerPoint ®
1. S
presentation. 1. Show the Session Three PowerPoint ®
presentation.
2. U
se the Kickoff Activity to get trainees
engaged and give them an idea of what they 2. U
se the Kickoff Activity to demonstrate how
will learn from this module. mechanical temperature measurement using
the bimetallic strip principle works.
3. D
escribe the initial four components of the
instrumentation and process control chain. 3. Introduce the most common temperature
sensing devices, including bimetallic strips,
4. P
oint out that components are often thermocouples, and RTDs.
combined in different ways, making a large
variety of instrumentation scenarios possible. 4. D
iscuss the different types of thermocouples
and the color code systems used to identify
them.
Session Two
5. Introduce pressure-measuring technologies,
Session Two introduces key terms related to discussing the various ways in which
instrumentation and the measuring process. pressure can be determined.
The way in which these concepts affect
instrument use will be addressed. This session
covers Sections 1.2.0 through 1.3.7.
Session Four
how the Session Two PowerPoint ®
1. S Session Four introduces specific sensors used
presentation. in measuring common process parameters.
Level and flow measurement technologies
2. U
se the Kickoff Activity to help trainees will be examined and compared. This session
understand the difference between accuracy covers Sections 2.3.0 through 2.4.6.
and precision, two commonly confused
terms. 1. Show the Session Four PowerPoint ®
presentation.
3. Introduce instrumentation and measurement
terminology, differentiating between the key 2. U
se the Kickoff Activity to introduce the
concepts of accuracy, precision, sensitivity, ultrasonic method of measuring flow.
responsiveness, and reproducibility.
3. Introduce level detection devices, including
4. D
iscuss measurement error, listing and both everyday ones and more exotic
distinguishing the different types of error and methods, such as nuclear level detection.
their sources.
4. Introduce flow detection devices, covering
5. Discuss the concept of standards, including the science behind the way in which they
primary, secondary, and working. Emphasize work.
the crucial idea of traceability in calibration.
12205-16 Detectors, Secondary Elements, Transducers, and Transmitters Module Two v
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Session Five Sessions Seven through Nine

Session Five introduces transducers of various Sessions Seven through Nine are laboratory
types and explains how they are used to sessions devoted to the practice and completion
convert information into an equivalent form that of Performance Tasks 1, 2, and 3.
is more useful than the original. This session
1. Note that no PowerPoint ® presentations are
covers Sections 3.0.0 through 3.3.2.
associated with these laboratory sessions.
how the Session Five PowerPoint ®
1. S
2. D
emonstrate how to identify various
presentation.
thermocouple types using a multifunction
2. U
se the Kickoff Activity to acquaint trainees calibrator and a calibrated heat source.
with industrial process equipment sales
3. D
emonstrate how to identify at least three
literature and other sources of information.
instructor-chosen thermocouples by color
3. Introduce the I/P and P/I transducers and code.
discuss how they convert information
4. D
emonstrate how to connect a
between electrical and pneumatic forms.
communication device to a smart transmitter
4. D
iscuss strain gauges, the way in which they and document the existing settings.
operate, and the uses to which they are put in
measurement.
requirements of Performance Tasks 1, 2, and
5. Address other kinds of transducers, including 3 in these hands-on sessions.
those that involve pressure and acceleration
measurement and make use of piezoelectric
crystals to perform the transducer operation. Session Ten
Session Ten is a review and testing session.
Session Six Have the trainees complete the Module Review
Questions. Alternatively, these may be assigned
Session Six introduces transmitter technology. as homework at the end of Session Nine. Go
Transmitter operation and types are examined. over the answers to the Review Questions
Modern digital and smart transmitters are in class prior to the exam and answer any
compared to more traditional types. This questions that the trainees may have.
1. Have trainees complete the module exam.
how the Session Six PowerPoint ®
1. S Any outstanding performance testing must
presentation. be completed during this session as well.
2. U
se the Kickoff Activity to clarify how 2. R
ecord the testing results on the Registration
traditional mechanical transmitters work. This of Training Modules form and submit the
subject may be confusing if the trainees have form to your Training Program Sponsor.
not worked with this technology before.
3. D
iscuss the operation of traditional
mechanical/pneumatic transmitters.
4. E
xplain how traditional transmitters work in
various common measurement settings.
5. Address electronic, digital, and smart
transmitters, emphasizing the advantages
that smart transmitters confer on plant
management.
6. Summarize the major communication
networks and protocols used by industrial
smart technology.
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Materials Checklist for Module 12205-16, Detectors, Secondary Elements, Transducers, and Transmitters

Personal protective equipment: Modern smart transmitter Selection of thermocouples
containing all four functions with color codes
Thermocouple color code chart
Example instruments with
Safety glasses appropriate to the provided
measurement scales
thermocouples
Work gloves Bimetallic strip thermostat Multifunction calibrator
Proper footwear as Calibrated heat source
designated by the instructor Thermocouples
Hearing protection as Smart transmitter
designated by the instructor Digital multimeter
Hard hat as designated by the Field communicator
instructor or training facility Thermocouple extension wire
provider
Whiteboard Pressure gauges or capsules
Markers Capacitance level detector

Pencils and paper Orifice plate
Venturi tube
DVD player or a computer with Pitot tube
a DVD drive
LCD projector and screen Magnetic flowmeter
Computer with internet access Ultrasonic flowmeter
Review Question answer key I/P and/or P/I transducers
Copies of the module Individual strain gauges
Profile Sheets
Detectors Example transducer
Various pneumatic and/or
Transducers
analog transmitters
Amplifiers Smart transmitter
Smart transmitter field
Transmitters
communicator
12205-16 Detectors, Secondary Elements, Transducers, and Transmitters Module Two vii
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Instrumentation Electrical Circuitry

Module Three (12305-16) covers the crucial topic of basic DC and AC electrical theory. Understanding these con-
cepts is essential for instrumentation personnel since many instruments are electrical or electronic. This module
addresses the foundational concepts and laws of DC voltage, current, and resistance. AC electricity is introduced
and compared to DC. Electrical technology as applied to signals and sensors is briefly examined.

Learning Objective 1 • Describe the primary types of electronic instru-
• Describe resistive circuits and explain how to mentation signals.
apply Ohm’s law and Kirchhoff’s laws. a. Describe analog signals and explain how
a. Describe series, parallel, and series-parallel they are used.
resistive circuits. b. Describe digital signals and explain how they
b. Explain how to apply Ohm’s law to different are used.
circuit types. c. Describe how PLCs interact with
c. Explain how to apply Kirchhoff’s laws to instrumentation signals.
determine current and voltage values. Learning Objective 5
Learning Objective 2 • Describe common applications for instrumen-
• Identify key characteristics of alternating cur- tation circuitry.
rent and explain resistance, inductance, capaci- a. Describe temperature applications using an
tance, and power concepts. RTD bridge.
a. Identify key characteristics of alternating b. Describe pressure applications using a strain-
current. gauge bridge.
b. Describe alternating current phase c. Describe remote level applications.
relationships.
c. Explain resistance in alternating-current Performance Tasks
circuits. Performance Task 1 (Learning Objective 1)
d. Explain inductance in alternating-current • Calculate the resistance range of three resistors
circuits. using their color bands. Using a multimeter,
e. Explain capacitance in alternating-current measure the actual resistance of each resistor
circuits. and determine if it is within the specified toler-
f. Explain power in alternating-current circuits. ance.
• Describe direct-current power supplies and • Connect three resistors in series and calculate
testing methods. the total nominal resistance using the color
bands and the appropriate formula. Using a
a. Describe direct-current power supplies.
multimeter, measure the actual total series re-
b. Describe how to select and test a direct- sistance and compare it to the calculated value.
current power supply.
• Connect three resistors in parallel and calculate
the total nominal resistance using the color
bands and the appropriate formula. Using a
multimeter, measure the actual total parallel re-
sistance and compare it to the calculated value.
12305-16 Instrumentation Electrical Circuitry Module Three iii
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Prerequisites
Before You Begin
The passing score for submission into NCCER’s Registry is 70% or above for the module exam; performance test-
ing is graded pass or fail.
supervision.

Whiteboard Appropriate PPE to include the Selection of resistors (1⁄4 or 1⁄2W,
Markers following: 5 percent tolerance)
Pencils and paper Safety glasses Multimeters
Instrumentation Level Three Work gloves Calculators
®
PowerPoint Presentation Proper footwear as designated by Resistor color code charts
DVD player or a computer with the instructor or training facility
a DVD drive provider
LCD projector and screen Hearing protection as designated
by the instructor or training facility
Computer with Internet access
provider
Calculators
Inductors instructor or training facility provider
Capacitors
Linear DC power supply
Switching DC power supply
Example PLC analog and digital
modules
RTD
Multimeter
Single unbonded strain gauge
Pressure sensor/DP cell
Level sensor
Copies of the module examination (for
paper-based exams) and Performance
Profile Sheets
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This module presents thorough resources for task training. The following resource material is recommended for
further study.
Electronics Fundamentals: Circuits, Devices, & Applications, Thomas L. Floyd. Eighth Edition. 2009. New
York, NY: Prentice Hall.
Introduction to Electric Circuits, Richard C. Dorf and James A. Svoboda. Ninth Edition. 2013. Hoboken, NJ:
Wiley.
Measurement and Control Basics, Thomas A. Hughes. Fifth Edition. 2014. Research Triangle Park, NC: Inter-
national Society of Automation.
Principles of Electric Circuits: Electron Flow Version, Thomas L. Floyd. Ninth Edition. 2009. New York, NY:
Prentice Hall.
Instructors are also encouraged to locate additional audiovisual aids available on the Internet, make personal
12305-16 Instrumentation Electrical Circuitry Module Three v
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Session One 1. Show the Session Two PowerPoint ®

presentation.
Session One introduces basic DC electrical 2. Use the Kickoff Activity to review Ohm’s
theory by discussing the two fundamental law and encourage the trainees to think of
circuit types: series and parallel. This idea is it not just as equations but as relationships
extended to combination circuits that contain between the three electrical parameters.
both series and parallel sections. The equations
for calculating circuit resistance in each type are 3. Introduce Ohm’s law and explain how the
examined. This session covers Sections 1.0.0 three forms allow for any one electrical
through 1.1.3. parameter to be calculated from the other two.
1. Show the Session One PowerPoint ® 4. Apply Ohm’s law to determine circuit current
presentation. and voltage drops in series circuits.
2. Use the Kickoff Activity to get trainees 5. Apply Ohm’s law to determine circuit current
engaged and give them an idea of what they and individual branch currents in parallel
will learn from this module. circuits.
3. Review resistance and introduce the concept 6. Apply Ohm’s law to analyze series-parallel
of a multi-resistance circuit. circuits.
4. Examine series circuits as well as the formula
for calculating total circuit resistance. Session Three
5. Examine parallel circuits as well as the
formulas for calculating total circuit Session Three extends the trainees’
resistance. understanding by adding Kirchhoff’s two laws
as the means by which series and parallel
6. Introduce series-parallel circuits and the circuits can be further analyzed. Trainees will
redrawing techniques that make its elements learn to create loop equations and use them to
more apparent. understand how current and voltage behave in
the circuit. This session covers Sections 1.3.0
7. Discuss how to calculate the total circuit
through 1.3.3.
resistance of a series-parallel circuit.
1. Show the Session Three PowerPoint ®
presentation.
Session Two
2. Use the Kickoff Activity to introduce the
Session Two explores one of the most trainees to Kirchhoff’s laws.
fundamental and useful laws of electricity, 3. Introduce Kirchhoff’s current law (KCL) and
Ohm’s law. The three forms of the law are Kirchhoff’s voltage law (KVL).
presented and their uses explored. Ohm’s law
is then used to help analyze series, parallel, 4. Clarify how signs are determined when
and series-parallel circuits. This session covers writing KCL and KVL equations.
Sections 1.2.0 through 1.2.3. 5. Demonstrate how to write loop equations.
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Session Four 3. Introduce inductive circuits by explaining

how an AC signal in a coil of wire produces
Session Four moves a step deeper into some significant effects.
fundamental electrical principles by looking 4. Describe an inductor and explain how its
at alternating current and comparing its various physical properties influence its
behavior to DC. Waveform terms as well as the circuit behavior. Mention inductive reactance.
average and RMS methods for determining
quantities are examined. The concept of phase 5. Introduce capacitive circuits by explaining
is introduced. Resistance is extended to include how an AC signal acting across a capacitor
AC. This session covers Sections 2.0.0 through produces some significant effects.
2.3.0. 6. Compare a capacitor’s behavior under DC
1. Show the Session Four PowerPoint ® and under AC.
presentation. 7. Introduce the equations used to calculate
2. Use the Kickoff Activity to review the total capacitance in series and parallel
differences between DC and AC. capacitive circuits.
3. Introduce alternating current and the sine 8. Describe capacitor voltage rating, leak
wave. resistance, and capacitive reactance.
4. Define and give examples of the various 9. Explore AC power and compare it to DC
parameters used to describe a sine wave. power.
5. Discuss the need for a “single” AC voltage
or current value in a setting in which the Session Six
waveform is constantly changing. Introduce
average and RMS values as a solution to this Session Six examines DC power supply
problem. technology. Both linear and nonlinear
6. Explain phase angles. (switching) supplies are examined. Power
supply selection and testing is considered from
7. Discuss resistance in an AC context, an instrumentation perspective. This session
comparing it to DC resistance. covers Sections 3.0.0 through 3.2.2.
1. Show the Session Six PowerPoint ®
Session Five presentation.
2. Use the Kickoff Activity to highlight the
Session Five carries AC theory further by differences between linear and switching
examining its effect on inductive and capacitive power supplies.
circuits. Capacitor and inductor equations are
introduced, as is the concept of reactance. 3. Discuss the role that DC power supplies play
Finally, AC power is addressed in contrast to in instrumentation and control systems.
DC power. This session covers Sections 2.4.0 4. Define linear and nonlinear (switching) power
through 2.6.0. supplies and identify their key qualities.
1. Show the Session Five PowerPoint ® 5. Explain how a DC power supply is selected
presentation. and tested.
2. Use the Kickoff Activity to review key AC
terminology and the sine wave.
12305-16 Instrumentation Electrical Circuitry Module Three vii
M03_12305-16_LP.indd 7 5/9/16 3:11 PM

Session Seven Session Nine

Session Seven introduces instrumentation Session Nine is a laboratory session devoted
signals. Both analog and digital signals to the practice and completion of Performance
are compared and contrasted. Digital Tasks 1, 2, and 3.
communications with intelligent devices such
1. Note that no PowerPoint ® presentation is
as PLCs is introduced. This session covers
associated with this laboratory session.
Sections 4.0.0 through 4.3.2.
2. Demonstrate how to calculate the resistance
1. Show the Session Seven PowerPoint ®
range of three resistors using their color
presentation.
bands. Then, compare their measured
2. Use the Kickoff Activity to give the trainees resistance and see if it comes within the
a chance to ask questions about previous expected tolerance.
material in this module.
3. Demonstrate how to connect three resistors
3. Survey analog instrumentation signals in series and determine their nominal
and explain how they represent physical resistance from their color bands. Then,
quantities as electrical voltage or current compare the measured circuit value to the
levels. calculated value.
4. Discuss the key details of 4–20mA current 4. Demonstrate how to connect three resistors
loops. Describe their limitations. in parallel and determine their nominal
resistance from their color bands. Then,
5. Introduce digital signals and compare them
compare the measured circuit value to the
to analog ones.
calculated value.
6. Discuss how PLCs send and receive
information in both analog and digital requirements of Performance Tasks 1, 2, and
formats.
3.
Session Eight Session Ten

Session Eight discusses a number of common Session Ten is a review and testing session.
electrical instrumentation technologies, Have the trainees complete the Module Review
including temperature, pressure, and level Questions. Alternatively, these may be assigned
sensors. Each is considered from an electrical as homework at the end of Session Nine. Go
perspective. Bridge circuits are examined over the answers to the Review Questions
briefly. This session covers Sections 5.0.0 in class prior to the exam and answer any
through 5.3.0. questions that the trainees may have.
1. Show the Session Eight PowerPoint ® 1. Have trainees complete the module exam.
presentation. Any outstanding performance testing must
2. Use the Kickoff Activity to review the Trade be completed during this session as well.
Terms introduced in the previous sessions. 2. Record the testing results on the Registration
3. Explore the RTD temperature sensor by of Training Modules form and submit the
describing its basic principles and features. form to your Training Program Sponsor.
4. Introduce the bridge circuit and its role in
instrumentation circuits.
5. Discuss strain-gauge pressure sensors and
explain how they convert strain into changes
of resistance.
6. Examine pressure-based level sensors.
viii NCCER – Instrumentation Level Three 12305-16
M03_12305-16_LP.indd 8 5/9/16 3:11 PM

Materials Checklist for Module 12305-16, Instrumentation Electrical Circuitry

Personal protective equipment: Selection of resistors
Inductors
(1⁄4 or 1⁄2W, 5 percent tolerance)
Safety glasses Capacitors Multimeters
Work gloves Linear DC power supply Calculators

Proper footwear as Resistor color code charts
designated by the instructor Switching DC power supply
Hearing protection as
Example PLC analog and
digital modules
Hard hat as designated by
the instructor or training RTD
facility provider
Whiteboard Multimeter
Markers Single unbonded strain gauge

Pencils and paper Pressure sensor/DP cell
Level sensor
a DVD drive
Calculators
Profile Sheets
12305-16 Instrumentation Electrical Circuitry Module Three ix
M03_12305-16_LP.indd 9 5/9/16 3:11 PM

Relays and Timers
Module Four (12208-16) introduces electromechanical, electronic, and pneumatic switching through the topic
of relays and timers. Trainees will learn about the various types of relays as well as the nomenclature used to
describe a relay’s behavior and internal arrangement. They will also learn about solid-state switching devices,
pneumatic relays, and various kinds of timing relays and clocks.
Objective Performance Task

• Identify and describe the operation of various • Select and connect various types of relays and
types of relays and timers. timers to create a functional circuit as directed
a. Identify and describe the operation of various by the instructor.
electromechanical relays.
b. Identify and describe the operation of solid-
state relays.
c. Identify and describe the operation of
pneumatic boosters.
d. Identify and describe the operation of various
timers and time clocks.

(Four 2.5-Hour Sessions)
Prerequisites
Before You Begin
The passing score for submission into NCCER’s Registry is 70% or above for the module exam; performance test-
ing is graded pass or fail.
12208-16 Relays and Timers Module Four iii
M04_12208-16_LP.indd 3 5/9/16 4:19 PM

This module requires that trainees work with tools, electrical devices, and potentially energized equipment.
Safety must be emphasized at all times. Trainees should be carefully observed to ensure that they wear
the proper PPE, follow safe practices, and give due respect to unseen hazards. Any deficiencies must be
corrected to ensure future trainee safety. All practice sessions and Performance Tasks must be completed
under your direct supervision.

Whiteboard Appropriate PPE, to include the Selection of relays and timers
Markers following: Appropriate wiring, connectors, and
Safety glasses sockets
Pencils and paper
Work gloves Suitable power supply
PowerPoint® Presentation Proper footwear as designated by Device to be controlled
the instructor or training facility
DVD player or a computer with provider
a DVD drive
Hearing protection as designated
LCD projector and screen by the instructor or training facility
Computer with Internet access provider
Reed relay Hard hat as designated by the
General-purpose relays of various instructor or training facility provider
types
Solid-state relay
Pneumatic booster relay
Dashpot timer relay
Time clock
Solid-state timer
Review Questions answer key
Profile Sheets
further study.
Electrical Motor Controls for Integrated Systems, Gary Rockis and Glen A. Mazur. Fourth Edition. 2009. Orland
Park, IL: American Technical Publishers.
M04_12208-16_LP.indd 4 5/9/16 4:19 PM

Relays and Timers
The Lesson Plan for this module is divided into four 2.5-hour sessions.

Session One introduces electromechanical Session Three is a laboratory session devoted
and electronic switching. Various types of to the practice and completion of Performance
electromechanical relays are covered. Trainees Task 1.
will learn about the key electrical parameters
ote that no PowerPoint ® presentation is
1. N
of relays, their contact arrangements, and
associated with this laboratory session.
their switching behavior. Solid-state relays are
described and compared to electromechanical 2. Demonstrate how to connect relays and
relays. This session covers Sections 1.0.0 timers to create a functional timing circuit.
through 1.2.1.
3. H
ave trainees practice and/or complete the
1. Show the Session One PowerPoint ® requirements of Performance Task 1 in this
presentation. hands-on session.
2. U
engaged and give them an idea of what they Session Four
will learn from this module.
3. Introduce the different types of electro Session Four is a review and testing session.
mechanical relays and the uses for each Have the trainees complete the Module Review
major category. Questions. Alternatively, these may be assigned
as homework at the end of Session Three.
4. Discuss the electrical parameters associated Go over the answers to the Review Questions
with relays as well as the nomenclature in class prior to the exam and answer any
connected with their internal arrangement. questions that the trainees may have.
5. C
ompare solid-state relays with electro 1. H
ave trainees complete the module exam.
mechanical relays, introducing the places Any outstanding performance testing must
where each technology works best. be completed during this session as well.
2. R
Session Two of Training Modules form and submit the
form to your Training Program Sponsor.
Session Two introduces pneumatic relays,
repeaters, and boosters. The internal arrange-
ments of these technologies are examined, as
well as their uses. Timing relays, clocks, and
other delay devices are discussed. Mechani-
cal, electrical, and electronic technologies are
compared. This session covers Sections 1.3.0
through 1.4.3.
1. Show the Session Two PowerPoint ®
presentation.
2. Use the Kickoff Activity to help trainees
recognize the need for pneumatic relays,
boosters, and repeaters.
3. Discuss pneumatic switching devices and
explain the purposes for each type.
4. Examine timing devices, such as timer relays,
delay devices, and time clock mechanisms.
5. Compare solid-state timing devices to
mechanical and electrical equivalents.
12208-16 Relays and Timers Module Four v
M04_12208-16_LP.indd 5 5/9/16 4:19 PM

Materials Checklist for Module 12208-16, Relays and Timers

Personal protective equipment: Reed relay Selection of relays and timers
General-purpose relays of Appropriate wiring,
Safety glasses
various types connectors, and sockets
Work gloves Solid-state relay Suitable power supply
Proper footwear as Device to be controlled
designated by the instructor Pneumatic booster relay
designated by the instructor Dashpot timer relay
the instructor or training Time clock
facility provider
Whiteboard Solid-state timer
Markers
Pencils and paper
a DVD drive
Profile Sheets
M04_12208-16_LP.indd 6 5/9/16 4:19 PM

Switches and Photoelectric Devices

Module Five (12209-16) introduces the many different types of switches encountered in typical industrial set-
tings. Various types of photoelectric devices will be considered in a number of applications. In addition to the
standard switch types, trainees will also examine other types of switches, including infrared-detecting, fiber-
optic, and proximity sensors.

• Identify and describe the operation of various • Select and connect various switches into a
types of switches and photoelectric devices. functional circuit as directed by the instructor.
a. Define switches and their various
characteristics.
• Select and connect various photoelectric
b. Describe the characteristics of various switch
devices into a functional circuit as directed by
types and styles.
the instructor.
c. Describe various switch applications.
d. Identify and describe the operation of
photoelectric devices.
e. Identify and describe the operation of
infrared-sensing devices.
f. Identify and describe the operation of fiber-
optic sensors.
g. Identify and describe the operation of
proximity sensors.

Prerequisites
Before You Begin
12209-16 Switches and Photoelectric Devices Module Five iii
M05_12209-16_LP.indd 3 5/9/16 4:20 PM

This module requires that trainees work with tools, electrical devices, and potentially energized equipment.

Whiteboard Appropriate PPE, to include the Selection of switches
Markers following: Selection of photoelectric devices
Pencils and paper Safety glasses Appropriate wiring, connectors, and
Instrumentation Level Three Work gloves sockets
®
PowerPoint Presentation Proper footwear as designated by Suitable power supply
DVD player or a computer with the instructor or training facility Devices to be controlled
provider
Copies of the module examination (for instructor or training facility provider
Profile Sheets
Disassembled switch, preferably
DPDT
Panel-mounted switches
Float switch
Pressure switch
Limit switch
SCR or TRIAC switch
Photoelectric, direct scanning sensor
Infrared thermometer
Inductive proximity sensor
further study.
National Electrical Code ® Handbook 2014, Mark W. Earley, Christopher D. Coache, Mark Cloutier, and Gil
Moniz. Thirteenth Edition. 2013. Quincy, MA: National Fire Protection Association.
M05_12209-16_LP.indd 4 5/9/16 4:20 PM

Switches and Photoelectric Devices
Session One 4. Introduce solar cells as an example of a

photoelectric energy conversion device.
Session One introduces various types of 5. D
iscuss infrared sensors and their
switches. Trainees will learn about switch applications, both as motion detectors and as
classifications, contact arrangements, poles, non-contact temperature sensors.
and throws. They will study specific switch
types and applications. Various types of 6. D
escribe fiber-optic sensors and inductive
electronic switches are also described. This proximity sensors and how they are used.
1. Show the Session One PowerPoint ® Session Three
presentation.
2. U
se the Kickoff Activity to get trainees Session Three is a laboratory session
engaged and give them an idea of what they designated for the practice and completion of
will learn from this module. Performance Tasks 1 and 2.
3. Introduce essential switch terminology and ote that no PowerPoint ® presentation is

1. N
definitions. associated with this laboratory session.
4. Discuss the major switch classifications, 2. Demonstrate how to connect various

including details such as contact switches into a functional circuit.
arrangements, poles, and throws. 3. D
emonstrate how to connect various
5. P
rovide an overview of major switch types photoelectric devices into a functional circuit.
and applications. 4. H
6. D
iscuss electronic (solid-state) switches and requirements of Performance Tasks 1 and 2 in
compare them to mechanical ones. this hands-on session.
Session Two Session Four

Session Two introduces several different types Session Four is a review and testing session.
of specialized switches. Photoelectric switches, Have the trainees complete the Module Review
used in different sensing situations, will be Questions. Alternatively, these may be assigned
examined. The use of infrared sensors, motion as homework at the end of Session Three.
detectors, and fiber-optic switches is described, Go over the answers to the Review Questions
and proximity switches are examined. This in class prior to the exam and answer any
session covers Sections 1.4.0 through 1.7.0. questions that the trainees may have.
1. Show the Session Two PowerPoint ® 1. H

be completed during this session as well.
2. Use the Kickoff Activity to help trainees
understand proximity sensors and their 2. R
applications. of Training Modules form and submit the
3. Discuss photoelectric switches and their uses
in scanning applications such as conveyor
belts.
12209-16 Switches and Photoelectric Devices Module Five v
M05_12209-16_LP.indd 5 5/9/16 4:20 PM

Materials Checklist for Module 12209-16, Switches and Photoelectric Devices

Personal protective equipment: Disassembled switch, Selection of switches
preferably DPDT
Selection of photoelectric
Safety glasses Panel-mounted switches
devices
Appropriate wiring,
Work gloves Float switch
connectors, and sockets
Proper footwear as Suitable power supply
designated by the instructor Pressure switch
Hearing protection as Devices to be controlled
designated by the instructor Limit switch
the instructor or training SCR or TRIAC switch
facility provider
Photoelectric, direct scanning
Whiteboard
sensor
Markers Infrared thermometer
Pencils and paper Inductive proximity sensor
a DVD drive
Profile Sheets
M05_12209-16_LP.indd 6 5/9/16 4:20 PM

Terminating Conductors
Module Six (12307-16) addresses the topic of cable termination. Instrumentation involves many different types of
cables carrying a wide variety of signals. In order to keep equipment operating reliably, proper cable termination
is essential. This module addresses cable and termination types, tools, termination methods, and testing strate-
gies to deal with problems. The causes of cable failure are also briefly examined.

Learning Objective 1 • Explain how to test and troubleshoot cable
installations.
• Identify and describe various types of instru-
mentation cable and their related terminal a. Identify common test equipment.
hardware. b. Identify various cable and conductor testing
a. Identify and describe various types of parameters used to determine condition.
communication cable. c. Describe cable and conductor
b. Identify and describe low-voltage connectors troubleshooting techniques.
and terminals. d. Identify various types of cable and conductor
failures and their potential causes.
• Explain how to terminate various types of low- Performance Tasks
voltage cable.
a. Explain how to terminate cables and Performance Task 1 (Learning Objective 1)
conductors with solderless terminals or • Physically distinguish between various types of
terminal blocks. cable, including twisted-pair, non-twisted-pair,
b. Explain how to terminate coaxial cable. and coaxial.
c. Identify considerations and installation Performance Task 2 (Learning Objective 2)
techniques related to cable and conductor • Terminate conductors using crimp connectors.
routing. Performance Task 3 (Learning Objective 2)
d. Identify considerations and installation • Terminate shielded cable.
techniques related to avoiding
electromagnetic interference. Performance Task 4 (Learning Objective 2)
• Install a coaxial cable connector.
• Test a cable using telephones.
• Inspect a cable for defects and classify any
defects found.

(Eight 2.5-Hour Sessions)
Prerequisites
Before You Begin
12307-16 Terminating Conductors Module Six iii
M06_12307-16_LP.indd 3 5/9/16 4:37 PM

supervision.

Whiteboard Terminated screw-terminal, UTP, STP, for Laboratories and
and coaxial cables/wires Performance Testing
Markers
Termination tools (cutter, stripper, Appropriate PPE, to include the
Pencils and paper
crimper, etc.) following:
Common cable terminations (screw- Safety glasses
terminal, UTP, STP, and coaxial) Work gloves
DVD player or a computer with a
Unterminated cables/wires Proper footwear as designated by
DVD drive
the instructor or training facility
LCD projector and screen AM radio
provider
Computer with Internet access Personal computer Hearing protection as designated
Samples of UTP cable Telephone test set by the instructor or training facility
(multiple categories, if possible) Tone generator and cable toner provider
Samples of STP cable Cable tester Hard hat as designated by the
(multiple shield types, if possible) instructor or training facility provider
Certification field tester
Samples of coaxial cable Selection of cables (twisted-pair, non-
TDR twisted-pair, coaxial)
(single and quad-shield, if possible)
Additional cable test instruments Wire and crimp-type connectors
Examples of UTP and STP (if available)
terminations STP cables and terminations
Sample lengths of UTP or coaxial Coaxial cables and terminations
Type 66 or type 110 punchdown block cable 50' or longer
Appropriate termination tools (cutters,
Examples of coaxial cable Multimeter strippers, crimpers)
terminations
Examples of failed cables Lengths of UTP cable
Sample data communications plates,
Review Questions answer key Telephone test sets
jacks, and connectors
Copies of the module examination Examples of terminated cable with a
Samples of properly and improperly
(for paper-based exams) and number of defects
terminated cables
Performance Profile Sheets
further study.
Cabling: The Complete Guide to Copper and Fiber-Optic Networking, 2014. Andrew Oliviero and Bill Wood-
ward. Indianapolis, IN: John Wiley & Sons, Inc.
Telecommunications Industry Association website, www.tiaonline.org
M06_12307-16_LP.indd 4 5/9/16 4:37 PM

The Lesson Plan for this module is divided into eight 2.5-hour sessions.
Session One 3. Introduce cable termination tools and the

proper way to prepare cables for termination.
Session One introduces the low-voltage 4. D
escribe crimp-on connectors and the tools
cabling used in instrumentation and data used to attach them.
communications applications. Different cables
types are examined and categorized. Twisted- 5. D
iscuss the guidelines for crimp-type
pair cable is stressed and the different types connections and the proper way to make
and shielded varieties are compared. Coaxial them.
cables are discussed as are the various types 6. Introduce terminal blocks and the guidelines
of cable terminations. This session covers for cabling to them.
7. D
iscuss coaxial cable termination and the
1. Show the Session One PowerPoint ® proper method for attaching each type of
presentation. connector.
2. U
engaged and give them an idea of what they
will learn from this module. Session Three
3. Introduce low-voltage cable of the types Session Three addresses the subjects of cable
commonly used in instrumentation and data inspection and proper routing. Many cabling
communications. problems stem from improperly handling
4. Discuss UTP cable, its categories, and its them and/or not protecting them from the
applications. environment. The issue of electromagnetic
interference (EMI) is introduced, along with
5. D
iscuss STP cable, its nomenclature, and its some of the ways in which it is managed and its
shielding systems. effects minimized. This session covers Sections
2.3.0 through 2.4.2.
6. D
escribe coaxial cable and the different ways
that it’s shielded. how the Session Three PowerPoint ®
1. S
presentation.
7. Present the major categories of crimp,
coaxial, and data communications cable 2. U
se the Kickoff Activity to demonstrate the
terminations. role that a properly grounded shield can play
in dealing with EMI.
Session Two 3. D
iscuss cable routing and inspection.
List common checkpoints used during
Session Two focuses on the proper way to inspections.
terminate different types of cables. Crimp-on 4. Introduce electromagnetic interference and
and coaxial terminations are stressed. Using explain how it passes from one cable to
the proper tools in the proper way is the key another.
to reliable and long-lasting terminations. This
session covers Sections 2.0.0 through 2.2.2. 5. S
ummarize common strategies for reducing
EMI problems in cables, particularly through
1. Show the Session Two PowerPoint ® routing techniques.
presentation.
6. E
xplain how shielded cables should be
2. Use the Kickoff Activity to show how terminated.
improper cable terminations can become a
source of major problems.
12307-16 Terminating Conductors Module Six v
M06_12307-16_LP.indd 5 5/9/16 4:37 PM

Session Four 2. D
emonstrate how to distinguish between
various types of low-voltage cable, including
Session Four surveys the primary tools used for twisted-pair, non-twisted-pair, and coaxial
testing cables. Testing as a means of confirming cable.
proper termination and routing as well as for 3. D
emonstrate how to terminate cables using
diagnosis is addressed. Different types of tools crimp-type connectors. Stress the correct use
are examined with a focus placed on their of the proper tools in this process.
proper use. Causes for cable failure are briefly
examined. This session covers Sections 3.0.0 4. D
emonstrate how to terminate shielded cable
through 3.4.3. using the proper tools and techniques.
1. Show the Session Four PowerPoint ® 5. D
emonstrate how to terminate coaxial cable
presentation. using the proper tools and techniques.
2. Use the Kickoff Activity to provide an 6. D
emonstrate the telephone test set and
overview of how a TDR is used to measure explain how to use it to perform a basic
cable length as well as to find faults in it. continuity test on a cable.
3. Introduce and summarize the primary cable 7. Demonstrate the steps used to inspect a cable
test instruments, focusing on their basic and identify faults. Emphasize determining
operation and major applications. the probable cause of faults as well, so future
problems can be prevented.
4. Summarize and define the key test
parameters used when examining 8. H
instrumentation and data cabling. requirements of Performance Tasks 1 through
6 in these hands-on sessions.
5. Describe common troubleshooting
strategies and explain how even simple test
instruments, such as a multimeter, can be Session Eight
used for basic fault-finding.
6. Discuss the common causes for low-voltage Session Eight is a review and testing session.
cable failure. Have the trainees complete the Module Review
as homework at the end of Session Seven.
Sessions Five through Seven Go over the answers to the Review Questions
in class prior to the exam and answer any
Sessions Five through Seven are laboratory questions that the trainees may have.
sessions devoted to the practice and completion 1. H
of Performance Tasks 1 through 6. Any outstanding performance testing must
1. Note that no PowerPoint ® presentations are be completed during this session as well.
associated with these laboratory sessions. 2. R
of Training Modules form and submit the
M06_12307-16_LP.indd 6 5/9/16 4:37 PM

Materials Checklist for Module 12307-16, Terminating Conductors

Personal protective equipment: Samples of UTP cable Selection of cables (twisted-
(multiple categories, if pair, non-twisted-pair, coaxial)
possible)
Samples of STP cable Wire and crimp-type
Safety glasses (multiple shield types, if connectors
possible)
Samples of coaxial cable STP cables and terminations
Work gloves (single and quad-shield, if
possible)
Proper footwear as designated Coaxial cables and
Examples of UTP and STP
by the instructor or training terminations
terminations
facility provider
Hearing protection as Appropriate termination tools
Type 66 or type 110
designated by the instructor or (cutters, strippers, crimpers)
punchdown block
training facility provider
Hard hat as designated by the Lengths of UTP cable
Examples of coaxial cable
terminations
provider
Sample data communications Telephone test sets
Whiteboard
plates, jacks, and connectors
Samples of properly and Examples of terminated cable
Markers
improperly terminated cables with a number of defects
Terminated screw-terminal,
Pencils and paper UTP, STP, and coaxial cables/
wires
Instrumentation Level Three Termination tools (cutter,
PowerPoint® Presentation stripper, crimper, etc.)
Common cable terminations
(screw-terminal, UTP, STP, and
a DVD drive
coaxial)
LCD projector and screen Unterminated cables/wires
Computer with Internet access Telephone test set
AM radio Tone generator and cable toner
Personal computer Cable tester
Multimeter Certification field tester
Review Questions answer key TDR
Copies of the module Additional cable test
examination (for paper-based instruments (if available)
Profile Sheets
Sample lengths of UTP or
coaxial cable 50' or longer
Examples of failed cables
12307-16 Terminating Conductors Module Six vii
M06_12307-16_LP.indd 7 5/9/16 4:37 PM

Grounding and Shielding of Instrumentation Wiring

Module Seven (12306-16) addresses the concept of grounding in instrumentation settings. Grounding carries
with it two distinct aspects. First of all, it is necessary to ensure safely operating equipment that minimizes risk
for those who use it. Second, grounding is a key facet in dealing with electromagnetic noise and interference
in instrumentation systems. Most shielding approaches involve ground connections as a part of their basic op-
eration. Failing to understand grounding can result both in hazardous situations and ones in which a shielding
system fails to do its job, leading to unreliable equipment performance.

• Define grounding and bonding and describe • Identify and explain the function of an equip-
grounding and bonding techniques. ment ground identified in an instructor-provid-
a. Describe grounding and bonding and define ed drawing.
key terms. Performance Task 2 (Learning Objective 2)
b. Describe basic grounding components and • Draw an example of a ground loop.
techniques.
c. Describe bonding and its purpose.
• Identify and explain the function of an equip-
Learning Objective 2 ment shield in an instructor-provided drawing.
• Describe different types of electromagnetic
interference and identify methods to reduce or
eliminate its influence.
a. Describe capacitive-coupled noise.
b. Describe inductive-coupled noise.
c. Describe directly-coupled noise.
d. Describe cable shielding and grounding
techniques.

Prerequisites
Before You Begin
12306-16 Grounding and Shielding of Instrumentation Wiring Module Seven iii
M07_12306-16_LP.indd 3 5/9/16 4:38 PM


Whiteboard Appropriate PPE, to include the Selection of drawings showing
Markers following if this laboratory is not grounding and shields
conducted in a regular classroom:
Pencils and paper
Safety glasses
Work gloves
Proper footwear as designated by
DVD player or a computer with the instructor or training facility
Computer with Internet access by the instructor or training facility
Grounding rod provider
Grounding conductor Hard hat as designated by the
instructor or training facility provider
Several examples of shielded cables
Backshell connectors with mating
connectors
Profile Sheets
further study.
Grounding and Shielding in Facilities, Ralph Morrison. 1990. New York, NY: John Wiley & Sons.
Grounding and Shielding Techniques, Ralph Morrison. Fourth edition. 1998. New York, NY: John Wiley &
Sons.
M07_12306-16_LP.indd 4 5/9/16 4:38 PM

Grounding and Shielding of Instrumentation Wiring
Session One 4. D
escribe the different ways in which noise
enters a system.
Session One introduces electrical grounding 5. Explain how cable shielding works to control
from the equipment and safety point of noise.
view. The function of grounding is to protect
operators against accidental contact with 6. Discuss ground loops and the proper way to
dangerous voltages. Different types of terminate a shield.
grounding systems are considered and the
proper way of bonding equipment is addressed.
This session covers Sections 1.0.0 through 1.3.1. Session Three
how the Session One PowerPoint ®
1. S Session Three is a laboratory session devoted
presentation. to the practice and completion of Performance
2. U
se the Kickoff Activity to get trainees Tasks 1, 2, and 3.
engaged and give them an idea of what they 1. Note that no PowerPoint ® presentation is
will learn from this module. associated with this laboratory session.
3. P
rovide an overview of electrical grounding 2. D
emonstrate how to identify and explain
and its associated terminology. the function of an equipment ground in a
roadly discuss the NEC® grounding
4. B drawing.
requirements. 3. D
emonstrate how to draw an example of a
5. Summarize basic grounding concepts and ground loop.
the ways that systems and devices can be 4. D
emonstrate how to identify and explain the
grounded. function of an equipment shield in a drawing.
6. Address bonding and its role in creating a 5. Have trainees practice and/or complete the
safe electrical system. requirements of Performance Tasks 1, 2, and
3 in this hands-on session.
Session Two
Session Four
Session Two addresses electromagnetic
interference and the role that grounding and Session Four is a review and testing session.
shielding play in controlling it. Different types Have the trainees complete the Module Review
and sources of noise are considered. Ways in Questions. Alternatively, these may be assigned
which noise enters a system are discussed. as homework at the end of Session Three.
Cable shielding is explored and the different Go over the answers to the Review Questions
types of shielding are compared. This session in class prior to the exam and answer any
covers Sections 2.0.0 through 2.4.5. questions that the trainees may have.
1. S 1. Have trainees complete the module exam.
2. U
se the Kickoff Activity to help trainees be completed during this session as well.
understand shielding systems and the 2. R
different types of cable shields. of Training Modules form and submit the
3. D
iscuss electromagnetic noise and its various form to your Training Program Sponsor.
forms.
12306-16 Grounding and Shielding of Instrumentation Wiring Module Seven v
M07_12306-16_LP.indd 5 5/9/16 4:38 PM

Materials Checklist for Module 12306-16, Grounding and Shielding of Instrumentation Wiring

Personal protective equipment: Selection of drawings showing
Grounding rod
grounding and shields
Safety glasses Grounding conductor
Several examples of shielded
Work gloves
cables
Proper footwear as
Backshell connectors with
mating connectors
provider
Whiteboard
Markers
Pencils and paper
a DVD drive
Profile Sheets
M07_12306-16_LP.indd 6 5/9/16 4:38 PM

Process Control Theory

Module Eight (12204-16) presents the basics of process control theory. Understanding how processes are
measured and control decisions are made is crucial to implementing and maintaining the systems that keep
processes happening reliably and safely. Trainees will learn about the basic features of control theory. They will
examine different types of loop control, along with the advantages and disadvantages of each type. Finally, they
will see how typical process measurements are used in control loops.

Learning Objective 1 • Describe various control applications and ex-
• Describe process control and identify basic plain their basic strategies.
components of the instrumentation control a. Describe the operation of typical
channel. temperature-control loops.
a. Describe the basic characteristics of a b. Describe the operation of typical pressure-
process. control loops.
b. Define and describe basic process control. c. Describe the operation of typical level-control
c. Identify basic components of an loops.
instrumentation control channel. d. Describe the operation of typical flow-control
d. Identify and describe basic types of final loops.
control elements.
Performance Tasks
• Define and describe the basic types of process
control loops. • Draw and accurately label a block diagram for a
basic process control loop.
a. Define and describe open control loops.
b. Define and describe closed control loops. Performance Task 2 (Learning Objective 2)
c. Define and describe cascade control. • From a piping and instrumentation drawing
d. Define and describe ratio control. (P&ID), identify the major components of each
of these process control loop types:
• Feedforward
• Identify and describe various control modes.
• Feedback
a. Identify and describe on-off control modes.
• Cascade
b. Identify and describe various modulating
control modes. • Ratio

Prerequisites
Before You Begin
12204-16 Process Control Theory Module Eight iii
M08_12204-16_LP.indd 3 5/9/16 3:44 PM

supervision.

Whiteboard Transducers for Laboratories
Markers Amplifier/signal conditioner and Performance Testing
Pencils and paper Transmitter Appropriate PPE to include the
Instrumentation Level Three Controller following if this laboratory is not
PowerPoint® Presentation conducted in a regular classroom:
Simple bimetallic thermostat
DVD player or a computer with Safety glasses
PID-capable controller
a DVD drive Work gloves
Temperature transmitter
LCD projector and screen (pneumatic or electronic) Proper footwear as designated by
Computer with Internet access the instructor or training facility
Pressure transmitter
provider
Review Questions answer key (pneumatic or electronic)
Copies of the module examination Level transmitter
(for paper-based exams) and (pneumatic or electronic)
provider
Performance Profile Sheets Flow transmitter
Sensors (pneumatic or electronic)
instructor or training facility provider
P&ID drawings
further study.
Instrument Engineers’ Handbook, Volume 1: Process Measurement and Analysis, Béla G. Lipták (editor).
Fourth Edition. 2003. Boca Raton, FL: CRC Press.
Instrument Engineers Handbook, Volume 2: Process Control and Optimization, Béla G. Lipták (editor). Fourth
Measurement and Control Basics, Thomas A. Hughes. Fifth Edition. 2014. Research Triangle Park, NC: Inter-
national Society of Automation (ISA).
Park, NC: The International Society of Automation, (ISA), www.isa.org
M08_12204-16_LP.indd 4 5/9/16 3:44 PM

Session One Session Two

Session One introduces the subject of process Session Two explores in greater detail the
control and the various tools that make a components of an instrument channel. Sensors,
process happen. Processes are defined and transducers, amplifiers, transmitters, and
examined, as are the factors that influence controllers are introduced. The way these
how they behave. The concept of maintaining components function together to create the
control over a process output relative to its instrument channel is addressed. The final
inputs is examined. The different components control element is examined; since it is often
in a process control channel are discussed. This a valve, different valve types are explored.
session covers Sections 1.0.0 through 1.2.0. Types of actuators are also introduced. Finally,
the technology used to ensure accurate valve
1. Show the Session One PowerPoint ® positioning is examined. This session covers
presentation.
2. U
1. S
engaged and give them an idea of what they presentation.
will learn from this module.
2. Use the Kickoff Activity to introduce the
3. Introduce and define the idea of a process. trainees to different types of sensors used in
4. Discuss disturbances and their effects on process control.
processes. Use this idea as the basis for 3. D
escribe the key parts of an instrument
control systems. channel.
5. P
resent the idea that a process is essentially 4. Define and explain the role of detectors,
an energy or material balance equation with transducers, amplifiers, transmitters, and
inputs and outputs. controllers in the instrument chain. Note
6. Introduce the concept of process limits that there are many different ways for these
and the need to maintain an equilibrium components to be combined and packaged.
condition. 5. Introduce the idea of the final control element
7. Describe a process control system and its (often a valve).
role in controlling process variables. Define 6. D
escribe different valve types and the
the two key variables involved. actuator technologies that control them.
8. L
ist the hardware involved in a process 7. Discuss the need for accurate control of the
control system. final element.
12204-16 Process Control Theory Module Eight v
M08_12204-16_LP.indd 5 5/9/16 3:44 PM

Session Three 3. Introduce on-off control as the simplest form

of closed-loop control.
Session Three presents information on types 4. Explain the idea of a process setpoint,
of control loops used to maintain equilibrium. measurement, and error. Discuss how on-off
Four different categories are examined and control reacts to error.
their relative advantages and disadvantages
are considered. Feedback is studied in more 5. Mention how adding a neutral zone corrects
detail, as it’s one of the major control methods. one weakness of on-off control (excessive
Issues commonly encountered are examined. cycling).
Cascade control is treated as an extension of 6. E
xplain how the neutral zone can make
feedback. Finally, ratio control is introduced as the process overshoot and undershoot the
a specialized type of closed-loop control. This setpoint.
1. Show the Session Three PowerPoint ®
presentation. Session Five
2. Use the Kickoff Activity to provide a graphical Session Five moves deeper into closed-loop
overview of feedforward (open-loop) control. control by looking at more sophisticated ways
3. Introduce the idea of a control loop as a of controlling the process. Different kinds of
means by which a process is manipulated modulated control are examined, each of which
and adjusted. has certain positive and negative qualities.
The concept of gain and proportionality is
efine feedforward control and examine its
4. D introduced and examined mathematically.
basic qualities. Proportional, Integral, and Derivative control
modes are examined both singly and in
efine feedback control and look at it in some
5. D
combination. This session covers Sections 3.2.0
detail, particularly in the way that its quality
through 3.2.6.
is assessed.
1. Show the Session Five PowerPoint ®
6. Discuss cascade control as a variant of basic
presentation.
feedback control.
2. Use the Kickoff Activity to point out the
efine ratio control as a specialized type of
7. D
limitations of on-off control and lead into
closed-loop control used when two variables
modulated control.
must be maintained in a particular ratio
relationship to each other. 3. Introduce modulating control as an
improvement over on-off control, particularly
as a result of its ability to continuously adjust
Session Four the process.
Session Four moves into some of the details 4. Discuss proportional control and define the
of closed-loop control. On-off control is terms gain and proportional band. Show their
examined as the simplest version of this form mathematical description and relationship.
of control. Its advantages and weaknesses are 5. Discuss integral control and explain what is
examined. Methods of reducing its weaknesses gained by using it.
are considered. The consequences of these
methods are considered as well. This session 6. Discuss derivative control and explain what is
covers Sections 3.0.0 through 3.1.0. gained by using it.
1. Show the Session Four PowerPoint ® 7. Discuss combinations of P, I, and D control
presentation. and explain their specific advantages and
disadvantages.
2. U
se the Kickoff Activity to introduce on-off
control through a familiar example.
M08_12204-16_LP.indd 6 5/9/16 3:44 PM

Session Six Sessions Eight and Nine

Session Six examines process control from the Sessions Eight and Nine are laboratory sessions
perspective of specific variables. Temperature devoted to the practice and completion of
and pressure are addressed. Each is considered Performance Tasks 1 and 2.
from both an electronic and a pneumatic
ote that no PowerPoint ® presentations are
1. N
context. This session covers Sections 4.0.0
associated with these laboratory sessions.
through 4.2.2.
2. Demonstrate how to draw and accurately
1. Show the Session Six PowerPoint ®
label a block diagram for a basic process
presentation.
control loop.
2. U
se the Kickoff Activity to expose trainees
3. D
emonstrate how to use a piping and
to pneumatic temperature control as an
instrumentation drawing (P&ID) to identify
example of a typical control loop approach.
the major components of each of these
3. Introduce the four key variables monitored in process control loop types: feedforward,
typical processes. feedback, cascade, and ratio.
4. D
escribe a pneumatic temperature-control 4. H
loop and its components. requirements of Performance Tasks 1 and 2.
5. D
escribe an electronic temperature-control
loop and its components. Session Ten
6. D
escribe a pneumatic pressure-control loop
and its components. Session Ten is a review and testing session.
Have the trainees complete the Module Review
7. Describe an electronic pressure-control loop Questions. Alternatively, these may be assigned
and its components. as homework at the end of Session Nine. Go
over the answers to the Review Questions
in class prior to the exam and answer any
Session Seven questions that the trainees may have.
Session Seven examines process control from 1. H
the perspective of specific variables. Level and Any outstanding performance testing must
flow are addressed. Each is considered from be completed during this session as well.
both an electronic and a pneumatic context. 2. R
This session covers Sections 4.3.0 through of Training Modules form and submit the
4.4.2. form to your Training Program Sponsor.
1. Show the Session Seven PowerPoint ®
presentation.
2. U
se the Kickoff Activity to give trainees
a chance to ask questions and request
clarification of difficult concepts.
3. D
escribe a pneumatic level-control loop and
its components.
4. D
escribe an electronic level-control loop and
its components.
5. D
escribe a pneumatic flow-control loop and
its components.
6. D
escribe an electronic flow-control loop and
its components.
12204-16 Process Control Theory Module Eight vii
M08_12204-16_LP.indd 7 5/9/16 3:44 PM

Materials Checklist for Module 12204-16, Process Control Theory

Personal protective equipment: P&ID drawings
Sensors
Safety glasses Transducers

Work gloves Amplifier/signal conditioner
Proper footwear as
designated by the instructor Transmitter
designated by the instructor Controller
the instructor or training Simple bimetallic thermostat
facility provider
Whiteboard PID-capable controller
Temperature transmitter
Markers
(pneumatic or electronic)
Pressure transmitter
Pencils and paper
(pneumatic or electronic)
Instrumentation Level Three Level transmitter
PowerPoint® Presentation (pneumatic or electronic)
DVD player or a computer with Flow transmitter
a DVD drive (pneumatic or electronic)
Profile Sheets
viii NCCER – Instrumentation Level Three 12204-16
M08_12204-16_LP.indd 8 5/9/16 3:44 PM

Controllers
Module Nine (12206-16) introduces the heart of any instrumentation system: the controller. This module introduces
the trainees to the two major technology families used for control: pneumatic and electronic. Broad principles of
control are addressed for both types of controllers. A number of specific controllers are also examined in order
to provide a few examples of these principles in action.

• Identify and describe the operation of various • Given a schematic for a pneumatic controller,
pneumatic and electronic controllers. explain the purpose and operation of all major
a. Identify and describe controllers and their components.
common operating modes. Performance Task 2 (Learning Objective 1)
b. Identify and describe basic and specific • Given a block diagram of an electronic control-
pneumatic controller configurations. ler, explain the function of each block.
c. Identify and describe basic electronic
controller configurations.

Prerequisites
Before You Begin
12206-16 Controllers Module Nine iii
M09_12206-16_LP.indd 3 5/9/16 4:10 PM


Whiteboard Appropriate PPE, to include the Pneumatic controller schematics
Markers following if this laboratory is not Electronic controller block diagrams
conducted in a regular classroom:
Pencils and paper
Safety glasses
®
PowerPoint Presentation Work gloves
DVD player or a computer with Proper footwear as designated by
a DVD drive the instructor or training facility
provider
Review Questions answer key provider
Copies of the module examination (for Hard hat as designated by the
paper-based exams) and Performance instructor or training facility provider
Profile Sheets
Pneumatic controllers
Analog electronic controllers
Digital electronic controllers
further study.
Instrument Engineers Handbook, Volume 2: Process Control and Optimization, Béla G. Lipták (editor). Fourth
Dwyer Instruments, www.dwyer-inst.com
Emerson Electric Co., www.emerson.com
Micromod Automation and Controls, www.micromod.com
Omega Engineering, www.omega.com
M09_12206-16_LP.indd 4 5/9/16 4:10 PM

Controllers
Session One 3. S
ummarize electronic controllers and
list their key advantages over pneumatic
Session One introduces controllers and controllers.
summarizes the different ways in which they 4. D
iscuss the basic operation of an electronic
operate. While this module focuses largely controller and examine the different control
on automatic control, the other modes are configurations that they can use.
briefly explored. Pneumatic controllers
are summarized, as are the basic control 5. E
xamine several specific electronic
configurations. Several specific pneumatic controllers to connect theory to practice.
controllers are examined to connect the
discussion to real systems. This session covers
Sections 1.0.0 through 1.2.9. Session Three
1. Show the Session One PowerPoint ® Session Three is a laboratory session devoted
presentation. to the practice and completion of Performance
2. U
se the Kickoff Activity to get trainees Tasks 1 and 2.
engaged and to briefly review the big ideas of ote that no PowerPoint ® presentation is
1. N
process control. associated with this laboratory session.
3. S
ummarize the purpose and operation of a 2. Demonstrate how to explain the purpose
controller. and operation of all major components in a
4. Summarize the four control modes, stressing pneumatic controller.
automatic control as the most commonly 3. D
emonstrate how to explain the function of
used. each block in an electronic controller.
5. D
iscuss the basic operation of a pneumatic 4. T
rainees practice and/or complete the
controller and examine the different control requirements of Performance Tasks 1 and 2 in
configurations that they can use. this hands-on session.
6. E
xamine several specific pneumatic
controllers in order to connect theory to Session Four
practice.
Session Four is a review and testing session.
Session Two Have the trainees complete the Module Review
Session Two addresses electronic controllers as homework at the end of Session Three.
and compares them to pneumatic control. Go over the answers to the Review Questions
Advantages are stressed and the basic features in class prior to the exam and answer any
of an electronic controller are examined. The questions that the trainees may have.
same control configurations are examined 1. H
from an electronic-control perspective. Finally, Any outstanding performance testing must
several specific electronic controllers are be completed during this session as well.
surveyed. This session covers Sections 1.3.0
through 1.3.4. 2. R
of Training Modules form and submit the
1. Show the Session Two PowerPoint ® form to your Training Program Sponsor.
presentation.
2. Use the Kickoff Activity to help trainees see
the advantages of electronic control over
pneumatic control.
12206-16 Controllers Module Nine v
M09_12206-16_LP.indd 5 5/9/16 4:10 PM

Materials Checklist for Module 12206-16, Controllers

Personal protective equipment: Pneumatic controller
Pneumatic controllers
schematics
Electronic controller block
Safety glasses Analog electronic controllers
diagrams
Work gloves Digital electronic controllers
Proper footwear as designated
by the instructor or training
facility provider
designated by the instructor or
training facility provider
provider
Whiteboard
Markers
Pencils and paper
a DVD drive
Profile Sheets
M09_12206-16_LP.indd 6 5/9/16 4:10 PM

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Lesson Plans for Module 12207-16

Control Valves, Actuators, and Positioners

Objectives Performance Tasks

Teaching Time: 15.0 hours

12207-16 Control Valves, Actuators, and Positioners Module One iii

M01_12207-16_LP.indd 3 5/9/16 4:17 PM

Classroom Equipment Equipment and Materials for Laboratories

iv NCCER – Instrumentation Level Three 12207-16

M01_12207-16_LP.indd 4 5/9/16 4:17 PM

Control Valves, Actuators, and Positioners

Session One Session Three

12207-16 Control Valves, Actuators, and Positioners Module One v

M01_12207-16_LP.indd 5 5/9/16 4:17 PM

Control Valves, Actuators, and Positioners

Sessions Four and Five Session Six

vi NCCER – Instrumentation Level Three 12207-16

M01_12207-16_LP.indd 6 5/9/16 4:17 PM

Equipment and Materials

12207-16 Control Valves, Actuators, and Positioners Module One vii

M01_12207-16_LP.indd 7 5/9/16 4:17 PM

Objectives Learning Objective 4

Teaching Time: 25.0 hours

M02_12205-16_LP.indd 3 5/9/16 4:18 PM

Classroom Equipment and Materials Equipment and Materials

iv NCCER – Instrumentation Level Three 12205-16

M02_12205-16_LP.indd 4 5/9/16 4:18 PM

D etectors , S econdary E lements ,

Session One Session Three

12205-16 Detectors, Secondary Elements, Transducers, and Transmitters Module Two v

M02_12205-16_LP.indd 5 5/9/16 4:18 PM

D etectors , S econdary E lements ,

Session Five Sessions Seven through Nine

vi NCCER – Instrumentation Level Three 12205-16

M02_12205-16_LP.indd 6 5/9/16 4:18 PM

Equipment and Materials

Whiteboard Pressure gauges or capsules

Markers Capacitance level detector

M02_12205-16_LP.indd 7 5/9/16 4:18 PM

Instrumentation Electrical Circuitry

Objectives Learning Objective 4

12305-16 Instrumentation Electrical Circuitry Module Three iii

M03_12305-16_LP.indd 3 5/9/16 3:11 PM

Classroom Equipment Equipment and Materials for Laboratories

iv NCCER – Instrumentation Level Three 12305-16

M03_12305-16_LP.indd 4 5/9/16 3:11 PM

12305-16 Instrumentation Electrical Circuitry Module Three v

M03_12305-16_LP.indd 5 5/9/16 3:11 PM

Instrumentation Electrical Circuitry

Session One 1. Show the Session Two PowerPoint ®

vi NCCER – Instrumentation Level Three 12305-16

M03_12305-16_LP.indd 6 5/9/16 3:11 PM

Instrumentation Electrical Circuitry

Session Four 3. Introduce inductive circuits by explaining

12305-16 Instrumentation Electrical Circuitry Module Three vii

M03_12305-16_LP.indd 7 5/9/16 3:11 PM

Instrumentation Electrical Circuitry

Session Seven Session Nine

Session Eight Session Ten

viii NCCER – Instrumentation Level Three 12305-16

Session One 1. Show the Session Two PowerPoint ®

Session Four 3. Introduce inductive circuits by explaining

Session One 4. Introduce solar cells as an example of a

3. Introduce essential switch terminology and ote that no PowerPoint ® presentation is

4. Discuss the major switch classifications, 2. Demonstrate how to connect various

1. Show the Session Two PowerPoint ® 1. H

Session One 3. Introduce cable termination tools and the

Grounding and Shielding of Instrumentation Wiring