COURSE SYLLABUS. COURSE NUMBER AND TITLE: INTC-1357 AC/DC Motor Controls (2-4-3)

Transcription

1 COURSE NUMBER AND TITLE: INTC-1357 AC/DC Motor Controls (2-4-3) COURSE SYLLABUS COURSE (CATALOG) DESCRIPTION A study of electric motors and motor control devices common to a modern industrial environment. A presentation of motor data characteristics with emphasis on starting, speed control, and stopping systems. INSTRUCTOR: George Lister OFFICE HOURS: M F 9am -5pm OFFICE PH: INSTRUCTOR ADDRESS: george.lister@tstc.edu MAJOR COURSE REQUIREMENTS: LAP 1 INTRODUCTION TO ELECTRIC MOTOR CONTROL SEGMENT 1 ELECTRICAL SAFETY Activity 1 System familiarization SKILL 1 Perform a lockout/tagout SKILL 2 Use a voltmeter to verify supply voltage SEGMENT 3 DISCONNECTS AND PROTECTIVE DEVICES SKILL 3 Use a digital multimeter to check the condition of a fuse Activity 2 Size Circuit Protection SEGMENT 4 THREE-PHASE MOTORS SKILL 4 Connect a dual-voltage three-phase motor for low voltage operation SKILL 5 Connect a dual-voltage three-phase motor for high voltage operation LAP 2 MANUAL MOTOR CONTROL AND OVERLOAD PROTECTION SEGMENT 1 MANUAL MOTOR CONTROL SKILL 1 Connect and operate a simple motor control circuit SEGMENT 2 MANUAL MOTOR STARTER OPERATION Activity 1 Test the operation of a manual motor starter using a multimeter SKILL 2 Start and stop a motor using a manual starter Activity 2 Test the low-voltage protection capabilities of a manual starter SEGMENT 3 OVERLOAD PROTECTION SKILL 3 Set the trip level of a bimetallic overload Activity 3 Test the operation of a bimetallic overload SKILL 4 Select the correct heaters for a NEMA overload LAP 3 CONTROL TRANSFORMERS

2 SEGMENT 1 INTRODUCTION TO TRANSFORMERS SKILL 1 Calculate the turns ratio of a transformer SKILL 2 Calculate the secondary voltage of a transformer SEGMENT 2 CONTROL TRANSFORMER OPERATION SKILL 3 Connect and operate a control transformer SKILL 4 Test a control transformer SEGMENT 3 CONTROL TRANSFORMER APPLICATIONS IN MACHINE CONTROL SKILL 5 Size a control transformer LAP 4 CONTROL LADDER LOGIC SEGMENT 1 ELECTRICAL CONTROL SYSTEM BASICS SKILL 1 Connect and operate a basic electrical control circuit which uses a pushbutton switch SKILL 2 Connect and operate a basic electric control circuit using a selector switch SEGMENT 2 LADDER DIAGRAM BASICS SKILL 3 Draw a ladder diagram of a control circuit SKILL 4 Determine the operation of a control circuit given a ladder diagram SKILL 5 Connect and operate a control circuit given a ladder diagram SEGMENT 3 LOGIC ELEMENTS 1 SKILL 6 Connect and operate an AND logic circuit SKILL 7 Connect and operate an OR logic circuit SEGMENT 4 LOGIC ELEMENTS 2 SKILL 8 Connect and operate a NOT logic circuit SKILL 9 Connect and operate a NOR logic circuit SKILL 10 Connect and operate a NAND logic circuit SKILL 11 Design a multiple start/stop pushbutton station control circuit LAP 5 CONTROL RELAYS AND MOTOR STARTERS SEGMENT 1 CONTROL RELAYS SKILL 1 Connect and operate a control relay in a circuit OBJECTIVE 5 Describe the operation of memory logic and give an application SKILL 2 Connect and operate a memory logic circuit SEGMENT 2 MAGNETIC MOTOR STARTERS Activity 1 Identification of the basic components of a magnetic motor contactor SKILL 3 Connect and operate a magnetic motor starter connected to a three-phase motor SEGMENT 3 TWO-WIRE CONTROL SKILL 4 Connect and operate a two-wire motor control circuit SEGMENT 4 THREE-WIRE START/STOP CONTROL SKILL 5 Connect and operate a three-wire motor control circuit SKILL 6 Design a multiple operator station three-wire control circuit SKILL 7 Connect and operate a three-wire control circuit with a push-to-test pilot light LAP 6 INTRODUCTION TO TROUBLESHOOTING SEGMENT 1 INTRODUCTION TO TROUBLESHOOTING

3 SKILL 1 Test an indicator lamp SEGMENT 2 CONTROL COMPONENT TROUBLESHOOTING SKILL 2 Test a manual switch SKILL 3 Test a control relay SEGMENT 3 MOTOR STARTER TROUBLESHOOTING SKILL 4 Test a motor contactor SKILL 5 Test an overload relay SEGMENT 4 POWER COMPONENT TROUBLESHOOTING SKILL 6 Test the windings of a 3-phase motor with a digital multimeter SKILL 7 Test the windings of a control transformer with a digital multimeter LAP 7 SYSTEMS TROUBLESHOOTING SEGMENT 1 TEST EQUIPMENT FOR TROUBLESHOOTING SKILL 1 Select and use a DMM to measure voltage for a given application SKILL 2 Select and use a voltage tester (wiggy) for a given application SKILL 3 Select and use a clamp-on ammeter for a given application SKILL 4 Select and use a continuity tester for a given application SEGMENT 2 INTRODUCTION TO SYSTEMS TROUBLESHOOTING SKILL 5 Perform and analyze circuit signal tests SKILL 6 Use the symptom and cause troubleshooting method to isolate a bad component SEGMENT 3 SYSTEM TROUBLESHOOTING METHODS SKILL 7 Use the output-back troubleshooting method to isolate a bad component SKILL 8 Use the half-split troubleshooting method to isolate a bad component SKILL 9 Use the shotgun troubleshooting method to isolate a bad component SEGMENT 4 TROUBLESHOOTING APPLICATION SKILL 10 Troubleshoot a 2-wire control system SKILL 11 Troubleshoot a 3-wire control system LAP 8 REVERSING MOTOR CONTROL SEGMENT 1 MANUAL MOTOR REVERSING SKILL 1 Connect and operate a drum switch to reverse a motor SEGMENT 2 REVERSING MAGNETIC MOTOR STARTER SKILL 2 Connect and operate a reversing magnetic motor starter to reverse a motor SKILL 3 Design a motor reversing circuit that uses a drum switch and a magnetic motor Starter SEGMENT 3 INTERLOCKING FOR REVERSING MOTOR CONTROL SKILL 4 Connect and operate a reversing motor circuit with mechanical and auxiliary contact interlocking SKILL 5 Troubleshoot a reversing motor control circuit SKILL 6 Design a reversing motor control circuit that uses pushbutton interlocking SEGMENT 4 MODES OF OPERATION OBJECTIVE 7 Describe the function of manual and automatic modes and give an application of each SKILL 7 Connect and operate a control circuit to jog a motor SKILL 8 Connect and operate a forward/reverse jog control circuit

4 SKILL 9 Troubleshoot a circuit that has manual and automatic modes SEGMENT 5 H-O-A CONTROL SKILL 10 Connect and operate a hand-off-automatic motor control circuit SKILL 11 Design a hand-off-automatic motor control circuit LAP 9 AUTOMATIC INPUT DEVICES 1 SEGMENT 1 LIMIT SWITCHES SKILL 1 Connect and operate a limit switch SKILL 2 Design an overhead door motor control circuit SEGMENT 2 FLOAT SWITCHES SKILL 3 Connect and operate a float switch SKILL 4 Connect and operate a pump control circuit SEGMENT 3 PRESSURE SWITCHES SKILL 5 Connect and operate a pressure switch SKILL 6 Design a pump control circuit that includes H-O-A operation SKILL 7 Test an automatic input switch SEGMENT 4 SEQUENCE CONTROL SKILL 8 Connect and operate a sequence control circuit SKILL 9 Troubleshoot a sequence control circuit SKILL 10 Design a sequence control circuit LAP 10 BASIC TIMER CONTROL: ON-DELAY AND OFF-DELAY SEGMENT 1 ON-DELAY TIMERS Activity 1 Identify the basic components of a multi-function timer SKILL 1 Connect and operate an On-Delay timer circuit SKILL 2 Design a control circuit to perform an unloaded start of a motor SEGMENT 2 OFF-DELAY TIMERS SKILL 3 Connect and operate an Off-Delay timer circuit SKILL 4 Design a motor control circuit to perform time-driven sequencing SEGMENT 3 TROUBLESHOOTING SKILL 5 Test a timer relay SKILL 6 Troubleshoot an On-Delay timer circuit SKILL 7 Troubleshoot an Off-Delay timer circuit In each unit you will be given a lecture/demonstration and then be expected to perform the assignments for each unit. Each assignment will be demonstrated and explained so that you can then attempt it. After each unit there will be a knowledge exam and a performance exam. Each exam is based on the information discussed during the lecture, the reading assignments and the lab assignments given. LEARNING OBJECTIVES: LAP 1 INTRODUCTION TO ELECTRIC MOTOR CONTROL SEGMENT 1 ELECTRICAL SAFETY OBJECTIVE 1 Explain the importance of the equipment ground connection

5 OBJECTIVE 2 Describe the function of five common standards associated with electrical control OBJECTIVE 3 Describe ten basic rules of electrical safety OBJECTIVE 4 Describe the purpose of the lockout/tagout system used in industry SEGMENT 2 THREE-PHASE POWER OBJECTIVE 5 Describe the operation of three-phase power OBJECTIVE 6 Describe the two most common three-phase voltage systems OBJECTIVE 7 Explain the function of neutral OBJECTIVE 8 Describe the operation of grounded and ungrounded systems SEGMENT 3 DISCONNECTS AND PROTECTIVE DEVICES OBJECTIVE 9 Describe two devices used to disconnect power to a circuit OBJECTIVE 10 Explain why time-delay fuses are used with motor starting circuits OBJECTIVE 11 Describe three important factors to consider with overcurrent protection devices Activity 2 Size Circuit Protection SEGMENT 4 THREE-PHASE MOTORS OBJECTIVE 12 Describe the operation of a three-phase motor OBJECTIVE 13 Describe the operating data on a motor's nameplate OBJECTIVE 14 Define service factor and explain its importance SKILL 4 Connect a dual-voltage three-phase motor for low voltage operation OBJECTIVE 15 Explain why dual-voltage motors should be run on the highest available voltage LAP 2 MANUAL MOTOR CONTROL AND OVERLOAD PROTECTION SEGMENT 1 MANUAL MOTOR CONTROL OBJECTIVE 1 Describe five functions of motor control OBJECTIVE 2 Describe the four basic requirements of a typical motor installation OBJECTIVE 3 Define motor controller and motor starter SEGMENT 2 MANUAL MOTOR STARTER OPERATION OBJECTIVE 4 Describe the functions of two categories of motor starters OBJECTIVE 5 Describe the functions of two types of manual starters OBJECTIVE 6 Describe the operation of a manual motor starter OBJECTIVE 7 Define low-voltage protection and describe its importance OBJECTIVE 8 Describe how low-voltage protection is accomplished in a manual starter SEGMENT 3 OVERLOAD PROTECTION OBJECTIVE 9 Describe the function of three types of overloads and give an application of each OBJECTIVE 10 Describe the operation of two types of thermal overloads OBJECTIVE 11 Describe the operation of a magnetic overload SKILL 4 Select the correct heaters for a NEMA overload LAP 3 CONTROL TRANSFORMERS SEGMENT 1 INTRODUCTION TO TRANSFORMERS OBJECTIVE 1 Describe the operation of a transformer and give its schematic symbol OBJECTIVE 2 Define turns ratio and describe how it is calculated OBJECTIVE 3 Describe how the turns ratio determines the secondary voltage of a transformer SEGMENT 2 CONTROL TRANSFORMER OPERATION OBJECTIVE 4 Describe the function of the four basic components of an electrical control circuit OBJECTIVE 5 Describe the function of an electrical schematic diagram OBJECTIVE 6 Describe the function of a control transformer OBJECTIVE 7 Describe the operation of a control transformer and give its schematic symbol OBJECTIVE 8 Describe how to test a transformer

6 SEGMENT 3 CONTROL TRANSFORMER APPLICATIONS IN MACHINE CONTROL OBJECTIVE 9 Describe how to size a transformer OBJECTIVE 10 Describe the operation of a separate control circuit LAP 4 CONTROL LADDER LOGIC SEGMENT 1 ELECTRICAL CONTROL SYSTEM BASICS OBJECTIVE 1 Describe the function of three types of electrical control systems and give an application of each OBJECTIVE 2 Describe the three steps of a control process OBJECTIVE 3 Describe the function of an indicator lamp and give an application OBJECTIVE 4 Describe the operation of a pushbutton switch and give its schematic symbol OBJECTIVE 5 Describe the operation of a selector switch and give its schematic symbol SEGMENT 2 LADDER DIAGRAM BASICS OBJECTIVE 6 Describe the function of a ladder diagram OBJECTIVE 7 Describe the function of four components of a ladder diagram OBJECTIVE 8 Describe six rules of drawing a ladder diagram OBJECTIVE 9 Describe how to determine the operation of a circuit given a ladder diagram SEGMENT 3 LOGIC ELEMENTS 1 OBJECTIVE 10 List six elements of control logic OBJECTIVE 11 Describe the operation of AND logic and give an application OBJECTIVE 12 Describe the operation of OR logic and give an application SEGMENT 4 LOGIC ELEMENTS 2 OBJECTIVE 13 Describe the operation of NOT logic and give an application OBJECTIVE 14 Describe the operation of NOR logic and give an application OBJECTIVE 15 Describe the operation of NAND logic and give an application LAP 5 CONTROL RELAYS AND MOTOR STARTERS SEGMENT 1 CONTROL RELAYS OBJECTIVE 1 Describe the function of a control relay and give an application OBJECTIVE 2 Describe the operation of a control relay and give its schematic symbol OBJECTIVE 3 Describe the operation of two types of control relays and give an application of each OBJECTIVE 4 Describe how detached symbology is used to show a control relay on a ladder diagram OBJECTIVE 5 Describe the operation of memory logic and give an application SEGMENT 2 MAGNETIC MOTOR STARTERS OBJECTIVE 6 Describe the operation of a magnetic motor starter SEGMENT 3 TWO-WIRE CONTROL OBJECTIVE 7 Describe the operation of a two-wire motor control circuit and give an application SEGMENT 4 THREE-WIRE START/STOP CONTROL OBJECTIVE 8 Describe the operation of a three-wire motor control circuit and give an application OBJECTIVE 9 Describe the function of a push-to-test pilot light and give an application OBJECTIVE 10 Describe the operation of a push-to-test pilot light and give its schematic symbol LAP 6 INTRODUCTION TO TROUBLESHOOTING SEGMENT 1 INTRODUCTION TO TROUBLESHOOTING

7 OBJECTIVE 1 Describe two levels of troubleshooting and give an application of each OBJECTIVE 2 Describe the three methods of testing a component and give an application of each OBJECTIVE 3 Describe how to test an indicator lamp SEGMENT 2 CONTROL COMPONENT TROUBLESHOOTING OBJECTIVE 4 Describe how to test a manual switch OBJECTIVE 5 Describe how to test a control relay SEGMENT 3 MOTOR STARTER TROUBLESHOOTING OBJECTIVE 6 Describe how to test a motor contactor OBJECTIVE 7 Describe how to test an overload relay SEGMENT 4 POWER COMPONENT TROUBLESHOOTING OBJECTIVE 8 Describe how to test the windings of a 3-phase motor with a digital multimeter LAP 7 SYSTEMS TROUBLESHOOTING SEGMENT 1 TEST EQUIPMENT FOR TROUBLESHOOTING OBJECTIVE 1 Describe the function of four common electrical test instruments used in troubleshooting OBJECTIVE 2 Describe how to select a DMM to measure voltage for a given application OBJECTIVE 3 Describe how to use a voltage tester (wiggy) OBJECTIVE 4 Describe how to use a clamp-on ammeter OBJECTIVE 5 Describe how to use a continuity tester SEGMENT 2 INTRODUCTION TO SYSTEMS TROUBLESHOOTING OBJECTIVE 6 Describe a six step troubleshooting sequence OBJECTIVE 7 Describe four methods of systems level troubleshooting and give an advantage of each OBJECTIVE 8 Describe five types of in-circuit component tests OBJECTIVE 9 Describe how to test and analyze circuit signals SEGMENT 3 SYSTEM TROUBLESHOOTING METHODS SEGMENT 4 TROUBLESHOOTING APPLICATION LAP 8 REVERSING MOTOR CONTROL SEGMENT 1 MANUAL MOTOR REVERSING OBJECTIVE 1 State the NEMA and IEC standard for reversing the rotation of a three-phase motor OBJECTIVE 2 List two common control methods used to reverse a three-phase motor OBJECTIVE 3 Describe the function and operation of a drum switch SEGMENT 2 REVERSING MAGNETIC MOTOR STARTER OBJECTIVE 4 Describe the function and operation of a reversing magnetic motor starter SEGMENT 3 INTERLOCKING FOR REVERSING MOTOR CONTROL OBJECTIVE 5 Describe the function of interlocking control and give an application OBJECTIVE 6 Describe three interlocking methods used in reversing motor control SEGMENT 4 MODES OF OPERATION OBJECTIVE 7 Describe the function of manual and automatic modes and give an application of each OBJECTIVE 8 Describe the operation of two types of motor jogging circuits

8 SEGMENT 5 H-O-A CONTROL OBJECTIVE 9 Describe the operation of a hand-off-automatic motor control circuit LAP 9 AUTOMATIC INPUT DEVICES 1 SEGMENT 1 LIMIT SWITCHES OBJECTIVE 1 Describe the functions of four types of automatic input devices and give an application of each OBJECTIVE 2 Describe the operation of a limit switch and give its schematic symbol SEGMENT 2 FLOAT SWITCHES OBJECTIVE 3 Describe the operation of a float switch and give its schematic symbol OBJECTIVE 4 Describe the operation of a pump control circuit SEGMENT 3 PRESSURE SWITCHES OBJECTIVE 5 Describe the operation of a pressure switch and give its schematic symbol OBJECTIVE 6 Describe how to test an automatic input switch SEGMENT 4 SEQUENCE CONTROL OBJECTIVE 7 Describe the function of a sequence control circuit and give an application OBJECTIVE 8 Describe the operation of a sequence control LAP 10 BASIC TIMER CONTROL: ON-DELAY AND OFF-DELAY SEGMENT 1 ON-DELAY TIMERS OBJECTIVE 1 Describe the function of a time-delay relay and give an application OBJECTIVE 2 Describe the function of two types of timer relays and give an application of each OBJECTIVE 3 Describe the operation of an On-Delay timer relay and give its schematic symbol OBJECTIVE 4 Describe the operation of a timer relay in an unloaded motor start circuit SEGMENT 2 OFF-DELAY TIMERS OBJECTIVE 5 Describe the operation of an Off-Delay timer relay and give its schematic symbol OBJECTIVE 6 Describe the operation of a time-delay relay in time-driven sequencing SEGMENT 3 TROUBLESHOOTING OBJECTIVE 7 Describe how to test a timer relay REQUIRED TEXTBOOK: None REQUIRED MATERIALS Safey glasses GRADING CRITERIA GRADING SCALE GRADING CRITERIA: GRADING SCALE: Unit exams 40% 95 to 100% A Lab Participation 30% 85 to 94% B Assignments 10% 75 to 84% C Final Performance 10% 65 to 74% D Final Exam 10% Below 64% F MAKE UP EXAMINATIONS Only students with documented excuses (hospital, doctor s note, etc.) will be considered

9 for make-up examination. Any make-up test may be different from that administered to the class. Make-up tests must be made up within three (3) days of returning to class or forfeit the grade. Make-up test will receive a ten percent (10%) reduction off the total score for that particular exam. For example, if you receive 80 points out of a total of 100 points in a make-up test, your score will be deducted 10 points (which is ten percent of 100), so the final score is 70. Only one make up test is allowed. If you miss additional work, those tests will be recorded as zeros (0 s) and may not be made up. Curving of scores and dropping of grades is not done and should not be expected. There will be a comprehensive exam at the end of the semester. DEPARTMENT PARTICIPATION POLICY: It will be the student s responsibility to read all assigned chapters, complete lab exercises, to attend all lectures, and to be in class on time. There will be open discussion and analysis of all circuitry in which your participation is expected. ACCOMMODATION STATEMENT: "If you have a documented disability which will make it difficult for you to carry out the work as the instructor has outlined and/or if you need special accommodations due to a disability, please contact (956) or visit Support Services located in the Tech Prep Bldg. P as soon as possible to make appropriate arrangements." CLASS POLICIES: Copyright Statement The materials used in the course (textbooks, handouts, media files (podcast, MP3, Videos, RSS Feeds), and all instructional resources on the colleges Learning Management System (Moodle) are intended for use only by students registered and enrolled in this course, and are only to be used for instructional use, activities associated with, and for the duration of the course. By "handouts," this means all materials generated for this course, which includes but are not limited to syllabi, quizzes, exams, lab problems, in-class materials, review sheets, and any additional materials. These materials may not be retained in another medium or disseminated further. They are provided in compliance with the provisions of the Teach Act. These materials may not be reproduced, displayed, modified or distributed without the express prior written permission of the copyright holder or TSTC. For further information contact your instructor. Communicating with your instructor (MyMail System) The use of Your Mymail TSTC College student account will be the only way to receive official notices from the college. When communicating with instructors and/or employees of the college you are required to use your TSTC Mymail student address. If you choose to forward your to another account, please be advised that all communication from and within the college will use your Mymail student .

10 "TSTC Harlingen faculty, staff, and students are asked to report all threats, perceived or real, immediately to College Police located in the Auxiliary Building. If the threat is imminent, the College Police emergency phone line at or should be called. College Police will then coordinate the proper response in accordance with State and federal laws and TSTC System/College rules and regulations." NOTE: Any changes to this document will be provided in writing to the student