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John Wood Community College Workforce Development Center 4220 Koch’s Lane Quincy, IL 62305 Instructor: Stan Barnhart Phone: (217) 222-7054 JWCC Mail Box Location: WDC ELE 215 Electric Motors and Controls Spring 2011 COURSE CATALOG DESCRIPTION: A lecture/lab course covering the fundamentals of electrical and mechanical features of electrical motors and transformers. A thorough analysis of single-phase and 3-phase AC motors including repair and maintenance. A theoretical and practical approach to the operation, designing, and maintenance of relay logic motor controller diagrams and circuits. Extensive study of solid state controls including SCR’s, Triacs, and Unijunction devices, as well as fundamentals of solid state digital logic control circuits and a treatment of 3-phase power concepts, transformers, and protection devices. 1.5 lecture hours, 3 lab hours. PREREQUISITES: ELE 100 – Survey of Electrical Trade, ELE 110 – Introduction to Electricity, or consent of instructor. TEXT/REFERENCES: Rockis, Gary J., Mazur, Glen A., Electrical Motor Controls for Integrated Systems. Third Edition, Illinois, American Technical Publishers, Inc., 2005, ISBN 0-8269-1207-9. Rockis, Gary J., Mazur, Glen A., Electrical Motor Controls for Integrated Systems Workbook. Third Edition, Illinois, American Technical Publishers, Inc., 2005, ISBN 0-8269-1208-7. National Electrical Code Handbook-2007. Quincy, MA: National Fire Protection Association, 2007. 1 COURSE GOALS/OBJECTIVES: Students who satisfactorily complete this course will be able to perform these goals without the use of reference materials unless otherwise noted. Individual levels of performance will comply with standards set within the textbook or through classroom presentation. 1. Describe proper safety procedures when installing, operating, and maintaining equipment. Must demonstrate proper precautions in all lab activities. 2. Identify and describe the major parts of a split phase motor including the Stator, Rotor, Start Winding, Run Winding, Start Switches, and Thermal Overloads. 3. Explain the meaning of motor control by giving examples of typical motor control functions. 4. Describe the basic concept of automatic motor control and give examples of applications. 5. Describe the structure of AC motors by listing the basic components of an AC motor. 6. Explain the electrical and mechanical characteristics of motors by stating typical specifications of motors and what those specs mean. 7. Describe some applications of single-phase motors in industrial and consumer environments. 8. Explain what a ploy phase induction motor is and describe how it works. 9. Explain and demonstrate the reversal of a polyphase motor. 10. Describe applications and connections for two-speed motors by explaining how the motor is configured and connecting to external circuit components. 11. Describe wound-rotor motors and how they differ from wound stator motors. 12. Describe how synchronous motors operate and give examples of applications. 13. Explain how a basic DV motor works by describing each component and its function. 14. Explain dynamic braking by describing how electromagnetic fields perform the task. 15. Recognize schematic symbols of motors and control components and describe their functions. 16. Follow schematics of motor control circuits, demonstrate how to read the drawings, and explain what the circuits are doing. 17. Define full-voltage and reduced-voltage starting by defining what they are and how they differ. 18. Explain the specific differences between wound-motor starting and synchronous motor starting. 19. Describe basic motor protection circuits by explaining possible motor failures and the prevention of those failures. 20. Describe starting a basic DC motor in electro-magnetic terms. 21. Explain what a relay is, how it works, and its applications in motor circuits. 22. Explain the difference between a Voltage Relay and a Current Relay by describing how each works. 23. Describe what a tine delay relay is and its application to motor circuits. 24. Describe an Overload Relay; its function, and its necessity. 25. Describe an automatic motor starter by explaining how it works. 26. Describe the difference between a Full-Voltage Starter and a Reduced-Voltage Starter by defining the requirements of their individual applications. 2 27. Describe 2 types of Speed Control Starters and explain how each works. 28. Define a Magnetic Starter for multi-speed motors by explaining how the components work. 29. Describe the Reversing Starter and how it is wired by explaining how the reversing action actually occurs. 30. Define a wound motor-rotor motor starter by describing each component and its function. 31. Describe a Capacitor Run motor and discuss a need for the capacitor. 32. Describe how to check/troubleshoot a capacitor by demonstrating doing it with an ohmmeter. 33. Explain a series motor starter by describing how it works. 34. Be able to identify worn brushes and burnt armatures by demonstrating the ability to identify them. 35. Be able to check windings for shorts and grounds by demonstrating how to check them with an ohmmeter. 36. Know the meaning of End Play and Bearing Play by demonstrating how to check for them. 37. Replace bearings in lab. 38. Define a Pressure Switch, Limit Switch, and a Flow Switch by describing their application. 39. Identify all basic symbols used in motor control circuits by reading motor control drawings. 40. Read and follow Ladder Diagrams. 41. Describe the operation of Sequence-Control circuit, follow sequence-control circuit drawings, and explain how they work. 42. Explain the operation of motor control circuits with limit switches by explaining why they are needed. 43. Define a Jogging Control by explaining its purpose and how it is achieved. 44. Describe an Automatic Plugging Control by explaining its purpose and how it is achieved. 45. Explain the operation of an Acceleration Control by explaining its purpose and how it is achieved. 46. Define Preselected Speed Control for a DV shunt motor by describing an application and how it works in that application. 47. Read drawings that depict forward and reverse control. 48. Demonstrate competency in reading drawings that depict start, stop, and jog control. 49. Describe a primary resistance reduced-voltage starter by explaining how it works. 50. Define a line contactor by explaining how it works. Explain the function of an accelerating resistor by defining its purpose and application. 51. Explain the function of an overload relay by defining its purpose and application. 52. Describe how a dynamic braking contactor works by explaining the action of the circuit components involved. 53. Define plugging and antiplugging relays by explaining why and how they are used. 54. Describe causes of trouble and maintenance procedures for motor starters by demonstrating proper maintenance procedures. 3 55. Explain how to maintain brakes and clutches by demonstrating how to inspect and maintain them properly. 56. Describe a general step-by-step procedure for troubleshooting control circuits using a volt ohmmeter and/or an oscilloscope. 57. Explain the function of a motor control center by defining its purpose and why it’s needed. 58. Define solid-state motor controllers by explaining their operation and reliability advantages. 59. Describe the function of a diode by explaining its operational characteristics and demonstrating its operation with an ohmmeter. 60. Describe the function of a Zener diode by explaining its operational characteristics. 61. Explain the characteristics of a tunnel diode by explaining its application to motor control circuits. 62. Describe the operation of NPN and PNP transistors by explaining their operational characteristics and their differences. 63. Define a unijunction transistor by explaining its application to motor control circuits. 64. Explain the operational characteristics and applications of SCR’s. 65. Explain the operational characteristics and applications of light activated semiconductors. 66. Describe the function of triacs and diacs by explaining their operational characteristics and applications. 67. Describe basic solid-state starter relays for DC and AC motors and discuss their operation and function. 68. Define a bridge rectifier by explaining what it does then demonstrate how it works with an ohmmeter. 69. Explain the firing function of SCR’s and triacs in motor circuits by describing their behavior and function in motor circuits. 70. Define the basic function of digital logic circuits and their characteristics. 71. Explain the operation and application of a basic transistor switch. 72. Describe basic operation of AND, OR, NAND, NOR, Buffer, and Inverter circuits by demonstrating with Truth tables. 73. Demonstrate the voltage levels associated with TTL logic gates by measuring the levels with a voltmeter. 74. Demonstrate the voltage levels associated with CMOS logic gates by measuring the levels with a voltmeter. 75. Describe a basic latch circuit by using circuit gates to explain action. 76. Describe a J-K Flip-Flop by using circuit gates to explain action. 77. Troubleshoot logic circuits by using a voltmeter and/or oscilloscope. 78. Operate a basic DC power supply and explain their function and application. 79. Operate a voltage regulator and explain their function and application. 80. Troubleshoot DC power supplies by using a voltmeter and /or oscilloscope. 4 COURSE OUTLINE: Course schedule is subject to change with notification of instructor. Week 1: Week 2: Chapter 3 Chapter 7 Week 3: Chapter 6 Week 4: Review/Chapter 4 Week 5: Week 6: Week 7: Week 8: Week 9: Week 10: Test over Chapters 3, 6, 7 Chapter 14 Chapter 8 Review/Chapter 9 Test over Chapters 4, 14, 8 Handouts/Chapter 5 Week 11: Chapter 18 Week 12: Review/Chapter 19 Week 13: Test over Chapters 9, 18, 5, and handouts Chapter 12 Solid state devices and system integration Review for Final Final Exam Week 14: Week 15: Week 16: 5 Electrical Safety. AC Generators, transformers, and Motors Solenoids, DC generators, and motors Electrical symbols and diagrams Relays and solid-state starters Contactors and Motor Starters Control Devices Ladder logic diagram and sequence control Accelerating and Decelerating Methods Preventative Maintenance and Troubleshooting HOMEWORK SCHEDULE: Workbook chapter 1 Workbook chapter 3 Workbook chapter 7 Workbook chapter 6 Workbook chapter 4 Workbook chapter 14 Workbook chapter 8 Workbook chapter 9 Workbook chapter 5 Workbook chapter 18 Workbook chapter 19 Workbook chapter 12 Pages 6-13 Pages 21-26 Pages 65-72 Pages 55-64 Pages 27-34 Pages 155-168 Pages 73-88 Pages 89-98 Pages 35-54 Pages 221-236 Pages 237-248 Pages 123-136 STUDENT CONTRIBUTIONS: 1. Attendance: Each student should plan on spending at least two hours per hour of instruction preparing for class. Lessons build upon the concepts presented in previous lessons, so attendance in both lectures and laboratories is critical. You are responsible for the material presented in class. It is expected that students will attend all meetings of class. Late arrival will count as an absence. Students who miss over three class sessions will have their final grade reduced. Excessive absence will result in the student being administratively withdrawn from the course. 2. Class assignments: Work submitted late will NOT be accepted. All homework and outside assignments are due on or before the date set by the instructor. All in-class assignments are due on the day of the assignment. 3. Exams and quizzes: All tests and quizzes are to be completed on the day they are given. Students missing tests for justifiable reasons will be allowed to make up the tests at the discretion of the teacher. 4. Disabilities: Students who feel they are not able to meet the requirements of the course should contact the instructor, a counselor, or Student Services immediately. Every effort will be made to accommodate student disabilities at the beginning of the semester. Incomplete grades will NOT be awarded on the basis of avoidable conditions. 6 DROP POLICY: Following a withdrawal for courses eight weeks or longer, grades are recorded as follows: Drop during first ten days of the semester No grade recorded; class does not appear on transcript W WI Drop up to midterm Drop after midterm, up to 75% completion of the course Drop after 75% completion of the course Grade earned, A-B-C-D-F, as outlined in the syllabus For courses more than two days but less than eight weeks: Drop during first five days of the semester No grade recorded; class does not appear on transcript W WI Drop up to midterm Drop after midterm, up to 75% completion of the course Drop after 75% completion of the course Grade earned, A-B-C-D-F, as outlined in the syllabus ACCOMMODATIONS FOR A DISABILITY: Students with disabilities who believe they have accessibility needs or the need for academic accommodations must contact Disability Services, where those concerns are handled. Disability Services is located within the Support Center in the Student/Administrative Center building on the Quincy campus. 7 COURSE EVALUATION: 1. 2. 3. 4. Tests: There will be three announced, major tests during the course, plus the final. Homework: Homework will be assigned periodically through the course. Lab assignments: Lab assignments will be graded. Percentage Grading Scale 90-100 A 80-89 B 70-79 C 60-69 D 0-59 F Final Grade Tests (5) Homework Lab grades 50% 10% 40% NOTE: Final Exam is worth 2 test grades. COURSE SCHEDULE: This course will meet on Thursdays from 6:00 to 9:45 PM in Room W139 of the JWCC Workforce Development Center, 4220 Koch’s Lane, Quincy, IL. Class Cancelation notice: Go to Current Students tab on the JWCC Home Page - http://www.jwcc.edu/ Inclement Weather – notification of school closings: 217-641-4100 or the JWCC Home Page – http://www.jwcc.edu/ JWCC Core Values Self-development, Excellence, Accountability, Integrity This workforce solution was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training Administration. The solution was created by the grantee and does not necessarily reflect the official position of the U.S. Department of Labor. The Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timelines, usefulness, adequacy, continued availability, or ownership. This solution is copyrighted by the institution that created it. Internal use, by an organization and/or personal use by an individual for non-commercial purposes, is permissible. All other uses require the prior authorization of the copyright holder. 8