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200-Hour Dislocated Workers’ Advanced Manufacturing/ Integrated Systems Technology Curriculum The 200-Hour Dislocated Workers’ Advanced Manufacturing/Integrated Systems Technology (AM/IST) curriculum is organized into three components: Electrical, Electronic and Mechanical. Each community college participating in the AM/IST grant received more curriculum than what is needed to complete the 200-Hour Dislocated Workers’ AM/IST curriculum. The areas that are shaded in gray are considered to be enhancement activities. Hence, these portions may be completed as time allows, but should not be considered as part of the core curriculum. They should be completed only if time permits. 1 ELECTRICAL 2 AC/DC ELECTRICAL SYSTEMS Objectives 1 2 3 4 5 6 7 8 9 10 11 12 Define electricity and give an application Describe the two types of electrical current and give an application of each Describe the function and operation of a circuit tester Describe the function of the four basic components of an electric circuit Describe the operation of two types of power supplies and give their schematic symbols Describe the function of an electrical schematic Describe the operation of a manual switch Describe the operation of N.O. and N.C. contacts and give their schematic symbols Describe the function of three types of manual switch operators and give an application of each Describe the operation of three types of manual switch operators and give their schematic symbols Describe the function of five types of electrical output devices and give an application of each Describe the operation of five types of electrical output devices and give their schematic symbols Skills 1 2 3 4 5 6 7 Use an AC tester to check a wall outlet for electricity Connect and operate a power supply Connect and operate a circuit using three types of manual switches Connect and operate an electrical circuit with a resistor Connect and operate an electrical circuit with a buzzer Connect and operate an electrical circuit with a solenoid Connect and operate an electrical circuit with a motor Objectives 1 2 3 4 5 Define voltage and give its units of measurement Describe the function of two types of voltmeters and give their schematic symbol Describe how to use a voltmeter to measure voltage Describe the function of two multimeters: analog and digital Define series and parallel circuits 3 6 7 8 9 10 11 12 13 14 15 Describe the voltage characteristics in series and parallel circuits Define current and give its units of measurement Describe the function of two types of ammeters and give their schematic symbol Describe how to use an ammeter to measure current Describe the current characteristics in series and parallel circuits Define resistance and give its units of measurement Describe the function of two types of ohmmeters and give their schematic symbol Describe how to use an ohmmeter to measure resistance Describe the resistance characteristics in series and parallel circuits Describe two methods of measuring continuity Skills 1 2 3 4 5 6 7 8 Use an analog voltmeter to measure the voltage at a point referenced to ground Use a DMM to measure the voltage of a point referenced to ground Use a DMM to measure voltage drops in series and parallel circuits Use a DMM to measure the electrical current Use a DMM to measure current in series and parallel circuits Use a DMM to measure the resistance of a component Measure the resistance in series and parallel circuits Test the continuity of wires using a DMM Objectives 1 2 3 4 5 6 7 8 9 10 State the formula for calculating series resistance and give an application State Ohm's Law, explain its importance and give an application State Kirchhoff's voltage law for a series circuit and give an application Define power and give its units of measurement State a formula for calculating the total power used in an electrical circuit State Kirchhoff's Current Law and give an application State a formula for calculating total parallel resistance Describe the function of two types of circuit protection and give an application of each Describe the operation of a fuse and give its schematic symbol Describe the operation of two types of circuit breakers and give their schematic symbols Skills 1 2 3 4 5 6 7 8 Calculate series resistance given each load's resistance Use Ohm's Law to calculate voltage, current, and resistance in a series circuit Calculate the total power used by a series circuit Calculate the main line current in a parallel circuit Calculate the total parallel resistance Calculate the total power used in a parallel circuit Operate a circuit using a fuse Test and replace a fuse 4 9 10 Operate a circuit using a circuit breaker Test and reset a circuit breaker 5 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Define electromagnetism and give an application Describe the functions of four electromagnetic devices Define inductance and give its units of measurement Describe the operation of an inductor and give its schematic symbol Describe the effect of an inductor in a DC circuit and give an application Describe the effect of an inductor in an AC circuit and give an application State the formulas for calculating total series inductance and inductive reactance State the formulas for calculating total parallel inductance and inductive reactance Define capacitance and give its units of measurement Describe the operation of a capacitor and give its schematic symbol Describe the functions of three types of capacitors Describe the effect of a capacitor in a DC circuit and give an application Describe the effect of a capacitor in an AC circuit and give an application State the formulas for calculating total series capacitance and capacitive reactance State the formulas for calculating total parallel capacitance and capacitive reactance Describe the function of a fluorescent light fixture Describe the function of an RC timing circuit in a time-delay relay Describe the function of capacitors and inductors in electric power supplies Skills 1 2 3 4 5 6 7 Connect and operate a relay in a circuit Calculate the total load on an AC circuit with inductors Discharge a capacitor Test a capacitor with a DMM Measure the voltage across a charged capacitor Calculate the total load on an AC circuit with capacitors Calculate the time to charge and discharge a capacitor Objectives 1 2 3 4 5 6 7 8 9 Define a series-parallel circuit Describe a method for identifying the series and parallel sections of a circuit Describe the seven steps for solving a combination circuit Describe how switches are used in combination circuits and give an application Describe the function of a variable resistor and give an application Describe the function of a voltage divider and give an application Describe the operation of three types of voltage dividers Explain the effect of a short circuit Describe the four steps for troubleshooting a short circuit 6 10 Describe the three basic steps for troubleshooting an open circuit Skills 1 2 3 4 5 6 7 8 9 Trace the current path in a combination circuit Solve a combination circuit Connect and operate a basic lighting circuit Connect and operate a ceiling fan circuit Connect and operate a rheostat as a light dimmer Design a voltage divider network Connect and operate a voltage divider network Locate a short circuit Locate an open circuit 7 ELECTRICAL MOTOR CONTROL Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Explain the importance of the equipment ground connection List ten basic rules of electrical safety Describe the purpose of the lockout/tagout system used in industry Describe the operation of three-phase power Describe the two most common three-phase voltage systems Explain the function of neutral Describe the operation of grounded and ungrounded systems Describe two devices used to disconnect power to a circuit Explain why time-delay fuses are used with motor starting circuits Describe three important factors to consider with overcurrent protection devices. Describe the operation of a three-phase motor Describe the operating data on a motor’s nameplate Define service factor and explain its importance Explain why dual-voltage motors should always be run on the highest available voltage Skills 1 2 3 4 5 Perform a lockout/tagout Use a voltmeter to verify supply voltage Use an ohmmeter to check the condition of a fuse Connect a dual-voltage three-phase motor for low voltage operation Connect a dual-voltage three-phase motor for high voltage operation Objectives 1 2 3 4 5 6 7 8 9 10 11 Describe five functions of motor control Describe the four basic requirements for a typical motor installation Define motor controller and motor starter Describe the functions of two categories of motor starters Describe the functions of two types of manual starters Describe the operation of a manual motor starter Define low-voltage protection and describe its importance Describe how low-voltage protection is accomplished in a manual starter Describe the function of three types of overloads and give an application of each Describe the operation of two types of thermal overloads Describe the operation of a magnetic overload 8 Skills 1 2 3 4 Connect and operate a simple motor control circuit Start and stop a motor using a manual starter Set the trip level of a bimetallic overload Select the correct heaters for a NEMA overload Objectives 1 2 3 4 5 6 7 8 9 10 Describe the operation of a transformer and give its schematic symbol Define turns ratio and describe how it is calculated Describe how the turns ratio determines the secondary voltage of a transformer Describe the function of the four basic components of an electrical control circuit Describe the function of an electrical schematic diagram Describe the function of a control transformer Describe the operation of a control transformer and give its schematic symbol Describe how to test a transformer Describe how to size a transformer Describe the operation of a separate control circuit Skills 1 2 3 4 5 Calculate the turns ratio of a transformer Calculate the secondary voltage of a transformer Connect and operate a control transformer Test a control transformer Size a control transformer Objectives 1 2 3 4 5 6 7 8 Describe the function of three types of electrical control systems and give an application of each List and describe the three steps of a control process Describe the function of an indicator lamp and give an application Describe the operation of a pushbutton switch and give its schematic symbol Describe the operation of a selector switch and give its schematic symbol Describe the function of a ladder diagram Describe the function of four components of a ladder diagram Describe six rules of drawing a ladder diagram 9 9 10 11 12 13 14 15 Describe how to determine the operation of a circuit given a ladder diagram List six elements of control logic Describe the operation of AND logic and give an application Describe the operation of OR logic and give an application Describe the operation of NOT logic and give an application Describe the operation of NOR logic and give an application Describe the operation of NAND logic and give an application Skills 1 2 3 4 5 6 7 8 9 10 11 Connect and operate a basic electrical control circuit which uses a pushbutton switch Connect and operate a basic electrical control circuit which uses a selector switch Draw a ladder diagram of a control circuit Determine the operation of a control circuit given a ladder diagram Connect and operate a control circuit given a ladder diagram Connect and operate an AND logic circuit Connect and operate an OR logic circuit Connect and operate a NOT logic circuit Connect and operate a NOR logic circuit Connect and operate a NAND logic circuit Design a multiple start/stop pushbutton station control circuit Objectives 1 2 3 4 5 6 7 8 9 10 Describe the function of a control relay and give an application Describe the operation of a control relay and give its schematic symbol Describe the operation of two types of control relays and give an application of each Describe how detached symbology is used to show a control relay on a ladder diagram Describe the operation of memory logic and give an application Describe the operation of a magnetic motor starter Describe the operation of a two-wire motor control circuit and give an application Describe the operation of a three-wire motor control circuit and give an application Describe the function of a push-to-test pilot light and give an application Describe the operation of a push-to-test pilot light and give its schematic symbol Skills 1 2 3 4 5 6 7 Connect and operate a control relay in a circuit Connect and operate a memory logic circuit Connect and operate a magnetic motor starter connected to a three-phase motor Connect and operate a two-wire motor control circuit Connect and operate a three-wire motor control circuit Design a multiple operator station three-wire control circuit Connect and operate a three-wire control circuit with a push-to-test pilot light 10 Objectives 1 2 3 4 5 6 7 8 Describe two levels of troubleshooting and give an application of each Describe three methods of testing components and give an application of each Describe how to test an indicator lamp Describe how to test a manual switch Describe how to test a control relay Describe how to test a motor contactor Describe how to test an overload relay Describe how to test a 3-phase motor Skills 1 2 3 4 5 6 7 Test an indicator lamp Test a manual switch Test a control relay Test a motor contactor Test an overload relay Test a 3-phase motor Test a control transformer Objectives 1 2 3 4 5 6 7 8 9 Describe the function of four common electrical test instruments used in troubleshooting Describe how to select a DMM to measure voltage for a given application Describe how to use a voltage tester (wiggy) Describe how to use a clamp-on ammeter Describe how to use a continuity tester Describe a six step troubleshooting sequence Describe the four methods of systems level troubleshooting and give an advantage of each Describe five types of in-circuit component tests Describe how to test and analyze circuit signals Skills 1 2 3 Select and use a DMM to measure voltage for a given application Select and use a voltage tester (wiggy) for a given application Select and use a clamp-on ammeter 11 4 5 6 7 8 9 10 11 Select and use a continuity tester for a given application Perform and analyze circuit signal tests Use the symptom and cause troubleshooting method to isolate a bad component Use the output-back troubleshooting method to isolate a bad component Use the half-split troubleshooting method to isolate a bad component Use the shotgun troubleshooting method to isolate a bad component Troubleshoot a 2-wire control system Troubleshoot a 3-wire control system Objectives 1 2 3 4 5 6 7 8 9 State the NEMA and IEC standard for reversing the rotation of a three-phase motor List two common control methods used to reverse a three-phase motor Describe the function and operation of a drum switch Describe the function and operation of a reversing magnetic motor starter Describe the function of interlocking control and give an application Describe three interlocking methods used in reversing motor control Describe the function of manual and automatic modes and give an application of each Describe the operation of two types of motor jogging circuits Describe the operation of a Hand-Off-Automatic motor control circuit Skills 1 2 3 4 5 6 7 8 9 10 11 Connect and operate a drum switch to reverse a motor Connect and operate a reversing magnetic motor starter to reverse a motor Design a motor reversing circuit that uses a drum switch and a magnetic starter Connect and operate a reversing motor control circuit with mechanical and auxiliary interlocking Troubleshoot a reversing motor control circuit Design a reversing motor control circuit that uses pushbutton interlocking Connect and operate a circuit to jog a motor Connect and operate a forward/reverse jog control circuit Troubleshoot a control circuit which has manual and automatic modes Connect and operate a Hand-Off-Automatic motor control circuit Design a Hand-Off-Automatic motor control circuit Objectives 1 2 Describe the functions of four types of automatic input devices and give an application of each Describe the operation of a limit switch and give its schematic symbol 12 3 4 5 6 7 8 Describe the operation of a float switch and give its schematic symbol Describe the operation of a pump control circuit Describe the operation of a pressure switch and give its schematic symbol Describe how to test an automatic input switch Describe the function of a sequence control circuit and give an application Describe the operation of a sequence control circuit Skills 1 2 3 4 5 6 7 8 9 10 Connect and operate a limit switch Design an overhead door motor control circuit Connect and operate a float switch Connect and operate a pump control circuit Connect and operate a pressure switch Design a pump control circuit that includes H-O-A operation Test an automatic input switch Connect and operate a sequence control circuit Troubleshoot a sequence control circuit Design a sequence control circuit Objectives 1 2 3 4 5 6 7 Describe the function of a time-delay relay and give an application Describe the function of two types of timer relays and give an application of each Describe the operation of an On-Delay timer relay and give its schematic symbol Describe the operation of a timer relay in an unloaded motor start circuit Describe the operation of an Off-Delay timer relay and give its schematic symbol Describe the function of a time-delay relay in time-driven sequencing Describe how to test a timer relay Skills 1 2 3 4 5 6 7 Connect and operate an On-Delay timer circuit Design a control circuit to perform an unloaded start of a motor Connect and operate an Off-Delay timer circuit Design a motor control circuit to perform time-driven sequencing Test a timer relay Troubleshoot an On-Delay timer circuit Troubleshoot an Off-Delay timer circuit 13 ELECTRICAL CONTROL WIRING SYSTEM Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Describe the function of an electrical print Describe the function of electrical print mnemonics Describe the function of notes on an electrical print Describe how to interpret an electrical print Describe the function of an electrical panel Describe the function of three types of electrical panels Describe the function of electrical terminal blocks Describe how to select a terminal block for an application Describe how to install a terminal block Describe the importance of using wire number labels Describe how to label wire numbers on an electrical print Describe how to determine the number of wires to run between panels Describe the function of wire color coding in electrical control Describe how to determine the wire colors needed in an electrical panel Skills 1 2 3 4 5 Interpret an electrical print Install a terminal block in an electrical panel Label wire numbers on an electrical print Determine the number of wires to run from a control panel to an operator station Determine the wire colors needed for an application Objectives 1 2 3 4 5 6 7 8 9 10 11 Describe how to terminate panel wires Describe how to install wire number labels on a wire Describe two methods used to run identity wires which are run between panels Describe how to hand feed wires through conduit Describe how to splice motor wires using ring lug connectors Describe how to tape motor leads Describe the function of panel wire ways Describe how to determine wire lengths inside a panel Describe two methods to connect wires to terminal screws Describe the function of wire bundling Describe three common methods of wire bundling 14 Skills 1 2 3 4 5 6 7 8 Terminate and label wires at a terminal block Run wires between panels Splice motor leads using ring lug connectors Connect a wire to a terminal screw Wire an electrical panel Bundle wires in an electrical panel Secure wire bundles in an electrical panel Wire an electrical machine 15 POWER DISTRIBUTION SYSTEM Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Describe the function of a wiring system Describe the function of the four basic parts of a wiring system Describe the function of conduit and list five types Describe three methods by which conduit is cut Describe the construction and operation of a hacksaw Describe the function of a pipe vise and give three types Describe the function of a pipe vise and describe three types Describe six safety rules to follow when operating the bench vise Describe the function of deburring conduit and give four tools that can be used Describe the function of an electrical box and give an application Describe the function of a conduit body and give an application Describe the function of conduit fitting Describe the function and operation of three types of connectors Describe the function of coupling Describe the function of a conduit strap and list three types Skills 1 2 3 4 5 6 7 Change a blade on a hacksaw Use a bench vise to hold conduit Cut EMT to length using a hacksaw Deburr Conduit Calculate conduit length given an application Connect EMT between two boxes Couple EMT conduit Objectives 1 2 3 4 5 6 7 Describe the function of conduit bending and list three basic bends Describe the function of a conduit bender and two methods that are used to bend conduit Describe four types of benders used with metallic conduit Describe the construction and operation of a hand bender Define the components of a 90 percent bend Describe bender take-up and explain its importance in making a 90 percent bend Describe the five steps used to determine bender take up 16 8 9 10 Describe the five steps to lay out accurate leg lengths and stub lengths Describe the components of an offset bend Describe the four steps used to determine and locate the bend centers of an offset bend Skills 1 2 3 4 5 Determine the take-up of a hand bender Lay out and bend EMT with proper leg length and stub-up Determine the bend centers of an offset Bend an offset in EMT conduit Construct a raceway of EMT conduit Objectives 1 2 3 4 5 6 7 8 Describe the similarities and differences between intermediate metallic and rigid conduit Describe three tools used to cut intermediate metallic and rigid conduit Describe two tools used to bend IMC and rigid conduit Describe the construction and operation of a mechanical bender Describe the method used to thread IMC and rigid conduit Describe the connectors and couplings used with IMC and rigid conduit Describe how flexible metal conduit is cut Describe the connectors used with flexible metal conduit Skills 1 2 3 4 5 6 7 Cut intermediate metallic conduit Change the shoes of a mechanical bender Bend IMC with a mechanical bender Thread rigid conduit Connect and couple IMC given an application Cut flexible metal conduit Connect flexible metal conduit Objectives 1 2 3 4 5 Describe the function of a conductor and its two components Describe five classifications of insulation and give an application of each Describe five common classifications of insulation and give an application of each Define conductor ampacity and describe the physical characteristics that affect it Describe how distance affects wire selection 17 6 7 8 9 10 Describe the function of a disconnect and give an application Describe three commonly used types of disconnects and give an application of each Describe how to size a disconnect Describe the function of overcurrent protection and list two types Describe how to size circuit protection Skills 1 2 3 Select wire size and type for an application Select a disconnect for an application Select circuit protection for an application Objectives 1 2 3 4 5 6 7 8 9 Describe percentage of fill and its importance in raceway selection Describe two methods used to select raceway diameter Describe the seven steps used to determine conduit size when conductors are of different size and/or types Describe why electrical codes limit the number of conductors in an electrical box Describe how to select the correct size electrical box Describe how conduit bodies are selected Describe three methods used to pull conductors Describe the function of a bus bar and give an application Describe the function of a bus plug Skills 1 2 3 4 5 6 7 Use NEC table to select the proper size raceway for same size/type conductors Determine conduit size when conductors are of different size and/or types Determine electrical box size when conductors are the same size Determine electrical box size when conductors are of different sizes Pull conductors using fish tape Connect a bus plug to a bus bar Design and install a wiring system given specifications 18 ELECTRONIC 19 PROGRAMMABLE CONTROLLERS ALLEN BRADLEY SLC500 Objectives 1 2 3 4 5 6 7 8 9 10 11 Describe the function of a programmable logic controller and give an application List six advantages of a PLC Describe the functions of the five basic components of a PLC Name three methods of entering a PLC program and give an advantage of each Describe the basic operation of a PLC Explain why PLCs use ladder diagrams Identify and describe the function of the parts of a SCL-500 discrete address. Describe the function and operation of input/output diagrams Describe the operation of XIC and XIO input instructions Describe the operation of an OTE instruction Describe the basic operation of PLC ladder logic Skills 1 2 3 4 5 View a directory of processor files using PLC software Restore a PLC processor file using PLC programming software Monitor a PLC processor file using PLC programming software Run a PLC processor file using PLC programming software Stop a PLC processor file using PLC programming software Objectives 1 2 3 4 5 6 7 8 9 10 List five types of numbering systems and explain their importance to PLCs Describe the operation of the decimal numbering system and give an application Describe the operation of the binary numbering system and give an application Describe the SCL-500’s memory organization Describe the operation of the SCL-500’s input and output data tables Describe the function of seven types of processor files Describe three advantages of PLC software Describe how an input device can reference multiple input instructions Describe how input device logic affects input instruction logic Describe how a PLC controls multiple outputs at the same time 20 Skills 1 2 3 4 5 6 7 8 Convert between decimal and binary View the status of the SCL-500’s Input and output data tables Create a PLC project using PLC software Configure the I/O for a PLC project using PLC software Enter a basic PLC program using PLC software Save a PLC program to disk using PLC software Edit a PLC program using PLC software Generate and print out a ladder logic report using PLC software Objectives 1 2 3 4 5 6 7 Describe two methods by which a PLC output can control a motor Describe how to draw a PLC output diagram for a motor application Describe how input instructions can be controlled by PLC output instructions Describe the function and operation of PLC seal-in logic Describe the function and operation of a program interlock and give an application Describe how a program interlock is used for safety Describe the function of the PLC program documentation and give an application Skills 1 2 3 4 5 6 Design a PLC program to jog a motor Design a PLC program to control the start/stop of a bi-directional motor Design a PLC program to interlock two motors Design a PLC program that uses a safety interlock to control the operation of a machine View project documentation and use it to operate a PLC program Document a PLC program file Objectives 1 2 3 4 5 Describe four features used to select a PLC discrete input module List and describe the five features used to select a PLC discrete output module Describe the effect of leakage current on an AC output module operation Explain how to interface to a discrete electronic sensor with NPN or PNP output Describe how to interface a PLC to a machine controller 21 Skills 1 2 3 4 5 6 7 Connect and test a limit switch to a PLC discrete input module Connect and test the operation of a solenoid valve to a PLC output Connect and test the operation of a motor starter to a PLC Connect and test the operation of an electronic sensor to a PLC input module Connect and test the operation of a PLC input module to a robot output module Connect and test the operation of a PLC discrete output module to a robot input module Develop an interface wiring diagram to interface a PLC to a machine controller Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 Describe two levels of troubleshooting and give an application of each Describe six types of PLC faults Describe the functions of PLC status and diagnostic indicators Describe the operation of the PLC power supply circuit Describe how to troubleshoot the PLC power supply circuit Describe how to troubleshoot a PLC DC power supply module Describe how to test PLC discrete input devices Describe the operation of the TEST mode and give an application Describe how to test a PLC discrete input module Describe the Force function and give an application Describe the function of the Force Table and its effect on the PLCs input and output data Describe how to test a PLC discrete output device Describe how to test a PLC discrete output module Skills 1 2 3 4 5 6 7 Use PLC status indicators to determine the status of PLC operation Troubleshoot the PLC power supply circuit Test a PLC discrete input device Test a discrete input module Use the Force function to force an input or output Use the Force function to test a PLC discrete output device Test a PLC discrete output module 22 Objectives 1 2 3 4 5 6 7 Describe the function of the processor status file and give an application Describe how to troubleshoot a PLC processor which controls local I/O Describe five methods of PLC troubleshooting and give an application of each Describe four types of PLC component tests Describe a six-step PLC troubleshooting sequence Describe the operation of the PLC Search function and give an application Describe the function of a Contact Histogram and give an application Skills 1 2 3 4 5 6 View and interpret the processor status file Troubleshoot a processor fault Use a six-step sequence to troubleshoot a PLC system Troubleshoot a PLC-controlled electric motor system Use the PLC Search function to find an instruction Create and view a PLC Contact Histogram Objectives 1 2 3 4 5 Define event-driven sequencing Describe the operation of a reciprocating actuator PLC program Describe the function of an internal output instruction and give an application Describe the operation of a continuous cycle reciprocating program Describe the operation of basic multiple actuator sequence program Skills 1 2 3 Design a reciprocating actuator sequence PLC program Design a continuous-cycle clamp and drill sequence PLC program Troubleshoot a clamp and drill sequence PLC program 23 Objectives 1 2 3 Describe the functions of the seven steps used to design a PLC program Describe the operation of a PLC program with manual and automatic modes Describe three methods of stopping a PLC controlled machine Skills 1 2 3 4 5 Design a PLC program using a seven-step design process Troubleshoot a PLC program with manual and automatic modes Design a motor control program which uses both manual and automatic modes Design a PLC program which has both Halt and Cycle-Stop functions Troubleshoot a PLC program which has both Halt and Cycle-Stop functions Objectives 1 2 3 4 5 6 7 Describe the function of two types of timer instructions and give an application of each Describe the operation of a retentive timer on-delay instruction Describe the function and application of two types of non-retentive timer instructions Describe the operation of the non-retentive timer on-delay instruction Describe the operation of an off-delay timer instruction Define time-driven sequencing and give three applications Describe the operation of a time-driven sequence program Skills 1 2 3 4 5 6 7 Enter and edit a PLC program that uses an RTO instruction Enter and edit a PLC program that uses a TON instruction Enter and edit a PLC program that uses a TOF instruction Design a PLC program that provides low voltage starting of an electric motor Design a PLC program that uses a time-driven sequence to control an actuator Design a PLC program to control a plastic injection molding machine Troubleshoot a PLC program which controls a plastic injection molding machine 24 Objectives 1 2 3 4 5 6 7 8 9 10 Describe the functions of two types of PLC counter instructions Describe the operation of an up-counter instruction Describe the operation of a down-counter instruction Describe the operation of the BCD numbering system and give an application Describe the function of a BCD thumbwheel switch and give an application Describe the operation of a BCD thumbwheel switch Describe the function and operation of the FRD instruction Describe the function of an LED display and give an application Describe the operation of an LED display Describe the function and operation of the TOD instruction Skills 1 2 3 4 5 6 7 8 9 Enter and edit a PLC program that uses an up-counter instruction Design a PLC program to control the number of production cycles Enter and edit a PLC program that uses an Up/Down-Counter instruction Design a PLC program that controls a conveyor queue station Convert between decimal and binary coded decimal Enter a PLC program that uses an FRD instruction Enter and run a PLC program that uses a TOD instruction Design a PLC program that controls an adjustable counting station Troubleshoot a PLC program which controls an adjustable counting station 25 MECHANICAL 26 BASIC HYDRAULICS Objectives 1 2 3 4 5 6 7 8 9 10 11 12 Define hydraulics and give an application Describe the functions of five basic components of a hydraulic system Define hydraulic pressure and give its units of measurement Describe the operation of a hydraulic power unit Describe the function of a hydraulic schematic Describe the function of a hydraulic quick disconnect fitting and give its schematic symbol Describe the function of a tee and give its schematic symbol Describe the operation of a pressure gage and give its schematic symbol Describe the function of a hydraulic cylinder and give an application Describe the operation of a double-acting hydraulic cylinder and give its schematic symbol Describe the operation of a 3-position, 4-way directional control valve (DCV) and give an application Describe the operation of a 3-position, 4-way directional control valve and give its schematic Skills 1 2 3 4 5 6 7 Read a hydraulic pressure gage Read the liquid level and temperature in the reservoir Operate a hydraulic power unit Connect and disconnect a hydraulic hose that uses quick-connect fittings Use a tee to connect two circuit branches together Connect and operate a double-acting hydraulic cylinder using a 3-position, manuallyoperated DCV Design a dual cylinder hydraulic circuit Objectives 1 2 3 4 5 Define flow rate and explain how it can be measured Describe the operation of two types of flow meters and give their schematic symbol Describe the operation of a fixed-displacement pump and give its schematic symbol Describe the operation of three types of fixed displacement pumps and give an application of each Describe the main function of a needle valve 27 6 7 8 9 10 Describe the operation of a needle valve and give its schematic symbol Describe the function of a hydraulic motor and give an application Describe the operation of a hydraulic motor and give its schematic symbol Describe the operation of three types of hydraulic motors and give an application of each Describe eight basic rules for drawing hydraulic schematics Skills 1 2 3 4 5 6 7 Connect and read a flow meter Connect and operate a needle valve to control the speed of an actuator Control the speed of an actuator using a manually-operated DCV Connect and operate a bi-directional hydraulic motor using a 3-position, manuallyoperated DCV Draw a hydraulic schematic from the actual circuit connections on the machine Connect a hydraulic circuit given a schematic Design a multiple actuator hydraulic circuit Objectives 1 2 3 4 5 6 7 8 9 Describe how to calculate the actual force output of an extending cylinder Describe how to calculate the force output of a hydraulic cylinder in retraction (pull) State Pascal's Law and explain its significance in hydraulics Explain how force is multiplied using Pascal's Law Describe two types of resistance in a hydraulic system Explain how Delta P describes hydraulic resistance Explain how pressure is distributed in a hydraulic system Describe two methods of representing hydraulic pressure Describe how oil flows on the suction side of the pump Skills 1 2 3 4 5 6 Calculate the extension force of a cylinder given its size and pressure Measure the force output of an extending cylinder Calculate the retraction force of a cylinder given its size and pressure Measure the force output of a retracting cylinder Measure Delta P across a hydraulic component Calculate between absolute pressure and gage pressure 28 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Describe the function of a relief valve and give an application Describe the operation of a direct-acting relief valve and give its schematic symbol Describe how a relief valve is used for system protection Describe how a relief valve is used for speed control assistance Describe the function of a check valve and give an application Describe the operation of three types of check valves and give their schematic symbol Describe the function of the flow control valve and give an application Describe the operation of a flow control valve and give its schematic symbol Describe the effect of actuator load changes on flow control valve operation Describe the operation of meter-in flow control circuit and give an application Describe the operation of a meter-out flow control circuit and give an application Define independent speed control and give an application Explain how speed control valves can be used to provide multiple speeds Describe how to calculate the speed of a hydraulic cylinder Describe how to calculate the retract speed of a cylinder Describe how to calculate the stroke time of a cylinder Skills 1 2 3 4 5 6 7 8 9 10 Connect a relief valve in a circuit to limit pressure in the system Design a circuit to provide bypass flow Connect and adjust a flow control valve to control speed of an actuator Connect and operate a meter-in flow control circuit Connect and operate a meter-out flow control circuit Design an independent speed control circuit Design a two-speed actuator circuit Calculate the speed of a hydraulic cylinder given its size and a flow rate Calculate the retract speed of a cylinder given its size and a flow rate Calculate the cylinder stroke times given its size and a flow rate Objectives 1 2 3 4 5 6 7 Describe the function of a pressure sequence valve and give an application Describe the operation of a direct-acting pressure sequence valve and give its schematic symbol Describe the function of a by-pass check valve in a sequence valve circuit Describe the operation of an integral check valve and give its schematic symbol Describe the function of a two-sequence valve control circuit Explain why a sequence valve is externally drained Describe the function of a pressure reducing valve and give an application 29 8 9 10 Describe the operation of a direct-acting PRV and give its schematic symbol Describe the function of a PRV’s bypass check valve Explain why a PRV is externally drained Skills 1 2 3 4 5 6 7 Connect and adjust the pressure setting of a sequence valve Connect and operate a pressure sequence circuit Design a pressure sequence circuit Design a two-sequence valve control circuit Connect and adjust the pressure setting of a PRV Connect and operate a reduced pressure circuit Design a hydraulic circuit that uses a pressure reducing valve 30 INTERMEDIATE HYDRAULICS Objectives 1 2 3 4 5 6 7 8 9 10 Describe and explain the terms used to specify DCVs Describe the function of a hydraulic 4/2 DCV and name one application Describe the operation of a hydraulic 4/2 DCV and give its schematic symbol Describe the function of a hydraulic 3/2 DCV and name one application Describe the operation of a hydraulic 3/2 DCV and give its schematic symbol Describe the function of a hydraulic pilot-operated DCV and name one application Describe the operation of a hydraulic pilot-operated DCV and give a schematic symbol Describe the function of a hydraulic cam-operated valve and name one application List and describe the applications of two types of hydraulic cam-operated valves Describe the operation of a hydraulic 4/2 cam-operated valve and give its schematic symbol Skills 1 2 3 4 5 6 7 8 9 Connect and operate a hydraulic DCV with a tandem-center spool Select a spool option for a hydraulic DCV based on application information Connect and operate a hydraulic 4/2 DCV Connect and operate a 4/2 DCV to function as a 3/2 DCV Design a hydraulic circuit using a 2-position DCV Connect and operate a hydraulic pilot-operated DCV Connect, adjust and operate a hydraulic cam-operated valve Design a hydraulic sequence circuit that uses a cam-operated hydraulic valve Design a hydraulic rapid traverse - slow feed circuit that uses a cam-operated valve Objectives 1 2 3 4 5 6 7 8 9 Describe the operation of four types of cylinders and give an application of each Describe the construction of two types of cylinders and give an application Describe three common cylinder mounting styles and give an application Describe three common cylinder feature options Describe the principle of cylinder regeneration and name an application Describe the operation of a basic regeneration circuit Describe how to calculate the extend speed of a cylinder in regeneration Describe how to calculate the extend force of a cylinder in regeneration Describe the function of a pressure-compensated flow control valve and name one application 31 10 11 12 13 14 15 Describe the operation of a pressure-compensated flow control valve and give its schematic symbol Describe the function of a double-rod cylinder and name one application Describe the operation of a double-rod cylinder and give its symbol Define cylinder synchronization and name three applications Explain why cylinders do not operate in synchronization List and describe the operation of five methods used to synchronize a circuit using flow control valves Skills 1 2 3 4 5 6 7 Select a cylinder mounting style for a given application Connect and operate a basic regenerative circuit Calculate the extend speed of a cylinder in regeneration Calculate the extend force of a cylinder in regeneration Connect and operate a pressure compensated flow-control valve Set up, adjust, and operate a cylinder synchronization circuit using flow control valves Set up and operate a synchronization circuit using series actuators Objectives 1 2 3 4 5 6 Explain the advantage of a pilot-operated relief valve Describe the operation of a pilot-operated relief valve and give its complete schematic symbol Describe the function of the vent port of a pilot-operated relief valve Describe two methods of pump unloading and give an application of each Describe the operation of a remote-controlled relief valve circuit Describe multiple pressure relief valve operation and give one application Skills 1 2 3 Connect a pilot-operated relief valve to unload a pump by venting Connect and operate a remotely controlled p.o. relief valve circuit Design a circuit to provide a two-pressure control with unloading Objectives 1 2 3 Explain how actuator relaxation occurs in a multi-actuator circuit Describe the operation of a P-port check valve circuit Design the construction of an integral P-port check valve 32 4 5 6 7 8 9 10 11 12 13 14 15 Describe the function of a pilot-operated check valve and give its schematic symbol Describe the operation of a pilot-operated check valve and give an application Describe the operation of load-lock circuits using one POC valve Describe the operation of load-lock circuits that use two POC valves Describe the operation of a double-POC check valve Describe the function of a prefill valve and give an application Define POC valve pilot ratio and explain its importance Describe how to calculate the pressure required to open a POC valve Define pressure intensification and explain its importance Describe how to calculate the maximum pressure in a POC valve circuit Describe the function and operation of a POC valve with decompression poppet List five application guidelines for POC valves Skills 1 2 3 4 5 6 7 Connect and operate a P-port check valve circuit Connect and operate a hydraulic pilot-operated check valve Connect and operate a load-lock circuit using a pilot-operated valve Measure pilot-operated check valve pilot pressure Calculate the pilot pressure required to open a POC valve Calculate the maximum pressure in a POC valve circuit Design a POC valve circuit 33 BASIC PNEUMATICS Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Define pneumatics and give an application Describe the functions of basic components of a pneumatic system Define pneumatic pressure and give its units of measurement Describe the function of a pneumatic schematic Explain six pneumatic safety rules Describe the function of a pressure regulator valve and give an application Describe the operation of a pressure regulator and give its schematic symbol Describe the function of an air filter Describe the operation of an air filter and give its schematic symbol Describe the function of a pneumatic quick connect fitting and give its schematic symbol Describe the function of a tee and a cross and give their schematic symbols Describe the function of a pneumatic cylinder and give an application Describe the operation of a double-acting pneumatic cylinder and give its schematic symbol Describe the function of a 3-position, 5-way pneumatic DCV and give an application Describe the operation of a 3-position, 5-way pneumatic DCV and give its schematic symbol Skills 1 2 3 4 5 6 7 8 Read a pneumatic pressure gage Connect and adjust a pressure regulator Drain a pneumatic filter Connect a pneumatic hose that uses quick-connect fittings Use a tee to connect two circuit branches together Use a cross to connect three circuit branches together Connect and operate a double-acting pneumatic cylinder using a 3-position, manuallyoperated DCV Design a multiple cylinder pneumatic circuit Objectives 1 2 Describe the function of a single-acting pneumatic cylinder and give an application Describe the operation of a single-acting, spring-return cylinder and give its schematic symbol 34 3 4 5 6 7 8 9 10 11 12 Describe the function of a 3/2 pneumatic DCV and give an application Describe the operation of a 3/2 pneumatic DCV and give its schematic symbol Describe the function of a pneumatic motor and give an application Describe the operation of a pneumatic motor and give its schematic symbol Describe the function of a muffler and give its schematic symbol List three common pneumatic motor designs and explain where they are used Describe the line symbols used with fluid power circuits Describe seven basic rules for drawing pneumatic schematics Describe the function of pneumatic simulation software and name two applications Describe the function of the pneumatic symbol library Skills 1 2 3 4 5 6 7 Connect and operate a single-acting pneumatic cylinder using a 3/2 manually-operated DCV Connect and operate a unidirectional pneumatic motor using a 3-way, manuallyoperated DCV Identify pneumatic symbols Draw a pneumatic schematic from the actual circuit connections on the machine Connect a pneumatic circuit given a schematic Design a multiple actuator pneumatic circuit Use software to simulate a pneumatic circuit Objectives 1 2 3 4 5 6 7 8 9 10 11 Describe how to calculate the force output of an extending cylinder Describe how to calculate the force output of a cylinder in retraction (pull) State Pascal's Law and explain its significance in pneumatics Explain how force is multiplied using Pascal's Law Describe two methods of representing pneumatic pressure Explain how air pressure is created in a pneumatic system State Boyle's Law and explain its significance Explain how a pneumatic system creates flow Describe two types of resistance in a pneumatic system Explain how Delta P describes pneumatic resistance and explain its importance Describe what determines the speed of a pneumatic actuator Skills 1 2 3 4 5 Calculate the extension force of a cylinder given its size and pressure Measure the force output of an extending cylinder Calculate the retraction force of a cylinder given its size and pressure Convert between gage and absolute pressures Use Boyle's Law to calculate changes in pressure and volume 35 6 Measure Delta P across a pneumatic component Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Describe the main function of a pneumatic needle valve and give an application Describe the operation of a needle valve and give its schematic symbol Define flow rate and give its units of measurement Describe the function of a flow meter and give an application Describe the operation of a rotameter and give its schematic symbol Describe the function of a pneumatic check valve and give an application Describe the operation of two types of pneumatic check valves and give their schematic symbols Describe the function of a flow control valve and give an application Describe the operation of a flow control valve and give its schematic symbol Describe the effect of actuator load changes on flow control operation Describe the operation of a meter-in flow control circuit and give an application Describe the operation of a meter-out flow control circuit and give an application Describe the operation of an exhaust port speed control circuit Describe the operation of a pressure port speed control and give an application Define independent speed control circuit Skills 1 2 3 4 5 6 7 8 9 10 11 Connect and operate a needle valve to control actuator speed Convert air volumes at pressures to free air volumes Connect and read a flow meter Connect and operate a check valve Connect and adjust a flow control valve to control the speed of an actuator Connect and operate a meter-in flow control circuit Connect and operate a meter-out flow control circuit Connect and operate an exhaust port speed control circuit Connect and operate a pressure port speed control circuit Design speed control circuits Design an independent speed control circuit 36 INTERMEDIATE PNEUMATICS Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 List four sources of compressed air contamination and explain their effect Describe the operation of three common filter elements Describe the function of a coalescing filter and give an application Describe the operation of a coalescing filter and give its schematic symbol Explain how air filter elements are rated Describe how to select a filter for an application Define dew point and relative humidity and explain their importance Explain how water condenses in a pneumatic system and its effect Describe two methods of removing water vapor from a pneumatic system Describe the function of an aftercooler and give an application Describe the function of a dryer and give an application Describe the principle of operation of three types of dryers and give an application of each Describe the operation of a refrigeration type air dryer Describe the function of pneumatic system trap Describe the operation of two types of pneumatic traps and give the schematic symbol of each Describe the function of air lubrication and list three lubrication methods Describe the function of a lubricator and give its schematic symbol Describe the operation of three types of pneumatic lubricators and give an application of each Describe the types of oils in lubricators Describe how pressure gages are calibrated Describe how acrylic flowmeters are cleaned Describe the importance of eliminating air leaks Describe how to locate air leaks Describe four common pneumatic component failures and their probable causes Skills 1 2 3 4 Change an air filter element Select an air filter for an application Connect, fill and adjust a lubricator Disassemble, inspect and service a pneumatic cylinder 37 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Describe the three functions of an air line Describe the construction of pneumatic rubber hose and give an application Describe three methods of connecting rubber hose to a fitting Describe the construction of 3 types of pneumatic fitting threads and give an application of each Describe the operation of dryseal tapered pipe threads (NPTF) Explain how to identify and specify pipe size Describe the function of a reducing bushing and give an application Describe how to specify the size of a reducing bushing Describe the operation of straight threaded fittings Describe the UNF thread size used for pneumatic fittings Describe the function of an adapter and give an application Describe the functions of four types of flexible plastic conductors and give an application of each Describe how to specify flexible tubing Describe the function of three pneumatic tubing fittings and give an application of each Describe the function of a bulkhead fitting and give an application Describe the function of six fitting shapes Describe the function of a subplate and give an application Give five guidelines used in the construction of pneumatic circuits Skills 1 2 3 4 5 6 7 8 9 10 11 12 Install a rubber hose onto a push-on type fitting Install and seal tapered pipe fittings using teflon sealing tape Identify the nominal pipe size of a fitting given an example Install a reducing bushing to connect an oversized port Install and seal a straight thread fitting Connect polyurethane ether tubing to a barbed fitting Connect tubing using a ferrule type fitting Connect tubing using a push-on type fitting Install a bulkhead fitting Identify the shape, type and size of tubing connectors Install and replace a DCV on its subplate Size, select, and install the fittings and tubing for an application 38 PIPING SYSTEMS Objectives 1 2 3 4 5 6 7 8 9 Describe the function of a piping system and give an application Describe the color code system to identify pipe function Describe the functions of the basic components of a piping system Describe four types of piping and give an application of each Describe five rules of safe dress for working with piping Describe nine piping rules List four types of metal pipe materials and give an application of each Describe how metal pipe is specified Describe how to calculate the head loss given pipe size and flow rate Skills 1 2 3 4 5 Identify pipe function by color code Identify pipe size by measurement Identify pipe size given a specification Write a pipe specification given its dimensions Calculate the head loss for a given pipe size and flow rate Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Describe two methods of attaching metal pipe Describe the functions of four categories of fittings Describe the functions of thirteen types of fittings Describe the construction of three types of pipe threads and give an application of each Describe how fittings are specified Describe how to cut metal pipe Describe the operation of a pipe threading machine Describe how to prepare a pipe for assembly Describe how to assemble threaded pipe Describe the construction of seven types of pipe hangers and give an application of each Describe how to install a pipe hanger Describe the function of an expansion joint and give an application Describe the operation of an expansion joint Describe the function of three types of pipe insulation and give an application of each Describe the function of a piping schematic Identify the piping fitting schematic symbols 39 17 Describe how to design a piping system Skills 1 2 3 4 5 6 7 8 9 10 Identify fitting type and size given a sample Use a cutoff saw to cut metal pipe Use a pipe threading machine to create threads on a pipe Prepare a pipe for assembly Assemble threaded pipe and fittings Install a pipe hanger Install an expansion joint Install pipe insulation Read and interpret a piping schematic Design and draw a piping schematic for a given application Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 Describe the characteristics of two categories of tubing and give an application of each Describe four types of metal tubing and give an application of each Describe the construction of metal tubing Describe how metal tubing is specified Describe how to cut tubing Describe the operation of a tube bender Describe how to determine bend locations and angles Describe three methods of assembling metal tubing Describe how to assemble tubing using flared and flareless fittings Describe how to solder metal tubing Describe how to calculate the head loss given metal tubing size and flow rate Describe how to select and size metal tubing for an application Describe how to maintain a metal tubing system Skills 1 2 3 4 5 6 7 8 9 10 Identify metal tubing size by measurement Identify metal tubing size given a specification Write a metal tubing specification given its dimensions Cut off tubing using a tube cutter Use a tube bender to bend tubing to certain angles Determine bend locations and angles given a tubing layout drawing Assemble metal tubing using flared and flareless fittings Solder metal tubing Calculate the head loss for a given metal tubing size and flow rate Select and size metal tubing for an application 40 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 Describe the characteristics of two categories of hose and give an application of each Describe the construction of six types of rubber hose and give an application of each Describe the construction of two types of metal hose and give an application of each Describe three types of hose fittings Describe how hose is specified Describe how to cut hose Describe three methods of attaching a fitting to a hose Describe the operation of a hose crimping machine Describe how to determine the length of a hose for an application Describe how to calculate the head loss given hose size and flow rate Describe how to select and size hose for an application Describe how to maintain a hose system Skills 1 2 3 4 5 6 7 8 9 10 Identify hose size by measurement Identify hose size given a specification Write a hose specification given its dimensions Cut off hose using a cutoff saw Attach screw-on fittings to hose Crimp fittings onto a hose Determine hose length given a layout drawing Attach a hose Calculate the head loss for a given hose size and flow rate Select and size hose for an application 41 ELECTRO-FLUID POWER Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Describe the function of a power diagram Describe the function of electro-hydraulic controls and give an application Describe the operation of two types of hydraulic solenoids and explain the application of each Describe the operation of a solenoid-operated hydraulic DCV and give its schematic symbol Describe the function and operation of a hydraulic DCV manual override Describe the function of electro-pneumatic controls and give an application Describe the operation of two types of solenoid-operated pneumatic DCVs Describe the operation of a pneumatic DCV Describe the function and operation of a pneumatic DCV manual override Describe the function of a control transformer Describe the operation of a control transformer and give its schematic symbol Describe the function of circuit protection and list two types Describe the operation of a fuse and give its schematic symbol Describe the operation of a circuit breaker and give its schematic symbol Skills 1 2 3 4 5 6 7 8 9 Use the manual override of a solenoid-operated hydraulic DCV to jog a cylinder Connect and operate a double-acting cylinder using a 4/3 solenoid-operated hydraulic DCV Connect and operate a double-acting cylinder using a 4/2 solenoid-operated DCV Connect and operate a hydraulic motor using a 4/2 solenoid-operated DCV Use the manual override of a solenoid-operated pneumatic DCV to jog a cylinder Connect and operate a double-acting cylinder using a 5/3 solenoid-operated pneumatic DCV Connect and operate a single-acting cylinder using a 5/2 solenoid-operated pneumatic DCV Connect and operate a unidirectional pneumatic motor using a 5/2 solenoid-operated DCV Replace a fuse 42 Objectives 1 2 3 4 5 6 7 8 9 10 11 Describe the function of a control relay and give an application Describe the operation of an electromechanical relay and give its ladder diagram symbol Describe the construction of a general purpose relay and give an application Describe how relay contacts are specified Describe the construction of a machine control relay Describe the operation of a relay used to energize a fluid power valve solenoid Describe the operation of a relay to perform control logic Describe the function of a seal-in circuit Describe the operation of a seal-in circuit Describe the operation of a uni-directional motor control start/stop circuit Describe the operation of a bi-directional motor control start/stop circuit Skills 1 2 3 4 5 6 7 8 Connect and operate a relay given a ladder diagram Connect and operate a relay to energize a fluid power solenoid Connect and operate a relay to perform a seal-in relay function Design a logic circuit that uses a relay Connect and operate a uni-directional motor control start/stop circuit Connect and operate a bi-functional motor control start/stop circuit Design a motor control circuit with multiple start/stop pushbuttons Design a bi-directional motor control circuit that uses a single pushbutton Objectives 1 2 3 4 5 6 7 8 9 10 11 12 Describe the function of a limit switch and give an application Describe the operation of a limit switch and give its schematic symbol Describe how to interpret limit switch symbols Describe the construction of a heavy duty limit switch and give an application Describe the construction of a light duty limit switch and give an application Describe the operation of limit switch in an event sequencing circuit Describe the operation of a single-cycle cylinder reciprocation circuit Describe the operation of a continuous-cycle reciprocation circuit Describe the operation of a single-cycle reciprocation circuit with a 2-solenoid DCV Describe the function of multiple cylinders in a machine Describe how multiple cylinders are controlled using one limit switch and give an application Describe how multiple cylinders are controlled with multiple limit switches and give an application 43 Skills 1 2 3 4 5 6 7 8 Connect and operate a control circuit containing a limit switch given a ladder diagram Design a logic circuit that uses a limit switch to sequence an event Connect and operate a single-cycle cylinder reciprocation circuit Connect and operate a continuous-cycle cylinder reciprocation circuit Connect and operate a single-cycle cylinder using a 2-solenoid DCV Design a relay circuit to continuously cycle a cylinder using a double solenoid DCV Design a dual cylinder sequence circuit using one limit switch Connect and operate a dual-cylinder control circuit using two limit switches 44 HYDRAULIC TROUBLESHOOTING Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Define hydraulic troubleshooting and explain its importance Describe two levels of hydraulic troubleshooting and give an application of each Describe two methods of testing a hydraulic component and give an application of each Describe six hydraulic safe dress rules Describe eight hydraulic troubleshooting safety rules Describe the function of a pressure-compensated pump and give an application List two types of pressure-compensated pumps and give an application of each Describe the operation of a pressure-compensated vane pump and give its schematic symbol Describe the operation of a pressure-compensated piston pump Identify the schematic symbol of a hydraulic pressure-compensated pump Describe how to start up a pressure-compensated vane pump Describe how to adjust the pressure setting of a pressure-compensated vane pump Describe how to set a pressure-compensated pump and relief valve combination Describe the procedure to shut down a hydraulic system Describe the function of automatic and manual modes and give an application of each Describe the procedure to shut down a hydraulic system for maintenance Describe the function of a maximum volume stop Describe how to adjust the setting of a maximum volume stop Skills 1 2 3 4 5 6 Start up a pressure-compensated hydraulic vane pump Adjust the pressure-compensator on a pressure-compensated pump Shut down a hydraulic system Use manual mode to operate an actuator Shut down a hydraulic system for a maintenance operation Adjust the maximum volume stop on a pressure-compensated pump Objectives 1 2 3 Describe four types of in-circuit component tests and give an application of each Describe three hydraulic troubleshooting measurements and give an application of each Describe the construction of three types of pressure test points and give an application of each 45 4 5 6 7 8 9 Name the two typical locations of pressure test points Describe three ways to use a flow meter to troubleshoot a hydraulic system Describe two methods of measuring flow Describe eleven symptoms of pressure-compensated pump failure Describe how to interpret a troubleshooting chart Describe how to inspect and troubleshoot a pressure-compensated pump Skills 1 2 3 Use a pressure test point to troubleshoot a hydraulic system Test a hydraulic system by measuring fluid flow Troubleshoot a pressure-compensated vane pump using an in-circuit test Objectives 1 2 3 4 5 6 7 8 9 Describe the function of a cylinder cushion and give an application Describe the operation of a cylinder cushion Describe how to adjust a cylinder cushion Describe the function of a cylinder rod boot and give an application Describe how to install a cylinder rod boot Describe the causes of five symptoms of hydraulic cylinder failure Describe how to inspect and troubleshoot a hydraulic cylinder Describe five symptoms of motor failure and their causes Describe how to inspect and troubleshoot a hydraulic motor Skills 1 2 3 Adjust a cylinder cushion Troubleshoot a cylinder using an in-circuit test Troubleshoot a motor using an in-circuit test Objectives 1 2 3 4 5 6 Describe six symptoms of direct-operated DCV failure and their causes Describe how to inspect and troubleshoot a direct-operated DCV Describe the function of DCV pilot chokes and give an application Describe the operation of a DCV pilot chokes Describe seven symptoms of pilot-operated DCV failure and their causes Describe how to inspect and troubleshoot a pilot-operated DCV 46 7 8 9 Describe the x functions of a sandwich valve and give an application Describe the operation of a sandwich valve Describe how to adjust a sandwich valve Skills 1 2 3 4 Troubleshoot a direct-operated DCV using an in-circuit test Adjust and operate DCV pilot chokes Troubleshoot a pilot-operated DCV using an in-circuit test Adjust a sandwich valve Objectives 1 2 3 4 5 6 7 8 9 10 Describe six symptoms of non-compensated flow control valve failure and their causes Describe how to inspect and troubleshoot a non-compensated flow control valve Describe the function of a dial-type pressure-compensated flow control valve and give an application Describe the operation of a pressure-compensated flow control valve Describe the six symptoms of compensated flow control valve failure and their causes Describe how to inspect and troubleshoot a compensated flow control valve Describe four symptoms of check valve failure and their causes Describe how to inspect and troubleshoot a check valve Describe five symptoms of pilot-operated check valve failure and their causes Describe how to inspect and troubleshoot a pilot-operated check valve Skills 1 2 3 4 5 Troubleshoot a non-compensated flow control valve using an in-circuit test Adjust and operate a dial-type pressure-compensated flow control valve Troubleshoot a compensated flow control valve using an in-circuit test Troubleshoot a check valve using an in-circuit test Troubleshoot a pilot-operated check valve using an in-circuit test 47 Objectives 1 2 3 4 5 6 7 8 9 Describe the construction of an R-series pressure control valve Describe how to change the pressure control setting of a pressure control valve Describe how to change the function of an R-series pressure control valve Describe nine symptoms of relief valve failure and their causes Describe how to inspect and troubleshoot a relief valve Describe ten symptoms of sequence valve failure and their causes Describe how to inspect and troubleshoot a sequence valve Describe ten symptoms of pressure reducing valve failure and their causes Describe how to inspect and troubleshoot a pressure reducing valve Skills 1 2 3 4 Identify the functions of the two pressure taps on an R-series pressure control valve Change the pressure control setting of a pressure control relief valve Troubleshoot a relief valve using an in-circuit Troubleshoot a pressure reducing valve using an in-circuit test Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Describe three categories of hydraulic system faults and give an application of each Describe how to use a troubleshooting flow chart to troubleshoot a hydraulic fault Describe how to troubleshoot low or zero system pressure Describe how to troubleshoot a hot hydraulic system Describe how to troubleshoot vibration in a hydraulic system Describe how to troubleshoot hydraulic system leaks Describe how to troubleshoot hydraulic fluid problems Describe how to troubleshoot an actuator that will not move Describe how to troubleshoot an actuator that moves out of sequence Describe how to troubleshoot an actuator that moves in the wrong direction Describe how to troubleshoot a pressure change problem in a multiple pressure circuit Describe how to troubleshoot a speed change problem in a multiple speed circuit Describe how to troubleshoot erratic actuator movement Describe how to troubleshoot slow actuator speed Describe how to troubleshoot fast actuator speed Describe how to troubleshoot actuator drift Describe how to troubleshoot incorrect acceleration or deceleration 48 Skills 1 2 3 4 5 6 7 8 9 10 11 12 Troubleshoot low or zero system pressure Troubleshoot high system pressure Troubleshoot a hot hydraulic system Troubleshoot an actuator that will not move Troubleshoot an actuator that moves out of sequence Troubleshoot a pressure change problem in a multiple pressure circuit Troubleshoot a speed change problem in a multiple speed circuit Troubleshoot erratic actuator movement Troubleshoot slow actuator speed Troubleshoot fast actuator speed Troubleshoot actuator drift Troubleshoot incorrect acceleration or deceleration 49 MECHANICAL SYSTEMS 1 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Describe the function of a mechanical power transmission and give an advantage Describe five methods of rotary mechanical power transmission and give an application of each Describe five rules of safe dress for working with power transmission equipment Describe eight mechanical transmission safety rules Describe the operation of the lockout/tagout system Describe the function of a foundation and give three types Describe the function and construction of a bedplate Describe the function of a spirit level and give an application Describe the operation of a spirit level Describe three types of motor mounts and give an application of each Describe how fasteners are used to attach a motor mount to a bedplate Describe how to select fastener size and type for a motor mount Describe how to mount and level an electric motor Describe two methods of measuring motor shaft speed and give an application Skills 1 2 3 4 5 6 Perform a lockout/tagout Use a spirit level to determine orientation of a surface Select a fastener size and type for a motor mount Mount and level an electric motor Use a digital tachometer to measure motor speed Mount and level an electric motor to correct for a soft foot condition Objectives 1 2 3 4 5 6 7 8 9 Describe the function and operation of a key fastener Describe the construction of six types of keys and give an application of each Describe how keys and keyseats are specified Describe how to measure the actual size of a key and key seat Describe six types of set screws Describe how to assemble a shaft to a hub using a key Describe two methods of loading a mechanical drive system Describe how to calculate rotary mechanical power Describe how to calculate mechanical efficiency and explain its importance 50 10 11 Describe two methods of measuring shaft torque and give an application of each Describe three methods of measuring electric motor current Skills 1 2 3 4 5 6 7 8 9 Select a key size for a given application Measure the actual size of a key and keyseat given a sample Cut and file key stock to fit a keyseat Assemble a hub to a shaft using a key fastener Use a pony brake to measure shaft torque Calculate rotary mechanical power Convert between English and S.I. units of motor power Calculate mechanical efficiency Measure electric motor current Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Describe the function of a shaft and give an application List four types of shaft materials and give an application of each Describe how shafts are specified Describe the function of a bearing and give an application Define three types of bearing loads and give an example of each Describe how bearings are positioned to support a load Describe the operation of two categories of bearings and give an application of each Describe two methods of mounting a shaft bearing and give an application of each Describe the function of a coupling and give an application Describe the function of four categories groups of mechanical couplings Describe the operation of flexible jaw coupling Describe the purpose of shaft alignment and give two types of misalignment Describe a general procedure for shaft alignment and give four measurement methods Describe the operation of the straight edge and feeler gage method Skills 1 2 3 4 Identify shaft size given a sample Install and adjust a pillow block antifriction bearing and shaft Install a flexible jaw coupling Align two shafts using a straight edge and feeler gage 51 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 Describe the function of the three basic components of a belt drive Define pitch and explain its importance Define pitch circle, pitch diameter, and pitch length and explain their importance Describe how to calculate the pulley ratio and explain its importance Describe how to calculate the shaft speed and torque of a belt drive system List five types of belt drives and give an application of each List three types of v-belts and give an application of each Describe the operation of a fractional hp v-belt drive Describe how to install and align a v-belt drive Describe how to determine belt tension for an application Describe three methods of adjusting belt tension Describe three methods of measuring belt tension and give an application of each Skills 1 2 3 4 5 6 Calculate pulley ratio Calculate the shaft speed and torque of a belt drive system Install and align a fractional HP v-belt drive with a finished bore Determine the belt deflection force for a given application Adjust belt tension using an adjustable mounting base Use a belt tension tester to measure belt tension Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 Describe the function of the three basic components of a chain drive Describe how to calculate sprocket ratio and explain its importance Describe how to calculate the shaft speed and torque of a chain drive system List four types of chain drives and give an application of each List four types of roller chain drives and give an application of each Describe the operation of a single-strand roller chain drive Describe how to install, align and remove a roller chain drive system with adjustable centers Describe how to determine allowable chain sag for a given application Describe two methods used to adjust chain sag Describe how to measure chain sag Describe the function and operation of a master link Describe two methods of installing a lightweight chain which uses a master link Describe the operation of a chain puller 52 Skills 1 2 3 4 5 6 7 8 Calculate the sprocket ratio Calculate the shaft speed and torque of a chain drive system Install, align and remove a roller chain drive system with adjustable centers Determine allowable chain sag for a given application Use a rule and straight edge to measure chain sag Adjust chain sag to a specified amount using adjustable centers Install and remove a chain with a master link using sprocket teeth Install and remove a chain with a master link using a chain puller 53 MECHANICAL SYSTEMS 2 Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 Describe the function of a bushing and list three types Describe the construction and operation of a QD bushing and give an advantage Describe the construction and operation of a conventional v-belt Drive Describe the construction and operation of a multiple belt v-belt drive Describe the construction and operation of a split taper bushing and give an advantage Describe the construction and operation of a wedge v-belt drive Describe the construction of a taper lock bushing and give an advantage Describe the construction and operation of a notched v-belt and give an advantage Describe the operation of a variable speed v-belt drive system and give an application Describe how to install and align a variable speed v-belt drive system Describe five v-belt configurations and give an application of each Describe the function of a belt idler pulley and give an application Describe the operation of four types of belt idler pulley configurations Skills 1 2 3 4 5 6 7 Install and align a conventional v-belt drive system with a QD bushing Install and align a multiple belt v-belt drive system with a split taper bushing Install and align a wedge v-belt drive system with a taper-lock bushing Install and align a notched v-belt drive system Install and align a variable speed v-belt drive system Install and align a backslide v-belt idler Install and adjust a kiss v-belt idler Objectives 1 2 3 4 5 6 7 8 9 Describe how v-belts are specified Describe three methods of identifying belt size and type Describe the function and operation of v-belt match codes Describe how sheaves and bushings are specified Describe how sheaves are specified Describe how to select a v-belt, bushing, and sheave for an application Describe preventive maintenance Describe nine maintenance steps for v-belt drives Describe how to troubleshoot a v-belt drive system 54 Skills 1 2 3 4 5 6 7 Use a belt code to determine the size and type of v-belt Use a belt gage to determine belt cross section belt size Use measurement to determine the size and type Use a sheave gage to identify a sheave size Identify size and type of sheave and bushing given a sample Select a v-belt, bushing, and sheave for a given application Troubleshoot a v-belt drive system Objectives 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Describe the operation of four types of sprockets (No Hub, Single Hub, Double Hub, and Bushing) and give an application of each Describe the operation of a silent chain drive Describe how to install and align a silent chain drive system Describe the operation of a multiple strand chain drive Describe how to install and align a multiple strand chain drive system Describe the construction and operation of a taper lock busing and give an advantage Define chain pitch, pitch circle, pitch diameter, and pitch length of a chain drive and explain their importance Describe how chains are specified Describe how sprockets are specified Describe how to select the type and size of chain and sprocket for a given application Describe four types of chain lubrication methods (manual, drip cup, oil bath or disc, and forced oil stream) Describe how to select a lubrication system for a chain drive system Describe how to select a lubrication type for a chain drive system Describe ten maintenance steps for chain drives Describe how to inspect and troubleshoot a chain drive system Describe the operation of a chain breaker Skills 1 2 3 4 5 6 7 8 Install and align a silent chain drive system Install and align a multiple strand chain system using a taper lock bushing Identify the characteristics of a chain and sprocket given a specification Select a chain and sprocket for a given application Select a lubrication system for a chain drive system Lubricate a chain drive using a manual method Troubleshoot a chain drive system Cut a chain using a chain breaker 55