JobMaster Mechatronics & Industrial Maintenance Program

Mechatronics & Industrial Maintenance

PROGRAM DESCRIPTION AND COURSE LIBRARY

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Validated by Industry . . . existing employees with new skills, JobMaster® provides a scalable training program custom-fit to your needs.

With a comprehensive skill list developed in tangent with many industries, students obtain skills that will serve in careers today and well into the future.

Industrial Manufacturing. Green Technology. New and Emerging Industries.

Employers in all sectors, from traditional manufacturing to emerging industries, need qualified workers to meet the increasing demands of a changing world.

Advancing technologies and global competition put new demands on the workforce. The shortage of qualified workers is felt whether searching for highly-skilled candidates or entry-level candidates with basic skills.

The JobMaster® Training program provides an effective solution to this critical

Skills-based training.

JobMaster® has created job task analyses on virtually every task necessary for industrial maintenance technicians! Our sophisticated algorithm, validated and funded by industry, measures the safety risk, difficulty level, frequency, and time spent for each technical task. This exclusive skill-based training method has been implemented in industrial training programs for Fortune 1000 companies such as:

need. JobMaster® training delivers the critical skills needed by industries of

Caterpillar

General Motors

all sectors, and for trainees of all types. Whether implemented in high school

DuPont

Ford

and community college programs, or in industrial training programs to equip

General Electric

U.S. Steel

COMPREHENSIVE INDUSTRIAL MAINTENANCE & MECHATRONICS TRAINING! LEARN MORE INSIDE:

F OUNDATION S KILLS

JobMaster® Course Library. . . . . . . . . . . . . . . . . . 5 Foundations (BA) Series . . . . . . . . . . . . . . . . . . . . 6 Electrical Series. . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Employability Introduction to Advanced Manufacturing Introduction to Lean Manufacturing Mathematics Lockout/Tagout

Mechanical Measurement & Quality Control Blueprint Reading Lubrication for Technicians Mechanical Fasteners Hand & Power Tools

How to build an Electrical Series Program. 10 Electrical Series Hardware. . . . . . . . . . . . . . . 11 Basic Power (EA01) Series. . . . . . . . . . . . . . . 13 Electrical Control (EA) Systems. . . . . . . . . . . 15 Industrial Electronics (EB) Series. . . . . . . . . 20

E LECTRICAL S YSTEMS

F LUID P OWER

Basic Power Electricity Electrical Control Systems Industrial Power Electronics

Hydraulics Pneumatics Electro-pneumatics

Fluid Power Series . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Automation Series. . . . . . . . . . . . . . . . . . . . . . . . 27 Robotics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A UTOMATION

CAD/C A M / C N C

Robotics Robotics and Automation Projects Programmable Logic Controllers (PLCs) Process Control

CAD/CAM CNC Milling and Turning Automated Manufacturing Projects

Programmable Logic Controlers (PLCs). . . . 30 Process Control. . . . . . . . . . . . . . . . . . . . . . . . 31 CAD/CAM/CNC Series. . . . . . . . . . . . . . . . . . . . . . 32 Mechanical (ME) Series. . . . . . . . . . . . . . . . . . . . 35 Electromechanical Maintenance Cell . . . . . . . . 38

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M ECHANICAL

E LECTROMECHANICAL

Mechanical Training Bench Laser Alignment Vibration Analysis Bearing Maintenance

Conveyor, Drive & Controls Industrial Lighting Circuits Variable Frequency Drive DC Motor & Drive

. . . powered by LearnMate® p

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LEARNMATE® IS THE DASHBOARD TO YOUR TRAINING PROGRAM, WITH POWERFUL ADMINISTRATIVE FEATURES AT YOUR FINGERTIPS JobMaster® is powered by LearnMate®, intelitek’s web-based Learning Management System (LMS). LearnMate® delivers powerful content delivery and classroom management capabilities.

Curriculum delivery Deliver consistent content across multiple organizations Compatible with ANY SCORM (Sharable Content Object Reference Model)-compliant content AICC (Aviation Industry CBT [Computer-Based Training] Committee)-compliant

Content authoring with LearnMate® Author Create your own SCORM-compliant, AICC-compliant, 508c capable curriculum, tests and assignments

Easy-to-use classroom management Quickly and easily set up users, groups and permissions Track student and class progress Create student portfolios and certifications Produce customizable multi-level reports

Standards and competency mapping Map program and student performance to any set of standards - even organization-specific competencies you create

Secure assessments Create, deliver and track computer-based assessments Evaluate student progress Establish any portion of content as an assessment Pinpoint skills gaps

Certifications and scalable accountability Track data on student outcomes, competencies, and learning gaps at multiple levels Provide a valid record of achievements with certifications

Online learning community Provide a dynamic environment for learning, including forums, real-time chat and e-mail

With over 2,500 hours of content in a wide array of career and technical pathways, LearnMate® offers a complete solution to your mechatronics training needs.

LearnMate®, intelitek’s flagship blended learning solution, is successfully deployed in over 500 LearnMate® labs worldwide. Developed to meet the specific needs of technical classrooms, LearnMate® enables your industrial training to be accessible, flexible and measurable.

Easily enroll users, set up groups and permission levels, and track progress. Import any set of competencies or create your own and map these competencies to the activities.

Deliver online assessments and produce robust custom reports to document and validate accomplishments as measured against competencies.

Students can engage in group discussions and projects and interact with instructors

Students can access content anytime, anywhere, and proceed at their own

Instructors can post assignments, create daily topics, get instant feedback from students

correlated to the JobMaster® training hardware - ensure relevant instruction keeps

Share resources and collaborate

for focused training.

individualized pace. Robust simulations, interactive animations and videos - all trainees engaged. Tests and quizzes with multiple question types identify skills gaps

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JobMaster® Course Library

JobMaster® provides a superior blended learning solution for mechatronics and industrial maintenance training by combining industrial-grade components with engaging e-learning content.

QUALITY HARDWARE No other training system provides exposure to industry-standard practices like JobMaster®, with hardware platforms consisting of industry-standard components.

From VFDs to solar-voltaic cells, all components are sourced from the same suppliers used by industry.

All wiring includes frame-mounted industry-standard conduit and is terminated with crimped ferrules, like those found in industry.

This allows students to learn the wiring techniques and skills critically needed by industry.

SKILL-BASED E-LEARNING CONTENT JobMaster® curriculum is skill-based, developed by industry experts from Fortune 1000 companies across a wide range of sectors.

Self-paced e-learning curriculum reinforces concepts by guiding students through skill-based activities using the hardware.

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COURSE LIBRARY Foundations Skills

p. 6

Foundations courses are 100% virtual courses delivered on-line through LearnMate®, accessible anywhere, anytime. Some Foundations courses have optional hardware available. Foundation Skills courses deliver essential skills for technical careers while also focusing on 21st Century skills.

Course Name Employability Introduction to Advanced Manufacturing Introduction to Lean Manufacturing Lockout/Tagout Mathematics 1 Mathematics 2 Blueprint Reading Lubrication for Technicians Mechanical Fasteners Hand Tools Power Tools Mechanical Measurement & Quality Control Mechanical Measurement & QC (Lab)

Electrical Series

Course # Page 3097 6 3096 6 3109 6 LOTO 7 BA01A 7 BA01B 7 BA02 7 BA03 7 BA04 8 BA05 8 BA06 9 3030 9 8014 9 p. 10

JobMaster® Electrical Series skills-based curriculum presents hands-on activities using industrial-grade electrical components mounted on Flexponent™ panels which attach to the JobMaster® Learning Station. Each individual course focuses on the specific skills by topic, and supplies the relevant Flexponent panels. This flexible, modular approach allows you to build a custom program for your needs.

Powered by LearnMate®, Electrical courses follow three main pathways: Basic Power Electricity, Electrical Control Systems and Industrial Power Electronics.

Basic Power Electricity Course Name Electrical Circuits Resistors & Conductors LCR Circuits Motors & Generators

Hydraulics Course Name Hydraulics 1: Fundamentals (Virtual) Hydraulics 1: Fundamentals (Lab) Hydraulics 2: Electro-Hydraulics

Course # Page 3024 25 8008 25 3025 25

Pneumatics Course Name Pneumatics 1: Fundamentals (Virtual) Pneumatics 1: Fundamentals (Lab) Pneumatics 2: Advanced (Virtual) Pneumatics 2: Advanced (Lab) Pneumatics 3: Electro-Pneumatics

Course # Page 3037 8068 26 3038 8069 26 3039 26

Automation

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Automation courses focus on automated manufacturing technologies in robotics, programmable logic controllers (PLCs) and process control. Robotics courses feature LearnMate® curriculum written specifically for our industrial desktop robotic workcells. User-friendly robotic control and simulation software integrates seamlessly with the content. PLC courses provide a choice between hardware or virtual content, while process control courses are all virtual.

Robotics

Course # Page EA02 15 EA03 15 EA04 16 EA07 17 EA08 17 EA09 18 EA11 18 EA12 19 EA16 19

Programmable Logic Controllers (PLC)

Industrial Power Electronics Course Name Oscilloscope Digital Multimeter Hand Held Digital Oscilloscope DC Power Supplies Single-phase & 3-phase Power Supplies Thyristor Electric Motor Drives Electronic Timers Stepper Motor Drives Servo Motor Drives

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JobMaster® Fluid Power courses feature standalone desktop training panels providing comprehensive training in hydraulic and pneumatic skills.

Modular components mount on the panels for course activities. The included software for simulating hydraulics and pneumatics circuits is tightly integrated with the LearnMate® online content.

Students can even launch the software directly from the content viewer. This enables engaging delivery of fluid power concepts and skills.

Course # Page EA01A 13 EA01B 13 EA01C 14 EA01D 14

Electrical Control Systems Course Name Electric Circuit Protection & Monitoring Transformers Electric Motors Electromagnetic Motor Starters Relays, Timers, & Time Delay Relays Pilot Devices Solid-State Starters Variable Frequency Drives (VFDs) DC Motor Control

Fluid Power

Course # Page EB01A 20 EB01B 21 EB01C 21 EB02A 22 EB02B 22 EB03 23 EB04 24 EB05 24 EB06 24

Course Name Robotics and Materials Handling 1 Robotics and Materials Handling 2 Flexible Manufacturing Systems Robotics & Automation Project Course Name PLC 1: Fundamentals (Virtual) PLC 1: Fundamentals (Lab) Micrologix PLC 1: Fundamentals (Lab) Allen-Bradley PLC 2: Advanced Ladder Logic (Virtual) PLC 2: Advanced (Lab) Micrologix PLC 2: Advanced (Lab) Allen-Bradley PLC 3: PLC-Controlled Pneumatic Systems PLC 4: PLC-Controlled Hydraulic Systems

Course # Page 8082 27 8083 28 8067 28 7016 29 Course # Page 3032 30 8009 30 8079 30 3033 30 8040 30 8080 30 3034 30 3035 30

Process Control Course Name Process Control: Temperature Process Control: Flow Process Control: Presssure Process Control: Level

Course # Page 3041 31 3043 31 3044 31 3045 31

CAD/CAM/CNC Machining

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CAD, CAM and CNC courses provide comprehensive training in automated manufacturing from design to production. The stand-alone curriculum features industry standard CAD/CAM software. CNC Machining courses feature LearnMate® curriculum written specifically for our classroom-friendly mills and lathes, along with the most user-friendly CNC control and simulation software available, tightly integrated to the content.

Course Name CAM with Mastercam® Milling CAM with Mastercam® Turning CAD with SolidWorks® CNC Milling Technology (Virtual) CNC Milling Technology (Lab) CNC Turning Technology (Virtual) CNC Turning Technology (Lab) AMT Project: Four Cavity Mold AMT Project: Planetary Gearbox

Course # Page 3006 32 3008 32 3108 33 3009 33 8007 33 3011 34 8016 34 7022 34 7023 34

Mechanical Systems

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JobMaster® Mechanical Systems features the Mechanical Training Bench, a stand-alone mobile training station providing comprehensive training in mechanical power transmission. This all-inone solution for mechanical training features industrial hardware and skills-based LearnMate® e-learning curriculum.

Course Name Mechanical Training Bench Includes: Basic Machines Machine Statics & Dynamics Machine Shafts & Keys Bearings Belt Drives Chain Drives Machine Shaft Couplings Gear Drives Machine Speed Reducers Electric Brakes Laser Alignment Vibration Analysis Bearing Service

Course # Page ME10 35 ME01 ME02 ME03 ME04 ME05 ME06 ME07 ME08 ME09 ME10 ME11 ME12 ME13

Electromechanical Maintenance Cell

36 37 37 p. 38

The JobMaster® Electromechanical Maintenance Cell is a capstone industrial maintenance/mechatronics project. An all-in-one solution, trainees assemble and troubleshoot the cell, performing all the common electromechanical tasks found in any industrial plant.

Course Name Electromechanical Maintenance Cell Includes: Basic Maintenance Cell Conveyor, Drive & Control Part Manipulation Industrial Lighting Circuits Variable Frequency Drive DC Motor Drive Fault Insertion System

Course # Page 1600 39 ZA01 ZA02 ZA03 ZA04 ZA05 ZA06 ZA07

Note: All LearnMate courses carry computer system requirements which vary depending on installation type. Contact intelitek or your distributor for details.

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Foundation Skills Course List Foundation Skills Courses

Foundation Skills courses deliver essential skills for technical careers as well as focusing on 21st Century skills like critical thinking, problem solving and collaboration skills!

This unique combination is delivered via 100% virtual courses - no hardware required!

With online simulations, computer-based assessments and robust activities, students obtain validated skills essential to mechatronics and maintenance careers, including blueprint reading, hand and power tool applications and safety. Hardware packages are also available as an optional supplement to some Foundation courses.

Course title Employability Introduction to Advanced Manufacturing Introduction to Lean Manufacturing Industrial Safety: Lockout/Tagout Mathematics for Technicians 1 Mathematics for Technicians 2 Blueprint Reading Lubrication for Technicians Mechanical Fasteners Hand Tools Power Tools Mechanical Measurement and Quality Control

*Hours are approximate and depend on class structure and teaching strategies.

Course # Skills

Hours*

3097

15

15

3096

9

15

3109

7

15

LOTO

6

9

BA01A

9

12

BA01B

9

14

BA02

12

18

BA03

15

23

BA04

12

18

BA05

17

25

BA06

12

18

3030/8014

15

15

Total:

138

197

Foundations Employability

Introduction to Advanced Manufacturing Course Outline

Developed in conjunction with career skills experts at SkillsUSA®, Employability delivers 21st Century career skills that ensure success in the workforce. Students develop essential qualities such as a positive attitude, communication skills, leadership skills, and work ethics.

Course Outline Lesson 1: Time-Management Techniques Lesson 2: Personal Qualities Desirable for the Workplace Lesson 3: Interpersonal Communication Lesson 4: Conflict Resolution Lesson 5: Teamwork Lesson 6: Problem-Solving Techniques and Decision-Making Skills Lesson 7: Proper Business and Personal Ethics Lesson 8: Business Etiquette and Ethical Computer Behavior Lesson 9: Employer-Employee Relationships Lesson 10: Proper Communication with Diverse Populations Lesson 11: Career Goals Lesson 12: Resumés and Cover Letters Lesson 13: Job Applications Lesson 14: Potential Employer Interviews Lesson 15: Interviewing Skills Career Skills Education Program Materials Included Order #16-3097: LearnMate® E-learning Content: Employability 6

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Introduction to Advanced Manufacturing provides students a comprehensive overview of principles, processes and career fields in manufacturing. Hands-on activities in career seeking and planning a manufacturing company culminate in a capstone project in which students follow all the steps of the manufacturing process to produce a product.

1.0 (Core): Introduction 2.0 (Core): Careers in Manufacturing 3.0 (Activity): Seeking a Manufacturing Career 4.0 (Core): The Manufacturing Company 5.0 (Activity): Planning and Staffing a Manufacturing Company 6.0 (Core): Manufacturing Processes 7.0 (Core): Computers in Manufacturing 8.0 (Core): Automation in Manufacturing 9.0 (Project): The Arrow Plane

Materials Included Order #16-3096: LearnMate® E-learning Content: Introduction to Advanced Manufacturing

Introduction to Lean Manufacturing

Lean Manufacturing explores the principles and techniques involved in lean manufacturing including minimizing waste in production and improving work flow in industrial processes.

Course Outline Lesson 1: Definition Lean Manufacturing Lesson 2: Understanding Waste Lesson 3: Designing the Manufacturing Workplace Lesson 4: Designing Lean Production Processes (1) – Concept Lesson 5: Designing Lean Production Processes (2) – Method Lesson 6: Designing a Lean Production Scheduling System Lesson 7: Problem Solving Tools Materials Included Order #16-3109: LearnMate® E-learning Content: Employability

Foundations Industrial Safety: Mathematics for Lockout/Tagout (LOTO) Technicians 1 (BA01A)

Mathematics for Technicians 2 (BA01B)

Industrial Safety : Lockout/Tagout delivers critical skills for creating and maintaining a safe work environment. Through interactive online activities, students learn about lockout devices, energy control analyses, and perform lockout/tagout.

Mathematics for Technicians 1 conveys skillsbased math curriculum through nine virtual activities. Students gain the fundamental math skills needed for working in a variety of technical and industrial environments.

Mathematics for Technicians 2 applies advanced mathematics concepts to everyday tasks. Through interactive activities students apply drive ratios, Ohm’s Law and mechanical principles.

Skills Acquired Skill 1: Acquiring Lockout/Tagout Basics Skill 2: Attaching Lockout Devices Skill 3: Completing and Attaching Tagout Devices Skill 4: Conducting an Energy Control Analysis Skill 5: Performing Lockout/Tagout Skill 6: Performing Lockout/Tagout Release Materials Included

Skills Acquired Skill 1: Working with Arithmetic and Algebra Skill 2: Working with Whole Numbers Skill 3: Working with Fractions Skill 4: Working with Decimals Skill 5: Working with Percentages Skill 6: Working with Ratios and Proportions Skill 7: Working with Systems of Measurement Skill 8: Working with Geometry Skill 9: Working with Trigonometry

Order #16-LOTO: LearnMate® E-learning Content: Industrial Safety:Lockout/Tagout

Blueprint Reading (BA02)

Skills Acquired Skill 1: Working with Conversion Formulas Skill 2: Applying Mechanical Principles Skill 3: Calculating Drive Ratios Skill 4: Calculating Speed Reducer Service Factor Skill 5: Using Ohm’s Law in Series and Parallel Circuits Skill 6: Converting Binary, Binary Coded Decimal (BCD), Hexadecimal and Decimal Numbers

Skill 7: Calculating Pressure, Force, Head and Flow Skill 8: Calculating Shim Requirements Skill 9: Selecting Pipe Size

Materials Included

Materials Included

Order #16-BA01A: LearnMate® E-learning Content: Mathematics for Technicians 1

Order #16-BA01B: LearnMate® E-learning Content: Mathematics for Technicians 2

Lubrication for Technicians (BA03)

In the Blueprint Reading course, students learn all aspects of reading and interpreting blueprints, including views, tolerances, cutting planes, thread dimensions, and welding symbols.

Skills Acquired Skill 1: Identifying Lines and their Functions Skill 2: Single, Multiple and Auxiliary View Skill 3: Reading and Locating Blueprint Dimensions Skill 4: Determining Tolerances Skill 5: Identifying Thread Dimensions Skill 6: Identifying Tapers and Machine Surfaces Skill 7: Cutting Plane and Sections Skill 8: Geometric Dimensioning, Wear Limits Skill 9: Identifying Welding Symbols Skill 10: Reading Plot Plans Skill 11: Reading Footing, Foundation and Floor Plans Skill 12: Reading Reinforced Concrete and Structural Steel Prints Materials Included Order #16-BA02: LearnMate® E-learning Content: Blueprint Reading

Lubrication for Technicians conveys skillsbased curriculum through virtual and handson activities. Students learn about lubrication equipment, application methods, lubrication schedules, packing bearings, synthetic lubricants and more.

Skills Acquired Skill 1: Applying Lubrication Fundamentals Skill 2: Identifying Lubrication Terms Skill 3: Identifying Lubricating Oils Skill 4: Identifying General Purpose Greases Skill 5: Identifying Special Purpose Greases Skill 6: Applying Lubricating Oils Skill 7: Applying Lubricating Greases Skill 8: Identifying Bearing Lubrication Needs Skill 9: Setting Up a Lubrication Schedule Skill 10: Selecting Synthetic Lubricants Skill 11: Using Grease Guns Skill 12: Packing Bearings Skill 13: Using Grease Lubricators Skill 14: Using Drop Feed Oilers Skill 15: Using Electric Chain Oilers Materials Included Order #16-BA03: LearnMate® E-learning Content: Lubrication for Technicians

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Foundations Mechanical Fasteners (BA04) Materials Included Order #16-BA04: LearnMate® E-learning Content: Mechanical Fasteners BA04 hardware-only package (optional)* *activity consumables not included

Mechanical Fasteners may be taught as a virtual course, delivered entirely online with interactive activities, or as a blended course with both virtual and hardware-based activities. Through twelve activities, students identify and work with the many types of fasteners used in engineering and industrial environments.

For blended lab applications, a separate hardware package is available with all the tools covered in the activities.

Skills Acquired Skill 1: Identifying Screws and Bolts Skill 2: Selecting Threaded Fasteners Skill 3: Applying Thread Standards Skill 4: Creating and Repairing Threads Skill 5: Identifying Nuts Skill 6: Installing Fasteners with a Torque Wrench Skill 7: Removing Fasteners with a Bolt Extractor Skill 8: Identifying Washers Skill 9: Installing Rivets Skill 10: Selecting Adhesives Skill 11: Attaching Hook and Loop Fasteners Skill 12: Connecting Cable Ties

Screw pitch gauge Thread gauge Nut and bolt gauge Tap and die set Tapping fluid, 4 oz.

Torque wrench, 3/8” drive Socket set Bolt extractor set Rivet tool kit with rivets Thread locker Hook and loop strap, 12”, 10-pack Cable tie, 8”, 100-pack Cable tie, 11”, 100-pack

Fastener assortment: 1/4”-20 flanged nut (5) Belleville washer (5) 1/4-20 wing nut (5) M6-16 BHCS (5) 3/8-16 x 1.5” FHCS (5) 3/8-16 x 1.5” HHCS (5) 10-32 x 3/4” SHCS (15) 1/4”-20 x 1” SHCS (15) M8 x 16 SHCS (5) 4-40 nylon hex nut (10) 3/8-24 nylon locking nut (5) M8 black hex nut (5) 1/4-20 Keps nut (5) 10-32 x 5/16” SSS, cup point (10) 1/4” washer (5) 7/16” flat washer (5) 3/8” stainless lock washer (5) 3/8” internal tooth lock washer (5) Plastic fastener organizer case

Hand Tools (BA05)

Hand tools play a key role in the everyday tasks of engineers, electrical technicians and other skilled professionals. Hand Tools features skills-based curriculum delivered through seventeen activities in which students learn all aspects of using hand tools. Hand Tools may be taught as a virtual course, delivered entirely online with interactive activities, or as a blended course with both virtual and hardwarebased activities. For blended lab applications, a separate hardware package is available with all the tools covered in the activities.

Skills Acquired Skill 1: Practicing Shop Safety Skill 2: Reading Rulers and Tape Measures Skill 3: Using Calipers and Feeler Gauges Skill 4: Working with Squares and Levels Skill 5: Cutting with Knives Skill 6: Scribing and Punching Materials Skill 7: Using Work Holding Devices Skill 8: Using Hammers Skill 9: Using Chisels Skill 10: Cutting with Saws Skill 11: Working with Pliers Skill 12: Identifying and Using Cutters Skill 13: Filing and Deburring with Hand Tools Skill 14: Working with Drivers Skill 15: Identifying and Using Hex Keys Skill 16: Identifying and Using Wrenches Skill 17: Identifying and Using Socket and Torque Wrenches Materials Included

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Order #16-BA05: LearnMate® E-learning Content: Hand Tools

BA05 hardware-only package (optional)* *activity consumables not included

Allen wrench set 12” steel rule 25’ tape measure 6” dial caliper Feeler gauge set Combination square with right/center/angle heads Utility knife, retractable Scribe 6” bench vise 16 oz. ball-peen hammer 3/8” cold chisel 12” hacksaw frame 12” hacksaw blade Bull nosed pliers Straight tin snips Fine, flat metal file Ratcheting screwdriver with bits Combination wrench set Socket set with 3/8” driver

Foundations Power Tools (BA06)

Mechanical Measurement and Quality Control

Power Tools delivers twelve skillsbased activities in which students learn all aspects of using power tools, and the role they play in the tasks of skilled professionals. Power Tools may be taught as a virtual course, delivered entirely online, or as a blended course with both virtual and hardware-based activities. For lab applications, a separate hardware package is available with all the tools covered in the activities.

Skills Acquired Skill 1: Practicing Shop Safety Skill 2: Operating a Power Drill Skill 3: Setting Up and Operating a Drill Press Skill 4: Operating a Rotary Tool Skill 5: Setting Up and Operating a Jigsaw Skill 6: Setting Up and Operating a Reciprocating Saw Skill 7: Setting Up and Operating a Circular Saw Skill 8: Adjusting and Operating a Table Saw Skill 9: Setting Up and Operating a Bandsaw Skill 10: Setting Up and Operating a Sander Skill 11: Adjusting and Operating a Bench Grinder Skill 12: Adjusting and Operating an Angle Grinder Materials Included Order #16-BA06: LearnMate® E-learning Content: Power Tools BA06 hardware-only package (optional)* *activity consumables not included

Power drill 1/4” bi-metal twist drill bit Drill press 1/4” bi-metal twist drill bit for drill press Rotary tool Rotary tool accessory kit Jigsaw Assorted jigsaw blades Reciprocating saw Assorted reciprocating saw blades Circular saw Assorted circular saw blades Table saw Assorted table saw blades Table saw rip fence Table saw miter gauge Push stick Bandsaw Bandsaw rip fence Bandsaw miter gauge Bi-metal bandsaw blade Stationary belt sander Assorted sanding belts Benchtop grinder Assorted grinding wheels Angle grinder Assorted grinding disks

Mechanical Measurement and Quality Control with lab hardware Available as a virtual course or with lab hardware, Mechanical Measurement and Quality Control delivers a solid foundation in precision measuring principles and statistical analysis. Students learn to use precision measurement tools, read mechanical drawings, select inspection tools, collect sample data and prepare QA/QC reports.

Course Outline Activity 1: Getting Started Activity 2: Accuracy, Precision and Measurement Tools Activity 3: Units of Measurement and Conversion Activity 4: Fractions, Decimals, and Rounding Activity 5: Scaled Measurement Tools Activity 6: Vernier, Dial, and Digital Calipers Activity 7: Micrometers Activity 8: Height Gauges and Dial Indicators Activity 9: Fixed Gauges Activity 10: Transfer Measurement Tools Activity 11: Statistical Analysis Activity 12: Statistical Process Control Activity 13: Nominal Dimensions and Tolerance Activity 14: Parts Inspection and Inspection Reports Activity 15: Conclusion

Materials Included Order #16-3030 (Virtual): LearnMate® E-learning Content: Mechanical Measurement and Quality Control

Order #16-8014 (Lab): LearnMate® E-learning Content: Mechanical Measurement and Quality Control

“Tools and Rules for Precision Measurement” Booklet Tool Usage Educational Charts Inch/Metric Tap Drill Sizes and Decimal Equivalents Wall Chart

Inch/Metric Tap Drill Sizes and Decimal Equivalents Card Millimeter/Inch Equivalents Card Spread Sheet Software Precision Measurement Tools Kit: 12” wooden ruler 16” tape measure 6” rule 300mm steel rule 6” dial caliper 6” electronic digital caliper 1” micrometer Feeler gage set (6 leaves) 4” inside caliper 4” outside caliper Dial indicator with attachments 6” height gauge Steel protractor 5 piece gauge block set 12” x 8” x 2” granite surface plate 12 plug gauge pins 6” vernier caliper Ground-slotted angle plate Cable and adapter Carrying case

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Electrical Series Course List The ultimate flexibility in electrical maintenance skills training!

HOW TO BUILD YOUR ELECTRICAL SERIES TRAINING PROGRAM: Electrical Series Overview Total hours of instruction*

325

Total critical skills taught

214

Total Flexponent panels

75

1

The JobMaster® two-sided mobile learning station is the hardware foundation of the JobMaster® Electrical Training courses. This sturdy anodized aluminum learning station provides the mounting points for the Flexponent™ panels provided with the JobMaster® courses.

Hardware and courses included in the Electricals Series are listed below:

Each learning station accommodates 30 Flexponent™ panels and four students. Students can quickly and easily mount and remove panels to configure their work area for each individual skill.

Lockable swiveling casters and the 32” (81 cm) depth enables easy mobility through standard facility doorways.

Electrical Sytems Hardware Learning Station

LS00

Single-phase power control panel

PC04

Three-phase power control panel

PC06

International step-down transformer

PC09

Portable panel storage unit

PPSU

Select Learning Station(s) to accommodate the number of students in your program.

Simply choose the number of Learning Stations necessary for the scope and size of your program!

Basic Power Electricity Electrical Circuits

EA01A

Resistors & Conductors

EA01B

LCR Circuits

EA01C

Motors & Generators

EA01D

2

Once you have equipped your program with the appropriate learning stations to accommodate your students, simply choose the courses that cover the skills and concepts needed in your training program.

Electrical Control Systems

In addition to content, each JobMaster® series of courses includes all the necessary FlexPonent™ panels for use on the learning station, along with any additional tools and hardware used in the skill-based activities, such as meters and scopes.

Electric Circuit Protection & Monitoring EA02 Transformers

EA03

Electric Motors

EA04

Electromagnetic Motor Starters

EA07

Relays, Timers, & Time Delay Relays

EA08

Pilot Devices

EA09

Solid-State Starters

EA11

Variable Frequency Drives (VFDs)

EA12

DC Motor Control

EA16

Industrial Power Electronics Oscilloscope

EB01A

Digital Multimeter

EB01B

Hand Held Digital Oscilloscope

EB01C

DC Power Supplies

EB02A

Single-phase & 3-phase Power Supplies EB02B Thyristor Electric Motor Drives

EB03

Electronic Timers

EB04

Stepper Motor Drives

EB05

Servo Motor Drives

EB06

*Hours are approximate and depend on class structure and teaching strategies.

Select the JobMaster® Electrical Series course(s) you need.

Panels are easily added and exchanged allowing the workspace to be re-configured as multiple students progress through the course. This flexible modular approach allows you to build a custom program for your needs.

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Select a Power Control Panel based on course requirements.

An essential element of the JobMaster® Training System, JobMaster® Power Control (PC) panels serve three vital purposes: Providing the necessary electrical connection from the learning station to your facility power.

Assuring a safe environment in the classroom.

Exposing trainees to the same environment they will encounter in industrial settings.

Each JobMaster® technology training course specifies the model power controller needed. PC panels feature industrial-level safety controls, including the lockout/tagout point, emergency stop, and the on/off switch for all the learning station components. Each power control panel provides three forms of lockout: one for the instructor, one for the student, one for emergency stop conditions.

Power controllers are available for both 120V single-phase and 220V three-phase power supplies.

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Electrical Series Hardware With the versatile JobMaster® learning station, the appropriate power control panels and your choice of JobMaster® technology training courses, you can be sure your industrial maintenance and automated manufacturing programs are fully equipped for success!

JobMaster® hardware includes:

Hardware Specifications Frame Construction:

(See next page for specifications)

Each Learning station requires one power control panel for each side in use. Each JobMaster® Module specifies which power controller is needed.

International step-down transformer package required for international applications.

industry.

standard conduit, allowing students to learn effective wiring practices when wiring from panel to panel.

JobMaster® Learning Station (LS00)

Materials Required (sold separately) Power Control Panels

All wiring is terminated with crimped ferrules, like those found in The JobMaster® learning station includes frame-mounted industry-

JobMaster® Learning Station Power Control Panels Flexponent Panels

The JobMaster® two-sided mobile learning station is the hardware foundation of the JobMaster® Electrical Series courses. Each side of the learning station accommodates two students and can mount up to 15 Flexponent™ panels.

No other training system provides exposure to industry-standard practices like JobMaster:

Portable Panel Storage Unit (PPSU)

The Portable Panel Storage Unit stores up to 50 Flexponent™ panels.

Material: Anodized aluminum U-shaped frame

with 1-1/2” (38 mm) square t-slot table Overall size: 76”H X 44.25”W X 32”D

1930mm x 1120mm x 813mm Bench height: 34” (864 mm) Vertical rack : 42” (1067 mm) Wireway: 1” (25.4 mm) wiring conduit mounted along frame

allows for industry-standard wiring practices Casters : 4” (100 mm) swiveling and locking Drawers: (1/side) Full-suspension ball bearing slides

Interior dimensions:

6”H x 12”W x 16”D

(152 mm x 305 mm x 406 mm) Table surface material:

3/8” (9.5 mm) thick high density polyethylene

Environmentally stabilized, chemically resistant

Non-conductive Safety shield (2 included)

8.5"H x 18"W x 14.75"D

(216 mm x 457 mm x 375 mm) Weight: 150 lbs (68 kg) Assembled weight: Materials Included Shipping weight: 245 lbs (112 kg)

Order #10-PPSU-0200 Portable panel storage unit Hardware Specifications Frame Construction: Material: Overall size:

Casters :

Anodized aluminum U-shaped frame 76”H X 44.25”W X 32”D 1930mm x 1120mm x 813mm 4” (102 mm) swiveling and locking

Materials Included Order #10-LS00-0200 JobMaster® Learning Station Nylon panel mounting nuts kit Hook-up lead wire kit: Color-coded 16-gauge insulated and stranded lead wires, various lengths Leads terminated on each end with industry-standard uninsulated crimped metal ferrules, no banana jacks Installation guide Hex key for assembly

(800) 221-2763

11

Electrical Series Hardware Power Control Panels (PC04 & PC06)

FlexPonent™ Panels

Materials Required (sold separately) JobMaster® Learning Station Each Learning station requires one power control panel for each side in use. Each JobMaster® course specifies which power controller is needed.

JobMaster® Electrical Series course(s) with Flexponent panels Facility power source

Materials Included Order #10-PC04-0000 120V Single-phase Power Control Panel (PC04) All Flexponent™ panels are constructed of nonconductive, high density polyethylene with industry-standard recessed and insulated terminal strip connections.

JobMaster® Power Control (PC) panels mount on the Learning Station to provide the electrical connection to your facility power.

PC panels feature industrial-level safety controls, including the lockout/tagout point, emergency stop, and the on/off switch for all the learning station components. Each power control panel provides three forms of lockout: one for the instructor, one for the student, one for emergency stop conditions. These features assure a safe environment in the classroom and expose trainees to the same environment they will encounter in industrial settings.

Power controllers are available for both 120V singlephase and 220V three-phase power supplies. Each JobMaster® technology training course specifies the model power controller needed.

Two keys enable instructors to control access to the learning station: The power lock switch must be activated using the power lock switch key before power will flow through the panel. Once the power lock switch is engaged, indicated by the power indicator light, the on/off toggle switch serves as the power switch to any components wired to the panel.

The emergency stop key is required to reset the e-stop once activated.

Overload protection: If tripped because of a circuit overload, the 5-amp breakers and power lock switch must be reset.

Emergency stop disconnects power to the entire system when activated. Once engaged, both the e-stop and the power lock switch must be reset using the respective keys.

Beacon warning light flashes when the e-stop is activated and continues flashing until the emergency stop button is reset.

Industry-standard terminal strips.

12

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120V single-phase* Weight 6.75 lbs (3 kg) Dimensions 8”W x 14”H x 6.375”D

(203 mm x 356 mm x 162 mm)

Order #10-PC06-0000 240V Three-phase Power Control Panel (PC06)

220V (+/- 10%) three-phase* Weight 7.45 lbs (3.375 kg) Dimensions 8”W x 14”H x 6.375”D

(203 mm x 356 mm x 162 mm) Note: The PC06 power connection cable does not include a plug. You must provide and install the plug to match your facility’s receptacle type.

Order #10-PC09-0000 International step-down transformer package* *International step-down transformer package required for international applications.

Hardware Specifications Mounting board Material: 3/8” (9.5 mm) thick high density polyethylene Properties: Environmentally stabilized, chemically resistant,

non-conductive Dimensions 8”W x 11.5”H x 0.375”D

(203 mm x 292 mm x 9.525 mm) Terminal strips Industry-standard, field serviceable fasteners for electrical connections Rated for 50-amps at 600 volts Recessed and insulated for safety

Flexponent™ panels are a component of JobMaster® courses. Each course specifies what materials are included. Flexponent panels require a JobMaster® Learning Station with the appropriate Power Control Panel.

All Flexponent™ panels meet the following specifications:

Hardware Specifications Construction: 3/8" (9.5 mm) thick environmentally stabilized, chemically resistant, non-conductive, high density polyethylene.

Terminal strips Industry-standard, field serviceable fasteners for electrical connections Rated for 50-amps at 600 volts Recessed and insulated for safety Dimensions 8"W x 11.5"H x 0.375"D (203 mm x 292 mm x 9.525 mm)

Basic Power Electricity Basic Power Electricity Courses

Course title Electrical Circuits Resistors and Conductors LCR Circuits Motors and Generators

Course # Skills

Hours*

Panels

EA01A

14

21

5

EA01B

9

14

1

EA01C

14

21

5

EA01D

8

12

0

Total:

45

68

11

With 45 total skills and 11 total Flexponent panels, Basic Power Electricity teaches the introductory electrical skills essential for entry level maintenance technicians. *Hours are approximate and depend on class structure and teaching strategies.

Electrical Circuits: (EA01A) Electrical Circuits (EA01A) introduces students to concepts including lockout/tagout and safety; connecting circuits and measuring electrical quantities like voltage and current. The skills-based curriculum includes a digital multimeter and five Flexponent™ panels.

Skills Acquired Skill 1: Performing Lockout/Tagout Skill 2: Connecting a Basic Circuit Skill 3: Identifying Switches Skill 4: Connecting a Momentary Switch Skill 5: Connecting a Toggle Switch Skill 6: Identifying Sources of Electricity Skill 7: Measuring DC Voltage Skill 8: Constructing a Series Circuit Skill 9: Constructing a Parallel Circuit Skill 10: Applying DC Voltage Principles Skill 11: Testing an Electrolytic Cell Skill 12: Testing a Battery Skill 13: Testing a Thermocouple Skill 14: Testing a Photovoltaic (PV) Cell Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel: (120V)* Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Materials Included Order #16-EA01A: LearnMate® E-learning Content: Electrical Circuits (EA01A) Teachers’ Guide Digital Multimeter (5) Flexponent™ panels: Panel E040: Switch, Lamp and Buzzer Panel E045: Sources of Electricity Panel E047: Heat and Light Source Panel E151: Series/Parallel Lamp Circuits

Hardware Specifications Digital Multimeter True-rms CAT III 600 V safety rated AC/DC volts, millivolts, amps Continuity Resistance Diode test Capacitance Hz (V or A input)

Panel E040: Switch, Lamp and Buzzer Panel type: Single 1 87dB Piezo pulse buzzer 1 12V jumbo lamp 1 SPST toggle switch 1 DPDT toggle switch 1 NO pushbutton switch 1 NC push button switch

Panel E045: Sources of Electricity Panel type: Single 1 Encapsulated PV cell 1 J-type surface thermocouple 1 Battery box 4 D-cell batteries

Panel E047: Heat and Light Source Panel type: Single 1 Heat gun 1 Flashlight

Resistors & Conductors (EA01B) Resistors and Conductors (EA01B) teaches circuit troubleshooting and testing skills including measuring resistance, calculating wire size and determining losses in a wire. The handson activities use industrial-grade resistors, potentiometers, rheostats and coils.

Adding one new Flexponent™ panel to the Basic Power Electricity series, Resistors and Conductors (EA01B) builds on the concepts learned in the prerequisite course: Electrical Circuits (EA01A).

Skills Acquired Skill 1: Measuring Resistance Skill 2: Measuring Resistance in Series Circuits Skill 3: Measuring Resistance in Parallel Circuits Skill 4: Drawing and Reading Resistor Symbols Skill 5: Testing an Adjustable Resistor Skill 6: Measuring Wire Size Skill 7: Applying Resistance and Wire Size Skill 8: Calculating Wire Size Skill 9: Determining Losses in a Conductor Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel: (120V)* Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses: Electrical Circuits (EA01A)

Order #16-EA01A

Materials Included Order #16-EA01B: LearnMate® E-learning Content: Resistors and Conductors (EA01B) Teachers' Guide (1) Flexponent™ panel: Panel E042: Resistance

Hardware Specifications Panel E042: Resistance

Panel E151: Series/Parallel Lamp Circuits Panel type: Single 6 Miniature bulb sockets 3 3.7V@0.30A bulbs 3 6.3V@0.30A bulbs

Panel E152: Adjustable Power Supply Panel E152: Adjustable Power Supply Panel type: Single 1 8V/16V/24V transformer 1 1000uF 50V 20% axial-lead electrolytic capacitor 1 4A 50PIV bridge rectifier 1 100-ohm rheostat

Panel Type: Double 1 Wire gauge, US standard 1 Resistance coils package 1 Rheostat, 100ohm 1 5K-ohm linear taper potentiometer 1 10K-ohm linear taper potentiometer 1 50K-ohm linear taper potentiometer 1 Knob, hexagon 1 Resistor, wire wound, 10ohm, 5%, 5W, ceramic 1 Resistor, wire wound, 400ohm, 5%, 5W 1 Resistor, wire wound, 900ohm, 5%, 5W 1 Resistor, wire wound, 10kohm, 5%, 5W, ceramic 1 Resistor, carbon film, 15kohm, 5%, 1/4W

(800) 221-2763

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Basic Power Electricity LCR Circuits (EA01C)

Motors and Generators (EA01D)

LCR Circuits (EA01C) teaches the relationships between electrical properties such as inductance, capacitance and reactance. The skills-based curriculum builds on concepts learned in the prerequisite Resistors and Conductors (EA01B) course. Using the same components they will find in industrial environments, including relays, contactors, capacitors and inductors, students learn to determine capacitance, assemble an electromagnet, induce voltage and operate transformers.

Skills Acquired Skill 1: Discharge a Capacitor Skill 2: Testing a Capacitor Skill 3: Determining Capacitance Skill 4: Applying Capacitance Principles Skill 5: Applying Magnetic Principles Skill 6: Inducing a Magnetic Field Skill 7: Assembling an Electromagnet Skill 8: Applying Electromagnetic Principles Skill 9: Inducing Voltage Skill 10: Inducing DC Voltage Skill 11: Assembling & Operating Transformers Skill 12: Applying Inductance Principles Skill 13: Operating Electromagnets Skill 14: Drawing Inductance Symbols Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel: (120V)* Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses: Resistors and Conductors (EA01B)

Order #16-EA01B

Materials Included Order #16-EA01C: LearnMate® E-learning Content: LCR Circuits (EA01C) Teachers’ Guide (5) Flexponent™ panels: Panel E029: Magnetism Panel E043: Capacitance Panel E044: Inductance Panel E057: Motor/Generator Panel E150: Relay/Contactor

Hardware Specifications Panel E029: Magnetism Panel type: Single 1 Current meter, 100-0-100, 3.5” x 3.5” 1 Mini compass, 1-1/2” diameter

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Panel E043: Capacitance Panel type: Single 1 Start capacitor, 88-106MFD, 110-125V 1 Capacitor, 100uf, 50V, axial, aluminum 1 Capacitor, 2200uf, 25V, axial, aluminum 1 Capacitor, 3.3uf, 10V, axial, ceramic 1 Capacitor, 47uf, 25V, axial, aluminum 1 Run capacitor, 12.5 MFD, 370V

Panel E044: inductance Panel type: Single 1 Primary-secondary coil 2 Bar magnets, 2”

Panel E057: Motor/Generator Panel type: Single 1 Motor/Generator 1 Cover, clear, 3.5” depth

Panel E150: Relay/Contactor Panel type: Single 1 Contactor, mini, 6A, 24V 1 Relay, 8 pin DPDT 1 Socket, relay, 8 pin 1 Solenoid, 24V, box frame

Motors and Generators (EA01D) delivers a complete understanding of phase relationships and the practical operation of motors and generators through activities including operating AC and DC generators, operating a series motor and demonstrating reactance and impedance.

The skills-based curriculum builds on concepts learned in the prerequisite LCR Circuits (EA01C) course. Motors and Generators (EA01D) adds interactive content for eight additional hands-on activities using the Basic Power Electricity equipment.

Skills Acquired Skill 1: Operating a PMDC Motor Skill 2: Operating a DC Generator Skill 3: Operating an AC Generator Skill 4: Operating a Series Motor Skill 5: Demonstrating Principles of Reactance and Impedance

Skill 6: Applying Phase Relationship Principles Skill 7: Illustrating Three-Phase Power Skill 8: Measuring AC Voltage Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel: (120V)* Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses: LCR Circuits (EA01C)

Order #16-EA01C

Materials Included Order #16-EA01D: LearnMate® E-learning Content: Motors and Generators (EA01D) Teachers’ Guide

Electrical Control Systems Electrical Control Systems Courses

Course title Electric Circuit Protection & Monitoring Transformers Electric Motors Electromagnetic Motor Starters Relays, Timers, & Time Delay Relays Pilot Devices Solid-State Starters Variable Frequency Drives (VFDs) DC Motor Control

Course # Skills

Hours*

Panels

EA02

10

15

3

EA03

8

12

1

EA04

14

21

10

EA07

8

12

9

EA08

8

12

2

EA09

10

15

4

EA11

5

8

1

EA12

6

9

2

EA16

8

12

7

Total:

77

116

39

The Electrical Control Systems series includes comprehensive instruction in electrical control including motor controls and variable frequency drives.

With 77 total skills, and 39 total Flexponent panels for use with the JobMaster® Learning Station, Electrical Control Systems teaches the essential skills for control operators, technicians and managers. *Hours are approximate and depend on class structure and teaching strategies.

Electric Circuit Protection & Monitoring (EA02) Electric Circuit Protection & Monitoring (EA02) delivers hands-on skills in the methods and devices used to protect industrial electric circuits.

Electric Circuit Protection & Monitoring (EA02) is an add-on to Electromagnetic Motor Starters (EA07), covering ten additional skills.

The skills-based curriculum presents hands-on activities using industrial-grade components mounted on the three included Flexponent™ panels which attach to the JobMaster® Learning Station (not included).

Skills Acquired Skill 1: Drawing and Reading Circuit Protection

Materials Included Order #16-EA02: LearnMate® E-learning Content: Electric Circuit Protection & Monitoring (EA02)

Teachers’ Guide (3) Flexponent™ panels: Panel E019 Capacitor-Start Motor Panel E022 Manual Starter Panel E030 Circuit Overload Protection & Monitoring

Hardware Specifications Panel E019 Capacitor-Start Motor Panel type: Double 1 1-phase motor, .08hp, 1725rpm 2 Fault switch, 4A, 250V push-on/ push-off momentary

Symbols

Skill 2: Sizing Fuses Skill 3: Installing Fuses Skill 4: Testing and Replacing Fuses Skill 5: Performing Preventive Maintenance and Troubleshooting Fuse Blocks

Skill 6: Sizing Circuit Breakers Skill 7: Testing and Resetting a Circuit Breaker Skill 8: Sizing and Installing an Overload Heater Skill 9: Adjusting and Testing the Overload Relay Skill 10: Installing and Setting Up a Three-Phase Monitor

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000

Panel E022 Manual Starter Panel type: Single 1 Single-phase fractional horsepower starter (FHP) 1 Thermal overload unit (0.41 to 16 A) with pilot light 1 Non-reversing manual starter with bimetallic thermal trip and magnetic trip 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E030 Circuit Overload Protection & Monitoring

Transformers (EA03) Transformers (EA03) delivers hands-on skills in installing, operating and troubleshooting transformers. Transformers (EA03) covers eight skills using industrial-grade components mounted on the included Flexponent™ panel.

Skills Acquired Skill 1: Applying Transformer Principles Skill 2: Drawing and Reading Transformer Symbols Skill 3: Installing a Control Transformer Skill 4: Troubleshooting Transformers Skill 5: Connecting a Transformer as an Auto Transformer for Buck and Boost Operation

Skill 6: Connecting Transformers in Delta and Wye Skill 7: Inspecting and Servicing a Transformer Skill 8: Sizing a Transformer Materials Required (sold separately) Order #10-LS00-0200 JobMaster® Learning Station Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Digital Multimeter (Fluke Model 115 or equivalent) Materials Included Order #16-EA03: LearnMate® E-learning Content: Transformers (EA03) Teachers’ Guide (1) Flexponent™ panel: Panel E003: Three-Phase Transformer

* International step-down transformer package (Order #10PC09-0000) required for international applications.

Hardware Specifications Panel E003: Three-Phase Transformer

Digital Multimeter (Fluke Model 115 or equivalent) Prerequisite courses: Electromagnetic Motor Starters (EA07) Order #16-EA07 Panel type: Double 1 Relay, overload 1 Circuit breaker, 2A 1 3-Phase line monitor 3 Midget fuse 2A 1 Midget fuse block, 30A, 3-pole

Panel type Double 1 Midget fuse 2A 1 Midget fuse block, 30A 3 0.05kVA, 50/60 Hz, Step-down transformer

(800) 221-2763

15

Electrical Control Systems Electric Motors (EA04) Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000

Panel E156 : Dissectible Motor Panel type: Single 1 3-phase motor, .13hp, 1725 rpm, disabled

* International step-down transformer package (Order #10PC09-0000) required for international applications.

DMM (Fluke Model 115 or equivalent) Clamp-on ammeter (Fluke Model 322 or equivalent) Insulation Tester (Fluke Model 1587 or equivalent) Strobe or Photo Tachometer

Panel E010: Three-Phase Motor Panel type: Double 1 3-phase motor, .13hp, 1725 rpm 3 Fault switch, 4A, 250V push-on/ push-off momentary

Materials Included Order #16-EA04: LearnMate® E-learning Content: Electric Motors (EA04) Teachers’ Guide (10) Flexponent™ panels:

Electric Motors (EA04) presents a wide array of hands-on activities using industrial motors, including three-phase, split-phase and capacitorstart motors. From wiring motor circuits to preventive maintenance and troubleshooting, students gain practical experience in all aspects of industrial motor operation.

The skills-based curriculum presents fourteen hands-on activities using industrial grade electrical components mounted on ten Flexponent™ panels.

Skills Acquired Skill 1: Connecting and Operating a

Split-Phase Motor Skill 2: Connecting and Operating a CapacitorStart Motor Skill 3: Connecting and Operating a Shaded-Pole Motor Skill 4: Connecting and Operating a DC Motor Skill 5: Connecting and Operating a Three-Phase Motor Skill 6: Performing Visual Inspection Skill 7: Lubricating Motors Skill 8: Performing DMM and Motor Megger Tests Skill 9: Troubleshooting a Split-Phase Motor Skill 10: Troubleshoot A Capacitor-Start Motor Skill 11: Troubleshooting a Shaded-Pole Motor Skill 12: Troubleshooting A DC Motor Skill 13: Troubleshooting A Three-Phase Motor

Skill 14: Testing Motors With Adjustable Loads

Panel E007: SCR Speed Controller Panel E012: Transformer Panel E027 : Shaded-Pole Motor Panel E154 : Lamps and Switches Panel E156 : Dissectible Motor Panel E010: Three-Phase Motor Panel E019: Capacitor-Start Motor Panel E034 : DC Motor Panel E065 : Split-Phase Motor Panel E066 : Adjustable Motor Load

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Panel type: Double 1 1-phase motor, .08hp, 1725rpm 2 Fault switch, 4A, 250V push-on/ push-off momentary

Panel E034 : DC Motor Panel type: Double 1 Motor, 90VDC, .13hp 1 Fault switch: 4A, 250V push-on/ push-off momentary

Hardware Specifications Panel E007: SCR Speed Controller Panel type: Single 1 115V DC SCR speed control 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E065 : Split-Phase Motor Panel type: Double 1 Motor, split phase, NEMA frame 42 2 Fault switch, 4A, 250V push-on/ push-off momentary

Panel E012: Transformer Panel type: Single 1 Midget fuse 2A 1 Midget fuse block, 30A 1 Transformer, 110V, 230 to 115V 1 Transformer finger guard 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E027 : Shaded-Pole Motor Panel type: Single 1 Shaded-pole motor, 1/20 hp 1 Fault switch: 4A, 250V push-on/push-off momentary

Panel E154 : Lamps and Switches Panel type: Single 1 125V raised indicator light, RED 1 125V raised indicator light, AMBER 1 125V raised indicator light, GREEN 3 Switches, toggle, SPST 1 Switch, toggle, 3PST, On/Off

16

Panel E019: Capacitor-Start Motor

Panel E066 : Adjustable Motor Load

1 1 1 1 1 1 1

Panel type: Double 1 Brake, magnetic particle, 0.6-35 lb-in 1 Power supply, 0-24VDC output, 220V AC input Bracket, adjustable torque brake mounting Coupling body, jaw type, size L050, 1/2” bore Coupling body, jaw type, size L050, 3/8” bore Coupling insert, jaw type, size L050 Relay, solid state, 10sec delay Relay, solid state, .1 To 100 min delay NO pushbutton switch

Electrical Control Systems Electromagnetic Motor Starters (EA07) Electromagnetic Motor Starters (EA07) guides students through hands-on activities using industrial motor controls. From wiring motor control circuits to troubleshooting, students gain practical experience in all aspects of industrial motor control, including testing and resetting overload protection, operating a three-phase reversing starter, and troubleshooting a threephase motor control circuit.

The skills-based curriculum presents eight critical skills using industrial magnetic starters, relays, and START-STOP motor control components mounted on nine included Flexponent™ panels.

Skills Acquired Skill 1: Connecting a Control Relay Seal-In Circuit Skill 2: Connecting, Adjusting, and Operating a Single Magnetic Starter Skill 3: Testing and Resetting Overload Protection Skill 4: Connecting, Adjusting, and Operating a Three-phase Reversing Starter Skill 5: Connecting and Operating a Magnetic Starter for Jogging Skill 6: Troubleshooting a Three-phase Motor Control Circuit Skill 7: Troubleshooting a Reversing Three-phase Motor Control Circuit Skill 8: Performing Preventive Maintenance on Magnetic Starters

Materials Required (sold separately) Order #10-LS00-0200 JobMaster® Learning Station Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

DMM (Fluke Model 115 or equivalent) Materials Included Order #16-EA07: LearnMate® E-learning Content: Electromagnetic Motor Starters (EA07) Teachers' Guide (9) Flexponent™ panels: Panel E002: START-STOP Control Panel E004: Single Magnetic Starter Panel E005 : START-REVERSE-STOP Switch Panel E006 : Reversing Magnetic Starter Panel E010: Three-Phase Motor Panel E012: Transformer Panel E016 : Analog Relay Panel E154 : Lamps and Switches Panel E155: HOA Switch

Hardware Specifications Panel E002: START-STOP Control Panel type: Single 1 Switch, pushbutton, momentary, black, NO w/contact block 1 Switch, pushbutton, momentary, red, NC w/contact block 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E004: Single Magnetic Starter Panel type: Single 1 Contactor, 9A, 43mm 1 AUX Contact 1NO/1NC 1 Relay, thermal overload, 0.8-1.2A 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E005 : START-REVERSE-STOP Switch Panel type: Single 1 Switch, pushbutton, momentary, red LED, NC w/contact block 1 Switch, pushbutton, momentary, green LED, NO w/contact block 1 Switch, pushbutton, momentary, yellow LED, NO w/contact block 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E006 : Reversing Magnetic Starter Panel type: Single 2 Contactor, 9A, 43mm 2 AUX contact 2NO/2NC 1 Relay, thermal overload, 0.8-1.2A 1 Interlock unit 1 Reversing unit load side 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E010: Three-Phase Motor Panel type: Double 1 3-phase motor, .13hp, 1725 rpm 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E012: Transformer Panel type: Single 1 Midget fuse 2A 1 Midget fuse block, 30A 1 Transformer, 110V, 230 to 115V 1 Transformer finger guard 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E016 : Analog Relay Panel type: Single 1 Relay, 120V 2PDT 15A LED Test PB 1 Relay, socket 1 Timer multi-mode 2PDT, 100-240V 0.05S-60H 1 Relay, socket mount

Panel E154 : Lamps and Switches Panel type: Single 1 125V raised indicator light, red 1 125V raised indicator light, amber 1 125V raised indicator light, green 3 Switches, toggle, SPST 1 Switch, toggle, 3PST, on/off

Panel E155: HOA Switch Panel type: Single 1 Switch, 3 pos, maintained contact, black 2 Fault switch, 4A, 250V push-on/push-off momentary

Relays, Timers & Time Delay Relays (EA08) Relays, Timers & Time Delay Relays (EA08) features hands-on skills in installing, programming and maintaining control devices used in industrial electric circuits. Relays, Timers & Time Delay Relays (EA08) is an add-on to Electromagnetic Motor Starters (EA07), covering eight additional skills using a digital relay and an electronic timer mounted on the two included Flexponent™ panels.

Skills Acquired Skill 1: Connecting, Programming, and

Operating Analog On-Delays and Off-Delay Relays Skill 2: Using Analog Relays and Motors Skill 3: Connecting, Programming, and Operating Digital Interval, Repeat Cycle, and One Shot Relays Skill 4: Using Digital Relays and Motors Skill 5: Connecting and Operating Electric Timers Skill 6: Using Electric Timers and Motors Skill 7: Troubleshooting Relays Skill 8: Performing Preventive Maintenance on Relays

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Digital Multimeter (Fluke Model 115 or equivalent) Prerequisite Courses Electromagnetic Motor Starters (EA07) Order #16-EA07

Materials Included Order #16-EA08: LearnMate® E-learning Content: Relays, Timers & Time Delay Relays (EA08)

Teachers' Guide (2) Flexponent™ panels: Panel E017: Digital Relay Panel E041: Electric Timer

Hardware Specifications Panel E017: Digital Relay Panel type: Single 4 Fault switch, 4A, 250V, push-on/push-off momentary 1 Relay, 120V 2PDT 15A LED Test PB 1 Socket relay 1 Time delay relay, DPDT, multi-function 1 Socket relay, 11 pin octal

Panel E041: Electric Timer Panel type: Single 1 Timer mechanism, electronic

(800) 221-2763

17

Electrical Control Systems Pilot Devices (EA09) Pilot Devices (EA09) conveys skills in installing, operating and troubleshooting pilot devices used in electric control circuits. Pilot Devices (EA09) is an add-on to Electromagnetic Motor Starters (EA07), covering ten additional skills including connecting and operating photoelectric sensors with fiber optics, capacitive and inductive proximity switches, limit switches, pressure switches, liquid level switches, and magnetic reed switches.

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000

The skills-based curriculum presents hands-on activities using industrial-grade components mounted on the four included Flexponent™ panels.

Materials Included

Skills Acquired Skill 1: Connecting and Operating a

Photoelectric Detector Skill 2: Connecting and Operating a Photoelectric Sensor with Fiber Optics Skill 3: Connecting and Operating a Capacitive Proximity Switch Skill 4: Connecting and Operating an Inductive Proximity Switch Skill 5: Connecting and Operating a Limit Switch Skill 6: Connecting and Operating a Pressure Switch Skill 7: Connecting and Operating a Liquid Level Switch Skill 8: Connecting and Operating a Magnetic Reed Switch Skill 9: Troubleshooting Pilot Devices

Panel E018: Liquid Level and Pressure Switch

* International step-down transformer package (Order #10PC09-0000) required for international applications.

Digital Multimeter (Fluke Model 115 or equivalent) Prerequisite Courses Electromagnetic Motor Starters (EA07) Order #16-EA07

Order #16-EA09: LearnMate® E-learning Content: Pilot Devices (EA09) Teachers' Guide (4) Flexponent™ panels:

Panel type: Double 1 Pressure gauge, 60 psi, 1-1/2 dia 1 Pressure switch, NEMA 1 enclosed, 40-100 PSIG 2 Liquid level switch, 1/4” x 1/2” NPT 1 Liquid level switch, float, 1/4” NPT 4 Fault switch, 4A, 250V, push-on/push-off momentary

Panel E126: Proximity & Photoelectric Switch

Panel E011: Limit Switch Panel E018: Liquid Level and Pressure Switch Panel E126: Proximity and Photoelectric Switch Panel E153: AC/DC Circuit

Hardware Specifications Panel E011: Limit Switch Panel type: Single 2 Limit switch, snap action, one-way lever 4 Fault switch, 4A, 250V, push-on/push-off momentary

Panel type: Double 1 Switch, fiber optic photoelectric 1 Switch, proximity, 34mm, 120VAC 1 Switch, magnetic reed 1 Photoelectric sensor, 12-240VDC, w/6ft cable 1 Proximity sensor, 12mm dia, 24VDC, NO 4 Fault switch, 4A, 250V, push-on/push-off momentary

Panel E153: AC/DC Circuit Panel type: Single 1 Transformer, 24V output, 40 VA rating 1 Encapsulated solar cell, 0.45V/200mA 1 Bridge rectifier, 4A, 50PIV 1 Light bulb , 24V, w/socket

Skill 10: Performing Preventive Maintenance

Solid-State Starters (EA11) Solid-State Starters (EA11) guides trainees through installing, operating and troubleshooting solidstate starters used in electric motor circuits.

Solid-State Starters (EA11) is an add-on to Electromagnetic Motor Starters (EA07), covering five additional skills.

The skills-based curriculum presents hands-on activities using industrial-grade components mounted on the included Flexponent™ panel.

Skills Acquired Skill 1: Applying Solid-State Principles Skill 2: Connecting and Operating a Solid-State Starter Skill 3: Adjusting a Solid-State Starter Skill 4: Testing Solid-State Starters Skill 5: Troubleshooting Solid-State Starters

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Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Digital multimeter (Fluke Model 115 or equivalent) AC clamp-meter (Fluke Model 322 or equivalent) Prerequisite courses: Electric Motors (EA07)

Order #16-EA07

Materials Included Order #16-EA11: LearnMate® E-learning Content: Solid-State Starters (EA11) Teachers' Guide (1) Flexponent™ panel: Panel E024: Solid-State Starter

Hardware Specifications Panel E024: Solid-State Starter Panel type: Single 1 Solid-state soft starter, 1/2HP, 100-240V control voltage, 200-208V 3PH, 3A output 2 Fault switch, 4A, 250V push-on/push-off momentary

Electrical Control Systems Variable Frequency Drives (EA12) Variable Frequency Drives (EA12) delivers comprehensive coverage of installing, operating and troubleshooting variable frequency drives (VFDs) in motor control circuits. Variable Frequency Drives (EA12) is an add-on to Electric Motors (EA04), covering six additional skills.

The skills-based curriculum presents hands-on activities using an industrial-grade Mitsubishi VFD.

Skills Acquired Skill 1: Applying VFD Principles Skill 2: Connecting and Operating a Variable

Frequency Drive Skill 3: Adjusting VFD Operating Parameters Skill 4: VFD Protection Parameters and Inputs/ Outputs Skill 5: Troubleshooting the VFD Skill 6: Understanding Additional VFD Features

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Hardware Specifications Panel E067: Variable Frequency Drive Panel type: Single 1 AC adjustable drive, 115V, 0.5hp, 1 phase in 3 phase out

Digital multimeter (Fluke Model 115 or equivalent) Prerequisite courses: Electric Motors (EA04)

Order #16-EA04

Materials Included Order #16-EA12: LearnMate® E-learning Content: Variable Frequency Drives (EA12) Teachers' Guide (2) Flexponent™ panels: Panel E067: Variable Frequency Drive (Mitsubishi) Panel E002: START-STOP Control

Panel E002: START-STOP Control Panel type: Single 1 Switch, pushbutton, momentary, black, NO w/contact block 1 Switch, pushbutton, momentary, red, NC w/contact block 2 Fault switch, 4A, 250V, push-on/push-off momentary

DC Motor Control (EA16) DC Motor Control (EA16) delivers hands-on skills in installing, operating and troubleshooting DC drives used in electric motor circuits. An add-on to Electromagnetic Motor Starters (EA07), EA16 covers eight additional skills including operating SCR and PWM speed controllers, DC drives and braking controls. The skills-based curriculum presents handson activities using industrial-grade components mounted on the seven included Flexponent™ panels.

Skills Acquired Skill 1: Demonstrating DC Drive Principles Skill 2: Connecting an d Operating a SCR Speed Controller

Skill 3: Connecting and Operating a PWM Speed

Materials Included

Panel E007: SCR Speed Controller Panel E017: Digital Relay Panel E025: F-O-R Switch and Potentiometer Panel E034: DC Motor Panel E038: PWM Motor Control Panel E048: Inertial Load Panel E071: Regenerative Four Quadrant DC Drive

Hardware Specifications

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel: (120V)* Order #10-PC04-0000

Panel E017: Digital Relay

Digital multimeter (Fluke Model 115 or equivalent) Prerequisite courses: Electric Motors (EA07)

Order #16-EA07

Panel type: Double 1 Motor, 90VDC, .13hp 1 Fault switch: 4A, 250V push-on/ push-off momentary

Order #16-EA16: LearnMate® E-learning Content: DC Motor Control (EA16) Teachers' Guide (7) Flexponent™ panels:

Controller Skill 4: Connecting, Setting-up, and Operating a DC Drive Skill 5: Connecting and Operating Braking Controls Skill 6: Testing a DC Drive Skill 7: Troubleshooting a DC Drive Skill 8: Performing Preventative Maintenance

* International step-down transformer package (Order #10PC09-0000) required for international applications.

Panel E034: DC Motor

Panel E007: SCR Speed Controller Panel type: Single 1 115V DC SCR speed control 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel type: Single 1 Relay, 120V 2PDT 15A LED test PB 1 Socket relay 1 Time delay relay, DPDT, multi-function 1 Socket relay, 11 pin octal 4 Fault switch, 4A, 250V push-on/push-off momentary

Panel E038: PWM Motor Control Panel type: Single 1 Pulse Width Modulated (PWM) speed control, 115VAC input, 1 HP, 10A, 0-130VDC output

Panel E048: Inertial Load Panel type: Single 1 Rotor, balanced, 4” diameter, 1141 steel 1 Toggle shaft coupling, 5/8” bore 1 Flanged bearing and bearing mount

Panel E071: Regenerative Four Quadrant DC Drive Panel type: Single 1 4-Quadrant regenerative DC drive, 115V/230V input, 0.75HP/1.5HP, 90V/180VDC armature

Panel E025: F-O-R Switch and Potentiometer Panel type: Single 1 Toggle switch, SPDT, On-Off-On, contact rating 125V/15A, 250V/10A 1 Potentiometer, linear, 5k ohm, 1/2 w

(800) 221-2763

19

Industrial Power Electronics

Industrial Power Electronics Courses

Course title Oscilloscope Digital Multimeter Hand Held Digital Oscilloscope DC Power Supplies Single-phase & 3-phase Power Supplies Thyristor Electric Motor Drives Electronic Timers Stepper Motor Drives Servo Motor Drives

Industrial Power Electronics teaches the essential skills for industrial electronics technicians. The Industrial Power Electronics series delivers 92 validated skills with 23 additional Flexponent panels for use with the JobMaster® Learning Station. *Hours are approximate and depend on class structure and teaching strategies.

Course # Skills

Hours*

Panels

EB01A

8

12

2

EB01B

17

26

2

EB01C

8

12

2

EB02A

11

17

3

EB02B

13

20

3

EB03

15

23

8

EB04

7

11

1

EB05

7

11

1

EB06

6

9

1

Total:

92

141

23

Oscilloscope (EB01A) Oscilloscope (EB01A) guides students through hands-on activities using industrial-grade test equipment. Students gain essential skills in the function and operation of an oscilloscope including identifying oscilloscope controls, adjusting probe compensation, and measuring AC voltage and frequency with an oscilloscope.

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000

The skills-based curriculum presents hands-on activities using an industrial grade oscilloscope as well as electrical components mounted on two included Flexponent™ panels.

Order #16-EB01A: LearnMate® E-learning Content: Oscilloscope (EB01A) Teachers' Guide (2) Flexponent™ panels:

Skills Acquired Skill 1: Reading the Oscilloscope Screen Skill 2: Identifying Oscilloscope Controls Skill 3: Setting Up and Operating the

Oscilloscope Skill 4: Adjusting Probe Compensation Skill 5: Performing AC Voltage Calculations Skill 6: Measuring AC Voltage and Frequency Skill 7: Performing DC Voltage Calculations

Skill 8: Measuring DC Voltage

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Panel E153: AC/DC Circuit Panel type: Single 1 Transformer, 24v output, 40 VA rating 1 Encapsulated solar cell, 0.45V/200mA 1 Bridge rectifier, 4A, 50PIV 1 Candelabra socket 1 Lightbulb, 24Vs

* International step-down transformer package (Order #10PC09-0000) required for international applications.

Materials Included Oscilloscope

Panel E087 Adjustable Power Supply Panel E153 AC/DC Circuit Oscilloscope (BK Precision Model 2120B or equivalent)

Hardware Specifications Panel E087: Adjustable Power Supply Panel type: Single 1 Adjustable power supply, 3-12V @ 2A

30 MHz dual trace Dual or single trace operation 5 mV/div sensitivity Compact low profile

Industrial Power Electronics Digital Multimeter (EB01B) Using an industrial grade digital multimeter as well as components on the two included Flexponent™ panels, students gain essential skills in the function and operation of a digital multimeter.

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000

Digital Multimeter (EB01B) presents hands-on activities in a skills-based format covering safety, measuring voltage and resistance, testing grounds and more.

Prerequisite courses

Skills Acquired Skill 1: Digital Multimeter Safety Skill 2: DMM Controls and Features Skill 3: Locating and Reading DMM Icons and Symbols

Skill 4: Reading the Liquid Crystal Display Skill 5: Setting Up the DMM for Reading AC

Voltage Skill 6: Measuring AC Voltage Skill 7: Calculating & Converting AC Voltage Skill 8: Measuring DC Voltage Skill 9: Measuring Resistance Skill 10: Discharging a Capacitor Skill 11: Measuring Capacitance Skill 12: Testing Capacitors Skill 13: Measuring Current Skill 14: Measuring DC Millivolts Skill 15: Performing Continuity Tests Skill 16: Testing Grounds and Bonds Skill 17: Measuring Frequency

* International step-down transformer package (Order #10PC09-0000) required for international applications.

Oscilloscope (EB01A)

Order #16-EB01A

Materials Included Order #16-EB01B: LearnMate® E-learning Content: Digital Multimeter (EB01B) Teachers' Guide Digital Multimeter (Fluke Model 115 or equivalent) (2) Flexponent™ panels: Panel E052: Resistors Panel E055: Filters/Capacitors

Hardware Specifications Digital Multimeter True-rms CAT III 600 V safety rated AC/DC volts, millivolts, amps Continuity Resistance Diode Test Capacitance Hz (V or A input)

Panel E052: Resistors Panel type: Single 2 Composition, 470Kohm, 10%, 2W, ceramic 1 Ceramic power resistor 180ohm, 5%, 5W 1 Ceramic power resistor 330ohm, 5%, 5W 1 Ceramic power resistor 470ohm, 5%, 5W 1 Ceramic power resistor 680ohm, 5%, 10W 1 Ceramic power resistor 900ohm, 5%, 8W 1 Ceramic power resistor 1.2Kohm, 5%, 5W 1 Ceramic power resistor 2.7Kohm, 5%, 10W 1 Ceramic power resistor 3.3Kohm, 5%, 5W 1 Ceramic power resistor 6Kohm, 5%, 5W 1 Ceramic power resistor 10Kohm, 5%, 5W 1 47ohm resistor

Panel E055: Filters/Capacitors Panel type: Single 1 Capacitor, 2.2Uf, 50V, axial, aluminum 1 Capacitor, 10uf, 50V, axial, aluminum 1 Capacitor, 22uf, 50V, axial, aluminum 1 Capacitor, 100uf, 50V, axial, aluminum 1 Capacitor, 220uf, 50V, axial, aluminum 1 Capacitor, 470uf, 50V, axial, aluminum 2 Capacitor, 1000uf, 50V, axial, aluminum 1 Capacitor, 150uf, 10V, axial, aluminum 1 Inductor, high current, 27uH, 10%, 4.8A, Axial

Hand-held Digital Oscilloscope (EB01C) Hand-held Digital Oscilloscope (EB01C) covers eight skills including identifying oscilloscope controls, performing AC voltage calculations, and measuring frequency.

The skills-based curriculum presents hands-on activities using industrial-grade test equipment including a hand-held digital oscilloscope.

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Materials Included

Skills Acquired Skill 1: Reading the Oscilloscope Screen Skill 2: Identifying and Using Oscilloscope

Order #16-EB01C: LearnMate® E-learning Content: Hand-held Digital Oscilloscope (EB01C) Teachers' Guide (2) Flexponent™ panels:

Skill 3: Setting Up and Operating the

Panel E087: Adjustable Power Supply Panel E153: AC/DC Circuit Hand-held Digital Oscilloscope

Controls

Oscilloscope Skill 4: Performing AC Voltage Calculations Skill 5: Measuring AC Voltage and Frequency Skill 6: Performing DC Voltage Calculations Skill 7: Measuring DC Voltage

Skill 8: Storing and Recalling Screen Displays

Hardware Specifications Panel E087: Adjustable Power Supply Panel type: Single 1 Adjustable power supply, 3-12V @ 2A

Panel E153: AC/DC Circuit Panel type: Single 1 Transformer, 24v output, 40 VA rating 1 Encapsulated solar cell, 0.45V/200mA 1 Bridge rectifier, 4A, 50PIV 1 Candelabra socket 1 Lightbulb, 24Vs

Hand-held Digital Oscilloscope 5MHz Bandwidth 25MS/s (dual channel); 50MS/s (single channel) max. sample rate per channel 512 single shot; 256 all other modes record length Single shot, roll, normal sample mode 50mV max vertical sensitivity 600V DC or AC rms max input voltage Auto, normal, single trigger modes Channel A, B, external trigger source AC, DC trigger coupling 1μS to 5S timebase 1MΩ input impedance Compact low profile

(800) 221-2763

21

Industrial Power Electronics DC Power Supplies (EB02A) DC Power Supplies (EB02A) delivers hands-on skills in operating industrial-grade bridge rectifiers, transformers and test equipment.

The skills-based curriculum builds on the concepts learned in the prerequisite test instruments courses: Oscilloscope (EB01A) and Digital Multimeter (EB01B). DC Power Supplies (EB02A) presents eleven additional skills using bridge rectifiers, diode rectifiers and low-voltage transformers mounted on three included Flexponent™ panels.

Skills Acquired Skill 1: Drawing a Power Supply Block Diagram Skill 2: Drawing Schematic Symbols Skill 3: Testing a Transformer Skill 4: Locating Diodes and Symbols Skill 5: Testing a Diode Skill 6: Drawing a Half-Wave Rectifier Skill 7: Connecting and Operating a Half-Wave

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses Digital Multimeter (EB01B)

Order #16-EB01B

Hardware Specifications Panel E039: Single-Phase Bridge Rectifier Panel type: Single 1 Bridge rectifier, 25A, 200V 1 Heatsink, TO-3, 76.2mm 2 Fault switch, 4A, 250V, push-on/push-off momentary

Materials Included Order #16-EB02A: LearnMate® E-learning Content: DC Power Supplies (EB02A) Teachers' Guide (3) Flexponent™ panels: Panel E039: Single-Phase Bridge Rectifier Panel E061: Low-voltage Transformer

Panel E061: Low-voltage Transformer Panel type: Single 1 Transformer, bobbins, 115V to 24V, 96A 1 Midget fuse block, 30A 1 Fuse, midget, 10A, fast acting 2 Fault switch, 4A, 250V, push-on/push-off momentary

Panel E062: Diode Rectifiers Panel E062: Diode Rectifiers Panel type: Single 2 Recovery rectifier, 16A, 1.23V 1 Heatsink, TO-3, 76.2mm 2 Fault switch, 4A, 250V, push-on/push-off momentary

DC Power Supply

Skill 8: Drawing a Full-Wave Rectifier Skill 9: Connecting and Operating a Full-Wave Rectifier

Skill 10: Drawing a Single-Phase Bridge Rectifier Skill 11: Connecting and Operating a SinglePhase Bridge Rectifier

Single-phase and Three-phase Power Supplies (EB02B) Single-phase and Three-phase Power Supplies (EB02B) builds on the concepts learned in the prerequisite course: DC Power Supplies (EB02A).

The skills-based curriculum presents thirteen additional skills using three new Flexponent™ panels covering industrial-grade bridge rectifiers, transformers and test equipment.

Skills Acquired Skill 1: Drawing Filter Schematic Diagrams Skill 2: Connecting and Operating a Power Supply Skill 3: Drawing Zener Schematic Symbols Skill 4: Connecting and Operating a Zener Diode Voltage Regulator

Skill 5: Locating an IC Voltage Regulator Skill 6: Connecting and Operating a DC Power Supply with an IC Voltage Regulator

Skill 7: Connecting and Operating a Bleeder

Resistor Skill 8: Connecting and Operating a Voltage Divider Skill 9: Troubleshooting a DC Power Supply Skill 10: Confirming 3-Phase Bridge Rectifier Operation Skill 11: Testing a Three-Phase Bridge Rectifier Skill 12: Connecting and Operating a ThreePhase Bridge Rectifier Skill 13: Troubleshooting a Three-Phase Bridge Rectifier

22

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Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000 Power Control Panel (220V) 3-Phase Order #10-PC06-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses DC Power Supplies (EB02A)

Hardware Specifications Panel E049: Zener Diode Panel type: Single 1 Zener diode, 15V, 170mA 1 Heatsink, TO-3, 76.2mm 2 Fault switch, 4A, 250V push-on/ push-off momentary

Order #16-EB02A

Materials Included Order #16-EB02B: LearnMate® E-learning Content: Single-phase and Three-phase Power Supplies (EB02B)

Teachers’ Guide (3) Flexponent™ panels: Panel E049: Zener Diode Panel E050: Regulated Power Supply Panel E053: Three-Phase Bridge Rectifier

Panel E050: Regulated Power Supply Panel type: Single 1 Adjustable voltage power supply 2 Fault switch, 4A, 250V push-on/ push-off momentary

Panel E053: Three-Phase Bridge Rectifier Panel type: Single 1 Bridge rectifier, 3P, 1200V, 60A 2 Fault switch, 4A, 250V push-on/ push-off momentary

Industrial Power Electronics Thyristor Electric Motor Drives (EB03) Thyristor Electric Motor Drives (EB03) brings students in contact with the same industrialgrade components used in industrial electric motor drives. Students learn SCR control and PWM principles while acquiring skills including operating full-wave SCR DC motor drives, DIAC-controlled TRIAC AC motor drives and Schmitt Triggercontrolled TRIAC AC motor drives.

The skills-based curriculum builds on the concepts learned in the prerequisite Industrial Power Electronics courses. Thyristor Electric Motor Drives (EB03) presents fifteen additional skills and eight additional Flexponent™ panels.

Skills Acquired Skill 1: Locating an SCR and Drawing the Schematic Symbol Skill 2: Testing an SCR Skill 3: Connecting and Operating an SCR Skill 4: Confirming Full-Wave SCR Control Skill 5: Connecting and Operating a Full-Wave SCR DC Motor Drive Skill 6: Troubleshooting a Full-Wave SCR DC Motor Drive Skill 7: Locating the TRIAC and Drawing the TRIAC Symbol Skill 8: Testing a TRIAC Skill 9: Demonstrating TRIAC Control Principles Skill 10: Locating a DIAC and Drawing the Schematic Symbol Skill 11: Connecting and Operating a DIACControlled TRIAC AC Motor Drive Skill 12: Connecting and Operating a Schmitt Trigger-Controlled TRIAC AC Motor Drive Skill 13: Troubleshooting a TRIAC Motor Drive Skill 14: Demonstrating PWM Principles Skill 15: Connecting and Operating a PWM DC Motor Drive

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Panel E082: Full-Wave SCR Drive Panel type: Single 1 Speed control, DC 115V, SCR 2 Fault switch, 4A, 250V push-on/push-off momentary

Prerequisite courses Single-phase and Three-phase Power Supplies (EB02B)

Order #16-EB02B

Materials Included Order #16-EB03: LearnMate® E-learning Content: Thyristor Electric Motor Drives (EB03) Teachers’ Guide (8) Flexponent™ panels: Panel E034: DC Motor Panel E081: SCR Panel E082: Full-Wave SCR Drive Panel E083: TRIAC Panel E084: DIAC Adjustable Resistors Panel E085: TRIAC with Schmidt Trigger Panel E088: Pulse Width Modulation (PWM) Motor Driver Panel E157: Universal AC/DC Motor and PMDC Motor

Hardware Specifications Panel E034 : DC Motor Panel type: Double 1 Motor, 90VDC, .13hp 1 Fault switch: 4A, 250V push-on/ push-off momentary

Panel E083: TRIAC Panel type: Single 1 Heatsink, TO-3, 76.2mm 1 TRIAC, 15A, 600V 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel E084: DIAC Adjustable Resistors Panel type: Single 1 DIAC, 36V 1 Capacitor, 0.1uf, 600VDC, radial, metallized polyester 1 50K-ohm linear potentiometer 0.125 shaft 1 500K-ohm linear potentiometer 0.125 shaft

Panel E085: TRIAC with Schmidt Trigger Panel type: Single 1 Speed control, TRIAC 1 Switch, toggle, DPDT, flat lever

Panel E088: Pulse Width Modulation (PWM) Motor Driver Panel E081: SCR Panel type: Single 1 Heatsink, TO-3, 76.2mm 1 SCR thyristor, 25A 2 Fault switch, 4A, 250V push-on/push-off momentary

Panel type: Single 1 Speed control, PWM

Panel E157: Universal AC/DC Motor and PMDC Motor Panel type: Single 1 AC/DC motor, 1/15hp, 5000rpm 1 DC Motor, 12/24V, 1/44hp @ 12 VDC, 1/18hp @ 24VDC, 1800rpm @12 VDC, 4300rpm @24 VDC 2 Fault switch, 4A, 250V push-on/push-off momentary

(800) 221-2763

23

Industrial Power Electronics Electronic Timers (EB04)

Stepper Motor Drives (EB05) Servo Motor Drives (EB06)

In the Electronic Timers (EB04) course, students work with industrial-grade timer devices used extensively in time-delay relays, motor drives and digital circuits. Students acquire skills including connecting and operating a 555 timer, verifying an astable timer circuit and connecting and operating an electronic pulse train The skills-based curriculum builds on the concepts learned in the prerequisite course, Thyristor Electric Motor Drives (EB03). Electronic Timers (EB04) presents seven additional skills with a timer Flexponent™ panel.

Skills Acquired Skill 1: Locating Timer Pins Skill 2: Verifying a Monostable Timer Circuit Skill 3: Connecting and Operating a 555 Timer in Monostable (One-Shot) Mode

Skill 4: Verifying an Astable Timer Circuit Skill 5: Connecting and Operating a 555 Timer in Astable (Multivibrator) Mode Skill 6: Verifying a Pulse Train Circuit Skill 7: Connecting and Operating an Electronic Pulse Train

Materials Required (sold separately) JobMaster® Learning Station Order #10-LS00-0200 Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses Thyristor Electric Motor Drives (EB03) Order #16-EB03

Materials Included Order #16-EB04: LearnMate® E-learning Content: Electronic Timers (EB04) Teachers’ Guide (1) Flexponent™ panel: Panel E089: Timers and Triggers

Hardware Specifications Panel E089: Timers and Triggers Panel type: Single 1 Timer 1 Potentiometer 1 NO pushbutton switch

Servo Motor Drives (EB06) guides students through six additional skills with an industrialgrade servo motor and drive mounted on a Flexponent™ panel. Using precision servo motor systems found in CNC machines, robotic and hydraulic systems, students learn closed-loop servo motor control and system feedback principles while acquiring skills including installing and troubleshooting servo motor drives.

Stepper Motor Drives (EB05) delivers hands-on skills using stepper motor systems found in robots, precision linear positioning devices, CNC machines and other devices that provide motion control with calculated accuracy. Students acquire skills including confirming stepper motor step angle and troubleshooting stepper motor drives.

The skills-based curriculum builds on the concepts learned in the prerequisite courses in the Industrial Power Electronics series, presenting seven additional skills with an industrial-grade stepper motor and drive.

Skills Acquired Skill 1: Identifying Detent Torque Skill 2: Confirming Stepper Motor Step Angle Skill 3: Demonstrating Stepper Motor Principles Skill 4: Confirming Stator Winding Connections Skill 5: Demonstrating Unipolar Stepper Motor Drive Skill 6: Installing, Connecting and Monitoring a Basic Stepper Motor Drive Skill 7: Testing and Troubleshooting a Basic Stepper Motor and Drive

Materials Required (sold separately) Order #10-LS00-0200 JobMaster® Learning Station Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Electronic Timers (EB04)

Principles

Skill 3: Demonstrating Servo System Feedback Device Principles

Skill 4: Demonstrating Analog and Digital Servo Motor Drive Principles

Skill 5: Installing, Connecting and Monitoring a Basic Servo Motor Drive

Skill 6: Testing and Troubleshooting a Basic Servo Motor Drive

Materials Required (sold separately) Order #10-LS00-0200 JobMaster® Learning Station Power Control Panel (120V): Order #10-PC04-0000 * International step-down transformer package (Order #10PC09-0000) required for international applications.

Prerequisite courses Stepper Motor Drives (EB05) Order #16-EB05

Materials Included Order #16-EB06: LearnMate® E-learning Content: Servo Motor Drives (EB06) Teachers’ Guide (1) Flexponent™ panel: Panel E091: Servo Motor and Drive

Order #16-EB04

Materials Included Order #16-EB05: LearnMate® E-learning Content: Stepper Motor Drives (EB05) Teachers' Guide (1) Flexponent™ panel: Hardware Specifications Panel E090: Stepper Motor and Drive Panel type: Single 1 Stepper motor 1 Stepper drive 1 NO pushbutton switch 1 Potentiometer 1 Dial 1 IC test clip, 16-position 2 Fault switch, 4A, 250V, push-on/push-off momentary

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Control Principles

Skill 2: Demonstrating Closed-Loop Servo Motor

Prerequisite courses

Panel E090: Stepper Motor and Drive

24

Skills Acquired Skill 1: Demonstrating Closed-Loop Servo Motor

Hardware Specifications Panel E091: Servo Motor and Drive Panel type: Single 1 Servo motor 1 Servo drive 1 NO pushbutton switch 1 Potentiometer 1 Dial 1 IC test clip, 16-position

Fluid Power Series Course List Fluid Power courses feature standalone hydraulics and pneumatics training panels with modular hardware components that mount on the panels for course activities.

The included software for simulating hydraulics and pneumatics circuits is tightly integrated with the LearnMate® online content. Students can launch the software directly from the content viewer, enabling seamless and engaging delivery of fluid power concepts and skills.

Fluid Power courses include:

Hydraulics Pneumatics Fluid Power Courses

Hydraulics with HydraFlex training panel *Hours are approximate and depend on class structure and teaching strategies.

Course title Hydraulics 1: Fundamentals (Virtual) Hydraulics 1: Fundamentals (Lab) Hydraulics 2: Electro-Hydraulics Pneumatics 1: Fundamentals (Virtual) Pneumatics 1: Fundamentals (Lab) Pneumatics 2: Advanced (Virtual) Pneumatics 2: Advanced (Lab) Pneumatics 3: Electro-Pneumatics

Course # Hours* 3024

15

8008

15

3025

15

3037

15

8068

15

3038

15

8069

15

3039

15

Total:

120

Hydraulics The Hydraulics series is stand-alone curriculum that introduces the principles of hydraulics and fluid power. Available as virtual lab or with hardware, Hydraulics features HydraMotion software, which allows students to create, modify and operate simulated hydraulics and electro-hydraulic devices and circuits. Lab versions use the HydraFlex training panel which enables students to configure hydraulic applications using industrial grade components.

Hydraulics 1: Fundamentals Materials Included Order #16-3024 (Virtual): LearnMate® E-learning Content: Hydraulics 1 Teachers’ Guide HydraMotion hydraulic simulation software

Skills Acquired Activity 1: Getting Started Activity 2: Pressure and Force Activity 3: Pressure Gauges Activity 4: Hydraulic Power Transmission - Part 1 Activity 5: Hydraulic Power Transmission - Part 2 Activity 6: Hydraulic Power Source Activity 7: Determining Component Characteristics Activity 8: Controlling the Flow Rate Activity 9: Flow Control Valves Activity 10: 4/3 Closed-Center Valve Construction and Function

Activity 11: 4/3 Closed-Center Valve -

Characteristics Activity 12: Power Transformation Using a Double-Acting Cylinder Activity 13: Loading a Piston Activity 14: Controlling the Piston Location

Activity 15: Conclusion

Order #16-8008 (Lab): LearnMate® E-learning Content: Hydraulics 1 Teachers’ Guide HydraMotion hydraulic simulation software Science experiment - Hydraulic pressure Science experiment - Visualizing pressure 1 HydraFlex slotted aluminum panel.

(WxDxH): 31.5” x 20” x 29.5”

(800mm x 510mm x 750mm) 1 Hydraulic power pack 1 Oil collection tray 1 Double-acting Cylinder 1-1/8” 1 4/3 selector valve, closed center 1 Two-way flow control valve 2 One-way flow control valves 1 Pressure relief valve 1 Flow meter 2 Pressure gauges 2 T-connectors 10 Hydraulic hoses, various sizes Hex wrench 1 Funnel 2 Gallons hydraulic oil

Hydraulics 2: ElectroHydraulics Skills Acquired Activity 1: Getting Started Activity 2: Mechatronics and Hydraulic Systems Activity 3: Building a Dowel Insertion System Activity 4: Controlling a Hydraulic Press Activity 5: Controlling a Barricade Activity 6: Sequential Operation Activity 7: Grain Gate Valves Activity 8: Controlling a Cargo Airplane Door Activity 9: Increasing System Efficiency Activity 10: The Relay Activity 11: Latching a Relay Activity 12: Semi-Automatic Press System Activity 13: The Timer Activity 14: Irrigation System Activity 15: Improving Control in a Circuit with Sequential Operation

Materials Required (sold separately) Prerequisite courses Hydraulics 1

Materials Included Order #16-3025: LearnMate® E-learning Content: Hydraulics 2 Teachers’ Guide (800) 221-2763

25

Pneumatics Pneumatics with PneuFlex training panel The Pneumatics courses, available in fully virtual format or combined with hardware, teach the principles of pneumatics and pneumatically controlled systems. The pneumatic simulation software allows students to create, modify, operate and observe simulated pneumatic devices and circuits. The pneumatics training panel adds industrial grade pneumatic components in an easily modifiable modular form factor.

Pneumatics 1: Fundamentals

Pneumatics 2: Advanced

Pneumatics 3: Electro-Pneumatics

Skills Acquired Activity 1: Introduction to Pneumatics Activity 2: Atmospheric Pressure and Vacuum Activity 3: Atmospheric Pressure, Vacuum and

Skills Acquired Activity 1: Getting Started Activity 2: The Logic Function AND Activity 3: Implementing AND in a Pneumatic

Activity 4: The Double-Acting Cylinder Activity 5: 3/2 Valves Activity 6: Controlling a Piston with PBs Activity 7: 5/2 Air-Operated, Air-Returned Valve Activity 8: 5/2 Air-Air Valves Activity 9: Laws of Gases I Activity 10: Laws of Gases II Activity 11: 3/2 Air-Operated, Spring-Returned Valve Activity 12: Spot Welding System Activity 13: 3/2 Roller Valves Activity 14: The Punch - A Semi-Automatic System

Activity 4: The Toggle Valve Activity 5: Using AND to Build a Fully Automatic

Skills Acquired Activity 1: Getting Started Activity 2: Building a Basic Electrical Circuit Activity 3: The 5/2 Solenoid-Spring Valve Activity 4: The 5/2 Solenoid-Solenoid Valve Activity 5: Magnetic Switches Activity 6: Implementing the Logic Function AND Activity 7: Implementing the Logic Function OR Activity 8: Implementing the Logic Function NOT Activity 9: Sequential Operation Activity 10: The Relay Activity 11: Unlatching a Relay Activity 12: Building a Fully Automatic Circuit Activity 13: Adding a Delay Using an Electric Timer Activity 14: Unlatching a Fully Automatic Circuit Activity 15: Measuring Cylinder Speed

Materials Included

Activity 12: Opposing Control Signals Activity 13: Timing Diagrams Activity 14: Using a Single Pilot Valve to Prevent

Mechanical Work

Order #16-3037 (Virtual): LearnMate® E-learning Content: Pneumatics 1: Fundamentals Teachers’ Guide PneuMotion pneumatic simulation software Order #16-8068 (Lab): LearnMate® E-learning Content: Pneumatics 1: Fundamentals Teachers’ Guide PneuMotion pneumatic simulation software PneuFlex slotted aluminum panel with components (WxDxH): 31.5” x 20” x 29.5” (800mm x 510mm x750mm) 1 Conditioning Unit 2 3/2 mushroom push button valves 1 3/2 lever valve (manual toggle) 1 Manifold, 5 ports 1 Double-acting cylinder 1 5/2 double air pilot valve 1 3/2 double roller lever valve 1 3/2 pneumatic valve 4 T-connectors 4 Connectors 1 Quick-coupler AND gate, OR gate, NOT gate valves Science demo kit - Atmospheric pressure Science demo kit - Expansion of gases

26

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Circuit

System

Activity 6: The Logic Function OR Activity 7: Implementing OR in a Pneumatic Circuit

Activity 8: Circuit with Two Double-Acting Cylinders

Activity 9: Sequential Cycle Activity 10: A Delay Activity 11: Sequential Control with a Timed Delay

Opposing Control Signals Activity 15: Using A Single Pilot Valve in a Pneumatic Circuit

Materials Required (sold separately) Prerequisite courses Pneumatics 1

Materials Included Order #16-3038 (Virtual): LearnMate® E-learning Content: Pneumatics 2: Advanced Teachers’ Guide Order #16-8069 (Lab): LearnMate® E-learning Content: Pneumatics 2: Advanced Teachers’ Guide 1 Double-acting cylinder 1 5/2 double air pilot valve 2 Single air pilot valves 1 3/2 double roller lever valve 1 Pneumatic time delay valve 1 Manifold, 5 ports

Materials Required (sold separately) Prerequisite courses Pneumatics 2

Materials Included Order #16-3039: LearnMate® E-learning Content: Pneumatics 3: Electro-Pneumatics Teachers’ Guide

Automation Course List Automation Courses

Course title Robotics and Materials Handling 1 Robotics and Materials Handling 2 Flexible Manufacturing Systems Robotics and Automation Technology Project

PLC 1: Fundamentals (Virtual) PLC 1: Fundamentals (Lab) Micrologix PLC 1: Fundamentals (Lab) Allen-

Course # Hours* 8082

15

8083

15

8067

15

7016/ 7018

n/a

3032

15

8009

15

8079

15

3033

15

8040

15

8080

15

3034

15

3035

15

Bradley The Automation Courses feature stand-alone curriculum that focuses on automated manufacturing skills and concepts, including: Robotics Process Control Programmable Logic Controllers (PLC)

Robotics and Materials Handling with ER4u robot

PLC with PLCLine training panel and the Allen-Bradley SLC-500

Robotics features LearnMate® curriculum written specifically for our industrial desktop robotic workcells, along with user-friendly robotic control and simulation software integrated into the content.

The Process Control sequence is all virtual with simultation process software.

PLC 2: Advanced Ladder Logic (Virtual) PLC 2: Advanced (Lab) Micrologix PLC 2: Advanced (Lab) Allen-Bradley PLC 3: PLC-Controlled Pneumatic Systems PLC 4: PLC-Controlled Hydraulic Systems Process Control: Temperature Process Control: Flow Process Control: Pressure Process Control: Level

3041

15

3043

15

3044

15

3045

15

Total:

225+

*Hours are approximate and depend on class structure and teaching strategies. Projects are open-ended and can vary widely in time involved.

For PLC instruction, choose from virtual or hardware labs.

Robotics Robotics and Materials Handling 1 Robotics and Materials Handling gives students the fundamental skills needed to operate, maintain, program and test robotic systems. Students gain experience and skill in robotic operation and programming using the SCORBOT-ER4u, an industrial training robot. Using SCORBASE software, an intuitive tool for robot programming and control, students develop and write robot programs and design solutions for industrial robotic applications.

Skills Acquired Activity 1: Introduction to Robotics Activity 2: Using Robotic Control Software Activity 3: Recording Robot Positions Activity 4: Writing and Running a Robot Program Activity 5: Cartesian Coordinates Activity 6: Inputs and Program Jumps Activity 7: Outputs Activity 8: Joint and XYZ Coordinate Systems Activity 9: Relative Positions Activity 10: Loops, Polling, and Counters Activity 11: Subroutines Activity 12: Contact and Non-Contact Sensors Activity 13: Servo Control of the Conveyor Activity 14: I/O Control of the Conveyor Activity 15: Conclusion

Materials Required (sold separately) Robot workstation PC with 1 available USB port Materials Included Order #16-8082: LearnMate® E-Learning Content: Robotics and

Materials Handling 1 with SCORBOT-ER 4u 100140 SCORBOT-ER 4u mechanical arm Robot controller-USB USB cable Hex key set SCORBASE for Controller-USB Software Work cell components Laminated coordinate grid Teach pendant with cord, mounting bracket and hardware, and user guide I/O experiment table Experiment table sample parts Gravity feeder Packaging pallet tote with Linear conveyor Proximity sensor Materials package (800) 221-2763 27

SCORBOT ER4U Robotic Package

Robotics Robotics and Materials Handling 2 Robotics and Materials Handling 2 explores robotic programming. Using RoboCell, a 3D solid-modeling robotic simulation software, students gain greater understanding of the robotics concepts and programming commands learned in RMH1. This course gives students the advanced skills needed to operate, maintain, program and test robotic systems.

Skills Acquired Activity 1: Robotics Activity 2: Basic Robotic Programming Tools Activity 3: Manipulating Blocks Project Activity 4: Programming the Robot to Execute Circular Movements

Activity 5: Drawing a House

Activity 6: Roll and Pitch Activity 7: Block Alignment Project Activity 8: Feeders and Templates Activity 9: Peripheral Devices Activity 10: Linear Slidebase Project Activity 11: Programming Using Encoder Values Activity 12: Conditional Branching Activity 13: Programming with Conditional Branching Activity 14: Analog Inputs and Outputs Activity 15: Programming a Sorting System Project

Materials Required (sold separately) Robotics and Materials Handling 1 Materials Included Order #16-8083: LearnMate® E-Learning Content: Robotics and Materials Handling 2 with SCORBOT-ER 4u

RoboCell for Controller-USB

Flexible Manufacturing Systems Flexible Manufacturing Systems (FMS) combines CNC technology with robotics and materials handling. Students develop and edit programs, record precise robotic positions, accurately mill parts, and synchronize mill and robot operation. Students gain experience applying CNC and robot programming in solutions for industrial FMS applications with emphasis on real industrial concerns, such as optimized programming and accurate machine tending..

Skills Acquired Activity 1: Getting Started Activity 2: Using Robotic Control Software Activity 3: Moving the Robot in the FMS Cell Activity 4: Recording Robot Positions Activity 5: Writing and Running a Robot Program Activity 6: Preparing the Mill Activity 7: Recording Robot Positions for Mill Tending

Activity 8: More FMS Robot Programming Activity 9: Optimizing the FMS Robot Program Activity 10: Robot and Mill Handshaking Activity 11: More Robot and Mill Handshaking Activity 12: Completing the FMS Programs Activity 13: Running an FMS Production Cycle Activity 14: Final Project Activity 15: Conclusion

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Materials Required (sold separately) CNC mill workstation PC with 1 available PCI slot Robot workstation PC with 1 available USB port Materials Included Order #16-8067: LearnMate® E-Learning Content: Flexible

Manufacturing Systems SCORBOT ER4U Robotic Package 100140 SCORBOT-ER 4u mechanical arm Robot controller-USB USB cable Hex key set SCORBASE for Controller-USB Software Work cell components Teach pendant with cord, mounting bracket and hardware, and user guide Gravity feeder Packaging pallet tote with spectraLIGHT Mill #10-1001-0000 Controller box PCI card

Accessory kit

#21-0900-0002 AC power supply cord 25 pin cable Accessory adapter cable 3/8” end mill holder Spindle bar (2) 1/8” end mill Hex key (1/16”) Hex key (3/32”) Hex key (1.8”) Hex key (5/32”) Hex key (3/16”) Hold down set ACC-5510, 5511 Precision air vise #700077 1 Pneumatic clamping assembly 1 Adjustable “L” design clamping bracket 1 110V solenoid 1 Mounting hardware for vise and solenoid Multiple tool change kit #ACC-5560 3 3/8” tool holder 1 1/8” end mill, 3/8” shank, 4 flute HSS 1 3/16” end mill, 3/8” shank, 4 flute HSS 1 1/4” end mill, 3/8” shank, 4 flute HSS End mill set #ACC-5530 1 1/8” end mill, 3/8” shank, 4 flute HSS 1 3/16” end mill, 3/8” shank, 4 flute HSS 1 1/4” end mill, 3/8” shank, 4 flute HSS Wax stock package #PKG-9120 50 Machinable wax blocks, 1 1/2” x 2” x 3” Robot interface cable 32-5300-0026

Robotics Robotics and Automation Technology Project

intelitek’s Robotics and Automation Project is an engaging simulation of the industrial automated manufacturing process. By means of this SkillsUSA competition, students demonstrate the skills needed for employment in the field of automation technology.

This well-designed project follows a team approach to problem solving that promotes communication, time management and leadership skills, while enabling students to display their skills in a valid, measurable format. The enhanced level of student influence in the learning process contributes to an immersive instructional experience.

Each project involves all aspects of robotics, pneumatics, sensors, and electrical systems.

Students are guided through the each step via LearnMate® e-learning curriculum. Teams of two students layout and program a robotic production system as a solution to the project scenario. Teams are then presented with a change order and repeat the process to incorporate the changes.

All wiring is completed using standard industrial practices for routing and termination, for hands-on exposure to in-demand career skills!

The Robotics and Automation Technology competition package is available with all materials included (Order #16-7016), or as an add-on (Order #16-7018) for those who already have the SCORBOT-ER 4u robotic package.

Order #16-7016 (all-inclusive):

Order #16-7018 (add-on package):

Materials Required (sold separately) Computer system with 1 available USB port

Materials Required (sold separately)

Materials Included LearnMate® E-learning Content: Robotics and

Automation project with teacher supplement and one complete solution SCORBOT-ER 4u Robotic Package: Order #100140 SCORBOT-ER 4u mechanical arm Robot controller-USB USB cable Hex key set SCORBASE for Controller-USB Software Teach pendant Linear slide base Linear conveyor Proximity sensor Stack light with emergency stop I/O controller interface Pneumatic parts feeder and simulated pneumatic press Plastic and aluminum blocks Continuity and limit detection test device Cabling for project

Order #16-7018 requires one of the following: Robot workstation PC with 1 available USB port either one of the following: Robotics and Materials Handling 1: Order #16-8082 SCORBOT-ER 4u Robotic Package: Order #100140

Materials Included LearnMate® E-learning Content: Robotics and

Automation project with teacher supplement and one complete solution Stack light with emergency stop I/O controller interface Pneumatic parts feeder and simulated pneumatic press Plastic and aluminum blocks Continuity and limit detection test device Cabling for project Misc supplies for project

Misc supplies for project (800) 221-2763

29

Programmable Logic Controllers (PLCs) Programmable Logic Controller (PLC) courses teach students how to program and use PLCs in industrial applications that require electrical control.

Using PLCMotion software and the PLCLine training panel, students program PLCs, troubleshoot ladder diagrams and control programs, and also design original HMIs for displaying PLC program simulations. For hardware labs, choose between industrial Micrologix and Allen Bradley SLC 500 PLC controllers.

PLC 1: Fundamentals of Ladder Logic

PLC 2: Advanced Ladder Logic

PLC 3: PLC-Controlled Pneumatic Systems

Skills Acquired Activity 1: Getting Started Activity 2: Examining Input/Output Relationships Activity 3: PLC Monitoring Tools Activity 4: Writing and Simulating a Basic Ladder

Skills Acquired Activity 1: Getting Started Activity 2: Bits and Words Activity 3: Counter Up and Reset Activity 4: Counter Down Activity 5: Project: Implementing CTU and CTD Activity 6: The Equal (EQU) Instruction Activity 7: The Not Equal (NEQ) Instruction Activity 8: Project; Applying Equal and Not Equal Activity 9: The Less Than (LES) Instruction Activity 10: The Greater Than (GRT) Instruction Activity 11: Project: Implementing GRT and LES Activity 12: The Move (MOV) Instruction Activity 13: The Add (ADD) Instruction Activity 14: The Subtract (SUB) Instruction Activity 15: Conclusion

Skills Acquired Activity 1: Getting Started Activity 2: The Pneumatic HMI Activity 3: Manual Control of a Pneumatic Piston Activity 4: Semi-Automatic Control Systems Activity 5: Semi-Automatic Action Using a 5/2

Diagram

Activity 5: Project: Controlling a Sorting System Activity 6: NOT Logic Activity 7: AND Logic Activity 8: OR Logic Activity 9: Project: Arsenic Filling Station Activity 10: Latching and Unlatching Outputs Activity 11: Improving Elevator Control Activity 12: One Shot Rising Activity 13: Timer On Delay Activity 14: Timer Off Delay Activity 15: Conclusion Order #16-3032 (Virtual): Materials Included LearnMate® E-Learning Content: PLC Technology 1: Fundamentals of Ladder Logic Teachers guide PLCMotion simulation software

Order #16-8009 (Lab) - Micrologix Order #16-8079 (Lab) - Allen Bradley SLC-500: Materials Included LearnMate® E-Learning Content: PLC Technology 1: Fundamentals of Ladder Logic Teachers guide PLCLine training panel with components: 24 VDC 2A power supply Computer interface control unit for PLC Banana plug cables 1 DC servo motor 1 optical encoder 1 lead screw 3 output lamps 1 buzzer 1 solenoid 3 pushbutton toggle switches 2 limit switches 1 inductive proximity sensor PLCMotion simulation software

30

Materials Required (sold separately) Prerequisite courses PLC 1: Fundamentals of Ladder Logic

Order #16-3033 (Virtual): Materials Included LearnMate® E-Learning Content: PLC Technology 1: Fundamentals of Ladder Logic Teachers guide

Order #16-8040 (Lab) - Micrologix Order #16-8080 (Lab) - Allen Bradley SLC-500: Materials Included LearnMate® E-Learning Content: PLC Technology 1: Fundamentals of Ladder Logic

Spring-Return Valve

Activity 8: Timers Activity 9: Counters Activity 10: Sequential Operation with Two Double-Acting Cylinders

Activity 11: Sequential Operation with Three Double-Acting Cylinders

Activity 12: Solving Opposing Control Signals Activity 13: Solving Opposing Control Signals in a Three Cylinder System

Activity 14: Controlling a System with a Variable Timer Activity 15: Advanced Operation Materials Required (sold separately) Prerequisite courses PLC 2: Advanced Ladder Logic Pneumatics 3

Order #16-3034 (Virtual): Materials Included LearnMate® E-Learning Content: PLC Technology 3: PLC-Controlled Pneumatic Systems Teachers guide

Teachers guide

PLC 4: PLC-Controlled Hydraulic Systems Skills Acquired Activity 1: Getting Started Activity 2: Using a 4/2 Sol-Sol Valve to Control a

Activity 11: Sequential Operation with Two

Activity 3: Using a 4/2 Sol-Spring Valve to

Activity 13: Variable Timers Activity 14: Variable Counters Activity 15: Project: Port Soil Removal System

Double-Acting Cylinder

Control a Double-Acting Cylinder

Activity 4: Using a 4/3 Sol-Sol Valve to Control a Double-Acting Cylinder

Activity 5: Using a Fully Automatic Hydraulic Circuit Activity 6: Using a Fully Automatic Hydraulic Circuit with a Timer Activity 7: Using a 4/3 Sol-Sol Valve with a Counter Activity 8: Using a Fully Automatic Hydraulic Circuit with an OSR Instruction Activity 9: Sequential Operation with Two Double-Acting Cylinders Activity 10: Sequential Operation with Three Double-Acting Cylinders

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Spring-Return Valve

Activity 6: Fully Automatic Operation Activity 7: Fully Automatic Operation with a

Double-Acting Cylinders and a Delay

Activity 12: Sequential Operation with Three Double-Acting Cylinders and a Delay

Materials Required (sold separately) Prerequisite courses PLC 2: Advanced Ladder Logic Hydraulics 2

Order #16-3035 (Virtual): Materials Included LearnMate® E-Learning Content: PLC

Technology 4: PLC-Controlled Hydraulic Systems

Teachers guide

Process Control

The Process Control series of virtual courses gives students a solid understanding of the fundamentals of instrumentation and industrial process control.

Using ProcessMotion advanced 3D-modeling simulation control software, students gain hands-on experience with the measurement and control of pressure, liquid level, flow and temperature processes. Students learn open loop, on/off loop and three-element (PID) control methods, and use ProcessMotion software to control a virtual training panel to optimize the parameters for PID control and tuning.

Process Control: Temperature

Process Control: Flow

Skills Acquired Activity 1: Introduction to Process Control Activity 2: Introduction to ProcessMotion

Skills Acquired Activity 1: Introduction to Process Control Activity 2: Introduction to ProcessMotion

Skills Acquired Activity 1: Introduction to Process Control Activity 2: Introduction to ProcessMotion

Activity 3: Block Diagrams and Gain Activity 4: Calculating Process Gain Activity 5: Heating Element Control Activity 6: First Order Systems Activity 7: The Temperature System Time

Activity 3: Block Diagrams and Gain Activity 4: The System Block Diagram and Final

Activity 3: Block Diagrams and Gain Activity 4: Calculating Process Gain Activity 5: Calculating the Final Control Element

Simulation Software

Simulation Software

Control Element Gain

Activity 8: Controlling the Temperature System

Activity 5: Calculating Process Gain Activity 6: First Order Systems Activity 7: The Flow System Time Constant Activity 8: Controlling the Flow System Using

Activity 9: Introduction to On-Off Control Activity 10: On-Off Control - Tasks Activity 11: Controlling the Temperature System

Activity 9: Introduction to On-Off Control Activity 10: On-Off Control - Tasks Activity 11: Controlling the Flow System Using

Activity 12: Proportional Control Activity 13: First Order Systems Under

Activity 12: Proportional Control Activity 13: First Order Systems Under

Activity 14: Controlling the Temperature System

Activity 14: Controlling the Flow System Using

Activity 15: Proportional Integral Control Activity 16: Controlling the Temperature System

Activity 15: Proportional Integral (PI) Control Activity 16: Controlling the Flow System Using

Activity 17: PID Control Activity 18: Controlling the Temperature System

Activity 17: Proportional Integral Derivative (PID)

Constant

Using Open Loop Control

Using On-Off Control

Proportional Control

Using Proportional Control

Using Proportional Integral Control

Using Proportional Integral Derivative Control

Activity 19: Controller Selection and Design Activity 20: Designing Controllers for the Temperature System

Materials Included Order #16-3041: LearnMate® E-Learning Content: Process Control Temperature

ProcessMotion simulation software

Open Loop Control

On-Off Control

Proportional Control Proportional Control

PI Control

Control Activity 18: Controlling the Flow System Using PID Control Activity 19: Controller Selection and Design Activity 20: Designing Controllers for the Flow System

Materials Included Order #16-3043: LearnMate® E-Learning Content: Process Control

Process Control: Pressure Simulation Software

Gain Activity 6: First Order Systems Activity 7: The Pressure System Time Constant Activity 8: Controlling the Pressure System Using Open Loop Control Activity 9: Introduction to On-Off Control Activity 10: On-Off Control - Tasks Activity 11: Controlling the Pressure System Using On-Off Control Activity 12: Proportional Control Activity 13: First Order Systems Under Proportional Control Activity 14: Controlling the System Using Proportional Control Activity 15: Proportional Integral Control Activity 16: Controlling the Pressure System Using PI Control Activity 17: PID Control Activity 18: Controlling the Pressure System Using PID Control Activity 19: Controller Selection and Design Activity 20: Designing Controllers for the Pressure System

Materials Included Order #16-3044: LearnMate® E-Learning Content: Process Control Pressure

Flow ProcessMotion simulation software

ProcessMotion simulation software

Activity 11: Controlling the Level System Using

Activity 19: Controller Selection and Design Activity 20: Designing Controllers for the Flow

Process Control: Level Skills Acquired Activity 1: Introduction to Level Control Activity 2: ProcessMotion Simulation Software Activity 3: Block Diagrams and Gain Activity 4: The System Block Diagram and the Final Control Element Gain Activity 5: Calculating System Gain Activity 6: First Order Systems Activity 7: The Level System Time Constant Activity 8: Controlling the Level System Using Open Loop Control Activity 9: Introduction to On-Off Control Activity 10: On-Off Control - Tasks

On-Off Control Activity 12: Proportional Control Activity 13: First Order Systems Under Proportional Control Activity 14: Controlling the Level System Using Proportional Control Activity 15: Proportional Integral (PI) Control Activity 16: Controlling the Flow System Using PI Control Activity 17: Proportional Integral Derivative (PID) Control Activity 18: Controlling the Flow System Using PID Control

System

Materials Included Order #16-3045: LearnMate® E-Learning Content: Process Control Level

ProcessMotion simulation software

(800) 221-2763

31

CAD/CAM/CNC Manufacturing Course List The CAD/CAM/CNC Manufacturing series is standalone curriculum featuring in-depth coverage of the manufacturing process from design to production.

Hardware labs feature intelitek’s desktop CNC machines, and virtual labs present true web-based simulations of the same machines. Students design parts, use CAM programs to transfer design to CNC, and create prototypes and parts on the machine. Well-designed projects simulate the entire production/change order process used in manufacturing environments, providing an authentic learning experience.

CAD/CAM/CNC Manufacturing Courses

Course title CAM Milling with Mastercam® CAM Turning with Mastercam® CAD with SolidWorks® CNC Milling Technology (Virtual) CNC Milling Technology (Lab) CNC Turning Technology (Virtual) CNC Turning Technology (Lab) Automated Manufacturing Technology

Course # Hours* 3006

15

3008

15

3108

15

3009

15

8007

15

3011

15

8016

15

7022

n/a

7023

n/a

Total:

105+

Project: Four Cavity Mold

Automated Manufacturing Technology Project: Planetary Gearbox

*Hours are approximate and depend on class structure and teaching strategies. Projects are open-ended and can vary widely in time involved.

CAD/CAM/CNC Manufacturing Computer-Aided Manufacturing for Mastercam®

This course introduces students to the use of Mastercam®. The basic concepts of computer-aided machining (CAM) are introduced and developed. Computer-aided design (CAD) functions are reviewed, enabling the student to create 2D, 3D and surfaced part drawings. Through a series of projects, students learn to specify stock dimensions and material and create contouring, pocketing, drilling and surfacing tool paths and generate NC code.

Computer-Aided Manufacturing for Mastercam® Milling

Computer-Aided Manufacturing for Mastercam® Turning

Skills Acquired Activity 1: Getting Started Activity 2: Two-Dimensional Part Design Activity 3: Designing a Three-Dimensional Mill Part Activity 4: Applying Surfaces to Mastercam® Designs Activity 5: Tool Path Generation Activity 6: Tool Path Generation 2 Activity 7: Key Chain Project Activity 8: Tool Path Parameters - Part I Activity 9: Tool Path Parameters - Part II Activity 10: Tool Path Parameters: Facing and Pocketing Activity 11: Desk Set Project Activity 12: NC Utilities Activity 13: Domino Project Activity 14: Tool Path Parameters: Drilling Activity 15: Tool Path Parameters: Surface Tool Paths Activity 16: Review and Post-Test

Skills Acquired Activity 1: Getting Started Activity 2: Introduction to Mastercam® Lathe Activity 3: Project 1: Job Setup Activity 4: Project 1: Part Design Activity 5: Project 1: Generating the Facing Tool Path Activity 6: Project 1: Generating the Roughing Tool Path Activity 7 : Project 1: Generating the Finish and Parting Tool Paths Activity 8: Project 1: Verifying the Tool Paths Activity 9: Project 1: Saving the NC Program and Generating Setup Sheets Activity 10: Project 2: Job Setup and Part Drawing Activity 11: Project 2: Generating the Roughing and Drilling Tool Paths Activity 12: Project 2: Generating the First Grooving Tool Path Activity 13: Project 2: Creating the Tool and Generating the Tool

Materials Required (sold separately) Mastercam® software

Materials Required (sold separately) Mastercam® software

Materials Included

Materials Included

Order #16-3006: LearnMate® E-Learning Content: Computer-

Order #16-3008: LearnMate® E-Learning Content: Computer-

Aided Manufacturing for Mastercam® Milling

32

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Path for the Second Groove Activity 14: Project 3: Generating Threading Tool Paths Activity 15: Final Project and Post-Test

Aided Manufacturing for Mastercam® Turning

CAD/CAM/CNC Manufacturing Computer-Aided Design with SolidWorks®

Computer-aided Design (CAD) with SolidWorks® teaches how to use SolidWorks 3D mechanical design software by means of a project-based design tutorial. This course fasttracks students through many advanced features of SolidWorks, exposing them quickly to the power of 3D modeling.

Skills Acquired Lesson 1: Introduction to SolidWorks Lesson 2: Sketching the Cover Lesson 3: Extruding the Cover Lesson 4: Working Drawings Lesson 5: Drawing the Crank Wheel Lesson 6: Drawing the Link Arm Lesson 7: Drawing the Base Lesson 8: Drawing the Stamp Block Lesson 9: Adding Text Lesson 10: Assembly Project: Crank Handle

Materials Required (sold separately) SolidWorks® software Materials Included Order #16-3108: LearnMate® E-Learning Content: Computeraided Design (CAD) with SolidWorks

CNC Milling Technology The CNC Technology courses introduce students to the fundamentals of computer numerical control.

Whether using intelitek’s industrial-strength desktop CNC mill or the CNCMotion® simulated virtual equivalent, students gain experience with the design and production process through project-based activities. Students learn CNC programming, machine set up, tool selection, and mill operation. Students design solutions for industrial CNC applications emphasizing optimized programming, precision and productivity.

Skills Acquired Activity 1: Introduction and Safety Activity 2: CNCBase® Control Software Activity 3: Mounting the Workpiece Activity 4: Tooling Activity 5: Reference Positions Activity 6: Verifying a Program Activity 7: Running a Program Activity 8: Fundamentals of NC Programming Activity 9: Programming the House Activity 10: Machining Project #1 Activity 11: Arc Programming Activity 12: Programming the Star - Project #2 Activity 13: Machining Project #2 Activity 14: Programming Your Initials - Project #3 Activity 15: Final Project

Order #16-3009 (Virtual): Materials Included LearnMate® E-Learning Content: CNC Milling Technology with spectraLIGHT Mill

CNCMotion® for spectraLIGHT Mill simulation software

Order #16-8007 (Lab): Materials Required (sold separately) CNC mill workstation PC with: Available PCI slot 2 GB available HD space

Materials Included LearnMate® E-Learning Content: CNC Milling Technology with spectraLIGHT Mill #10-1001-0000 Controller box PCI card Accessory kit #21-0900-0002 AC power supply cord 25 pin cable Accessory adapter cable 3/8” end mill holder Spindle bar (2) 1/8” end mill Hex key (1/16”) Hex key (3/32”) Hex key (1.8”) Hex key (5/32”) Hex key (3/16”) Hold down set

spectraLIGHT Mill

Fixture and Tooling Kit

#ACC-5510 Jacobs chuck w/key 1/8” end mill holder J1 end mill holder (for Jacobs chuck) Vise w/mounting hardware Hold down set Hex key (3/32) Hex key(5/32) 1/4” end mill 3/16” end mill 1/8” end mill End mill 60° conical 3/8” end mill holder (2) Spindle locking pin (2) CNCBase® for spectraLIGHT Mill control software

(800) 221-2763

33

CAD/CAM/CNC Manufacturing CNC Turning Technology The CNC Turning Technology courses introduce students to the fundamentals of computer numerical control.

Whether using one of intelitek’s industrial-strength desktop CNC lathes, or the CNCMotion® simulated virtual equivalent, students gain experience with the entire design and production process.

Starting with developing and editing programs, students complete projects to learn proper machine set up, cutting tool selection, tool path simulation and turning center operation. Students design solutions for industrial CNC applications emphasizing optimized programming, precision and productivity.

Skills Acquired Activity 1: Introduction and Safety Activity 2: CNCBase Control Software Activity 3: Securing the Workpiece Activity 4: Tooling Activity 5: Reference Positions Activity 6: Verifying a Program Activity 7: Running a Program Activity 8: Fundamentals of NC Programming Activity 9: Programming a Taper Activity 10: Machining Project #1 Activity 11: Arc Programming Activity 12: Programming Project #2 Activity 13: Machining Project #2 Activity 14: Project #3 Activity 15: Final Project Order #16-3011 (Virtual): Materials Included LearnMate® E-Learning Content: CNC Turning Technology with spectraLIGHT Lathe

CNCMotion for spectraLIGHT Lathe simulation software

Order #16-8016 (Lab): Materials Required (sold separately) CNC lathe workstation PC with: Available PCI slot 2 GB available HD space

Materials Included LearnMate® E-Learning Content: CNC Turning Technology with spectraLIGHT Lathe

spectraLIGHT Lathe Controller box PCI card Tool turret Accessory kit #21-0900-0001 25 pin cable AC power supply cord Accessory adapter cable Hex key (5/32”) Hex key (9/64”) Short arm Hex key (1.8”) Hex key (3/32”) Hex key (5/64”) Spindle bar (2) Indexable tool holder CNCBase for spectraLIGHT Lathe control software

Automated Manufacturing Technology (AMT) Projects intelitek’s Advanced Manufacturing Technology (AMT) projects replicate the automated manufacturing process. These welldesigned projects follow a team approach that promotes communication, time management and leadership skills, while teaching rapid prototyping and concurrent engineering methods. The enhanced level of student influence in the learning process contributes to an immersive instructional experience.

Materials Included Order #17-7022: LearnMate® E-learning Content: Four Cavity Mold

project with LearnMate® Teacher supplement and one complete documented solution

Order #17-7023: LearnMate® E-learning Content: Planetary Gear-

box project with LearnMate® Teacher supplement and one complete documented solution

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Materials Required (sold separately) intelitek Desktop CNC Machining Center: Super proLIGHT 1000 or eXpertMill VMC-0600

Machinist vise Hold-downs and clamps Tool holders Appropriate size end mil Part(s) design Competition notebook Prototype material for machining 1 workstation PC with licensed CAD software

1 workstation PC with: Licensed CAM software 1 available full-sized PCI slot Windows 2000 or higher operating system 6” dial or digital vernier caliper 1 dial indicator (with 3/8” or ½” holding shank) 1 calculator 1 pair of ¾” or 1” parallels Soft-face hammer 6” or 12” steel rule 3/8 or ½ edge finder Machinist handbook

Mechanical Systems Series Course List The Mechanical Systems Series features the JobMaster® Mechanical Training Bench - a robust stand-alone mobile training station providing comprehensive training in mechanical power transmission.

A true all-in-one trainer, Mechanical Training Bench features industrial-strength components housed in a heavy duty mobile framework with a customized modular drawer storage system.

Designed for two students per side, the trainer features bearings, belt drives, chain drives, gear drives and more.

Mechanical Systems Courses

Course title Mechanical Training Bench Laser Alignment Vibration Analysis Bearing Service

Course # Skills

Hours*

ME10

63

95

ME11

4

6

ME12

11

17

ME13

12

18

Total:

90

136

Optional two-student add-on makes a complete double-sided work station for four students!

*Hours are approximate and depend on class structure and teaching strategies.

Mechanical Systems Mechanical Training Bench (ME10) The JobMaster® Mechanical Training Bench (ME10) presents the principles of power transmission using the same industrial-strength components used in factory environments. Through ten courses covering 63 skills, students work with basic machines, machine statics and dynamics, shafts and keys, bearings, belt drives, chain drives, speed reducers, electric brakes and gear drives.

Materials Included Order #16-ME10: LearnMate® E-learning Content: Mechanical Training Bench (ME10) Teachers’ Guide Training Bench with mechanical components: Steel shafting Shaft collars Plain-mounted pillow block bearings Roller-mounted pillow block bearings Fixed-pitch V-belt sheaves Variable-pitch V-belt sheaves V-belts Synchronous drive belts Synchronous belt sheaves Chain sprockets

Roller chain Chain puller Chain breaker Rigid 2-piece coupling Flexible grid coupling 3-piece jaw coupling Chain coupling Universal joint coupling S-flex coupling 3-phase C-face drive motor Adjustable-drive motor mounting base 120V electric disc brake Parallel shaft speed reducer C-face right angle speed reducer Spur gear set of 3 Helical gear set of 3 Worm gear set of 2 Bevel gear set of 2 Gear box housing with mounted flanged roller bearings and shafts Split taper bushings (5/8” and 1/2”) Keystock Dial indicator set with magnetic base and shaft alignment accessories Feeler gauges Belt tension gage Shim set Digital tachometer Level Taper gauge 36” rigid ruler Mounting hardware

Hardware Specifications Electrical construction: Master power controller and disconnect switch with pilot lamp provides for lockout/tagout Variable speed drive with adjustable speed trimpot Power Requirements: USA: 120 VAC (+5%/-10%), 50-60 Hz, 10A International: 240 VAC (+5%/-10%), 50-60 Hz, 8A * International step-down transformer package (Order #10-PC09-0000) required for international applications.

Mechanical construction: Frame Size (H x W x D): 39.5” x 60” x 29”

(1219mm x 1524mm x 737mm) Weight (approximate): 350 lbs (159 kg.)

1.5” (38mm) square anodized slotted aluminum frame 1/4” steel top mounting plates (3), pre-drilled and elevated for mounting mechanical drive components 1/4” aluminum slide-out shelves (8) with full-length ball-bearing slides and threaded fasteners for secure component storage Full swiveling and locking casters Drawer Full-suspension ball bearing slides

interior dimensions:

6”H x 12”W x 16”D

(15.25 cm x 30.5 cm x 40.5 cm) Safety shield

Optional Accessories Two-student add-on

Order #10-ME10

(factory hardware-only option) Vibration Analysis Tools Laser Alignment Tools Bearing Service Cart

Order #16-ME12 Order #16-ME11 Order #16-ME13 (800) 221-2763

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Mechanical Systems Mechanical Training Bench (ME10) (continued) Skills Acquired ME01: Basic Machines Skill 1: Measurement Skill 2: Torque Skill 3: Work Skill 4: Power Skill 5: Horsepower Skill 6: Friction Skill 7: Velocity Skill 8: Acceleration Skill 9: Mass and Inertia Skill 10: Energy Skill 11: Mechanical Advantage Skill 12: Inclined Planes Skill 13: Wedges Skill 14: Screws Skill 15: Levers Skill 16: Wheel and Axles Skill 17: Pulley ME02: Machine Statics and Dynamics Skill 1: Identifying Stress, Strain and Combined Stresses Skill 2: Identifying Material Fatigue and Fatigue Stress Points Skill 3: Identifying Fatigue Failure and Failure Modes ME03: Machine Shafts and Keys

Skill 1: Measuring and Verifying Shafts Skill 2: Demonstrating Shaft Expansion Principles Skill 3: Measuring Eccentricity and Shaft Runout Skill 4: Demonstrating Shaft Key Principles Skill 5: Preparing a Key from Keystock Skill 6: Shaft Troubleshooting and Failure Analysis ME04: Bearings Skill 1: Identifying Bearing Types Skill 2: Reading Bearing Dimensions Skill 3: Mounting Bearing Housings Skill 4: Reading a Tolerance Chart Skill 5: Bearing Troubleshooting and Failure Analysis ME05: Belt Drives

Skill 1: Demonstrating Belt Drive Ratio Principles Skill 2: Installing Belt Drives Skill 3: Aligning a Belt Drive Skill 4: Belt Tensioning Skill 5: Installing Adjustable Speed Sheaves Skill 6: Installing Positive Drive Systems Skill 7: Belt Troubleshooting and Maintenance

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ME06: Chain Drives Skill 1: Demonstrating Roller Chain and Sprocket Principles Skill 2: Sizing Chain Skill 3: Installing and Aligning Sprockets Skill 4: Installing Chain Drives Skill 5: Adjusting Slack Skill 6: Troubleshooting and Maintenance ME07: Machine Shaft Couplings Skill 1: Identifying Shaft Couplings Skill 2: Correcting Soft Foot Skill 3: Aligning Shafts Skill 4: Aligning Rims and Faces Skill 5: Connecting Chain Couplings Skill 6: Connecting Universal Joints

Laser Alignment (ME11) The Laser Alignment Tools (ME11) package is an optional supplement to the JobMaster® Mechanical Training Bench (ME10) trainer. This option adds Laser tools for both shaft and belt alignment along with all the hardware needed to deliver comprehensive instruction in all aspects of Laser Alignment.

Using Laser Alignment Tools with the JobMaster® Mechanical Bench, student learn to align shafts, pulleys and couplings, and check for soft foot using the same tools used in industry.

Skills Acquired Skill 1: Aligning a Belt Drive Skill 2: Aligning a Coupling Skill 3: Correcting for Soft Foot Skill 4: Filling Out an Alignment Report Materials Required (sold separately) JobMaster® Mechanical Training Bench Order #16-ME10 Materials Included

ME08: Gear Drives Skill 1: Demonstrating Gear Measurement Principles Skill 2: Installing a Worm Gear Drive Skill 3: Installing a Spur Gear Drive Skill 4: Measuring Backlash Skill 5: Installing a Helical Gear Drive Skill 6: Installing a Bevel Gear Drive Skill 7: Maintaining and Troubleshooting Gear Drives ME09: Machine Speed Reducers Skill 1: Demonstrating Basic Speed Reducer Principles Skill 2: Selecting a Speed Reducer Skill 3: Maintaining and Troubleshooting Speed Reducers ME10: Electric Brakes Skill 1: Operating Electric Brakes Skill 2: Installing Electric Brakes Skill 3: Maintaining and Troubleshooting Electric Brakes

Order #16-ME11: LearnMate® E-learning Content: Laser Alignment Tools (ME11) Teachers’ Guide Installation Guide 1 Laser V-Belt alignment kit: 1 Laser transmitter 2 Magnetic targets 1 AA battery 1 Soft case 1 Laser Shaft Alignment Kit: 1 Laser Alignment Display Unit 1 Stationary Laser Measuring Unit 1 Movable Laser Measuring Unit 2 Locking Chains 1 Measuring Tape with Spirit Level 1 Shim Set 2 D-Cell Batteries 1 Hard Case 2 Laser Coupling, Body 1 Clamp Journal 1 Mounting hardware kit

Laser Alignment Tools (ME11) shown with the Mechanical Training Bench (ME10)

Mechanical Systems Vibration Analysis (ME12) Materials Included

The Vibration Analysis Tools package is an optional supplement to the JobMaster® Mechanical Training Bench (ME10). This option adds a digital vibration analyzer, shafts, rotors and other industrial-grade components to deliver comprehensive instruction in all aspects of vibration analysis.

Using Vibration Analysis Tools with the Mechanical Bench, students learn to measure motor vibration, identify sources of vibration such as couplings, misaligned or bent shafts and unbalanced components.

Skills Acquired Skill 1: Reading a Vibration Severity Chart Skill 2: Filling Out a Maintenance Log Skill 3: Measuring the Vibration of a Motor Skill 4: Measuring the Axis and Location of

Materials Required (sold separately) JobMaster® Mechanical Training Bench #16-ME10

Order #16-ME12: LearnMate® E-learning Content: Vibration Analysis Tools (ME12) Installation guide 1 Digital vibration meter kit 1 Balanced rotor 1 Unbalanced rotor 1 Cocked rotor 1 Eccentric rotor 1 Shaft, 5/8" 1 Bent shaft, 5/8" 2 Adjustable bearing mounts Mounting hardware Batteries Vibration Analysis Tools (ME12) shown with the Mechanical Training Bench (ME10)

Vibration Skill 5: Measuring Shaft Misalignment Skill 6: Troubleshooting Misaligned Shaft Vibration Skill 7: Measuring Coupling Vibration Skill 8: Troubleshooting Bent Shaft Vibration Skill 9: Troubleshooting Defective Shaft Component Vibration Skill 10: Troubleshooting Resonant Vibration Skill 11: Demonstrating Vibration Source Principles

Bearing Service (ME13) The Bearing Service Cart (ME13) is a stand-alone mobile training station for installing, removing and servicing plain and roller bearings.

Bearing Service (ME13) presents the working principles of bearings the most effective way: using the same industrial-strength components used in factory environments. Students learn the principles of proper bearing service and work with a bearing packer, bearing pullers, an arbor press, grease gun and various bearing types.

Skills Acquired Skill 1: Identifying Anti-Friction Bearings Skill 2: Identifying Plain Bearings Skill 3: Using an Arbor Press Skill 4: Using a Bearing Puller Skill 5: Installing and Removing Bushings Skill 6: Using a Cone Heater Skill 7: Loading a Grease Gun Skill 8: Greasing a Pillow Block Skill 9: Hand Packing a Bearing Skill 10: Using a Bearing Packer Skill 11: Demonstrating Bearing Seal Principles Skill 12: Performing Bearing Failure Analysis

Materials Included Order #16-ME13: LearnMate® E-learning Content: Bearing Service Cart (ME13) Teachers' Guide Installation guide Bearing service cart mobile training station

Hardware Specifications Mechanical construction: Frame size : 36”W X 28.5”D X 48”H

(914mm x 724mm x 1219mm) Weight: Single-sided: 200 lbs. (91 kg.)

Double sided: 275 lbs. (125 kg.)

1.5” (38mm) square anodized slotted aluminum frame 1/4” (6.35 mm) aluminum top mounting plate 1/4” (6.35 mm) aluminum slide-out shelves with full-length ball-bearing slides and threaded fasteners for secure component storage Full swiveling and locking casters Drawer Full-suspension ball bearing slides Interior dimensions: 6”H x 12”W x 16”D

(152 mm x 305 mm x 406 mm) Power requirements: USA: 120 VAC (+5%/-10%), 50-60 Hz, 10A International: 240 VAC (+5%/-10%), 50-60 Hz, 8A * International step-down transformer package (Order #10-PC09-0000) required for international applications.

Optional Accessories Two-student add-on

Order #10-ME13

(factory hardware-only option)

(800) 221-2763

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Electromechanical Maintenance Cell The ultimate capstone to any industrial maintenance mechatronics program

In a footprint of 60 square feet (5.6 square meters), the JobMaster® 1600 Electromechanical Maintenance Cell simulates an automated manufacturing operation in an industrial plant. This platform delivers relevant skills in the installation, operation, troubleshooting and maintenance of industrial equipment.

The basic cell includes electrical power distribution and controls, wire and cable tray, wireways, conduit and equipment housings. Students gain enhanced understanding of industrial processes by installing, operating and troubleshooting sub-systems onto the cell including:

Conveyor drive and control Part manipulator and controls with paint bake & cool process tunnel Industrial lighting Three-phase motor controls and variable frequency drives DC motor controls and drive Lubrication components Pneumatic system and controls Instructor fault insertion system

The construction of the cell can be performed entirely by the trainees. Using industry-standard work orders, standard operating procedures, schematic diagrams and technical manuals as resources, students assemble the frame and install the electrical wiring for the cell and add-on components.

“The 1600 is the ultimate test for students. Any students that can assemble and troubleshoot the JobMaster 1600 cell as part of a team would be prime candidates for employment.”

Plant Supervisor, BAE Systems

Once assembled, instructors can remotely insert faults in the electromechanical systems. Trainees can thus develop troubleshooting skills in a relevant, engaging manner. Each task includes validated industry standards providing measurable criteria for assessing students’ performance. This authentic assessment ensures a more valid delivery of career skills.

Electromechanical Maintenance Cell Courses

Course title Basic Maintenance Cell Conveyor, Drive & Controls Part Manipulation Industrial Lighting Circuits Variable Frequency Drive DC Motor & Drive Fault Insertion System

Course # Skills

Hours*

ZA01

21

32

ZA02

13

20

ZA03

15

23

ZA04

14

21

ZA05

4

6

ZA06

7

11

ZA07

5

8

Total:

79

121

*Hours are approximate and depend on class structure and teaching strategies.

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Electromechanical Maintenance Cell Materials Included Order #16-1600: Electromechanical Maintenance Cell (ZA01-ZA07) E-learning Course

DC drive

and Teachers’ Guide

JobMaster® Electromechanical Maintenance Cell Hardware Specifications MECHANICAL CONSTRUCTION: Assembled frame size (H x W x D): 120" x 72" x 96" (3048mm x 1829mm x 2438mm) Weight (approximate): 1400 lbs (635 kg) 15" (38mm) square anodized slotted aluminum frame with adjustable frame levelers ELECTRICAL DISTRIBUTION COMPONENTS: Electrical equipment enclosures: NEMA-1 standard, steel with hinged latch door, pre-drilled and pre-punched for installation Wireways: NEMA-1 standard 16-gauge steel, 4" x 4" (102mm x 102mm), with hinged cover, knockouts and end closure caps Cable trays, ladder-style: Aluminum, (LxWxD) 144" x 12" x 4" (3658mm x 305mm x 102mm), with 90-degree turndown Cable trays, basket-style : Aluminum, (LxWxD) 84" x 6" x 6" (152mm x 152mm x 2134mm) Pull box enclosures: NEMA-1 Standard with knockouts and screw front cover Safety disconnects General duty, 3-phase, 3-pole, 240V, 30A cartridge-style fuse safety disconnects Quick-make, quick-break operating mechanism provides for OSHA standard lockout/tagout procedures and meets UL 98 standards Main load center NEMA-1 load center supplies 12 1-pole circuits 125 amp, 3-phase, main breaker Front cover with hinged door and 2-and 3-pole breakers Station transformer Type: Indoor/outdoor, wall mounted Input: 208/240V single phase Output: 120/110V at 1 kVA Conduit and components 0.75” (19mm) EMT 0.75" (19mm) flexible metal 0.50" (13mm) flexible, liquid-tight Steel bodies, fittings, and clamps Station/building Wire 14 AWG Type TFFN building wire, UL listed, stranded, PVC insulation and a nylon jacket ELECTRICAL PROCESS COMPONENTS AC motor: 208/240V, 3-phase, 1/3 HP (0.25 kW), 1725 rpm, 1.8 FLA, 56 C-face, TEFC, with a rigid mounting base DC motor: 90V, 0.25 HP (0.18 kW), TENV, 1725 rpm, 3.0 FLA, 56 -face, with a rigid mounting base Motor controllers: Motor contactor, overload relay, station transformer, pushbutton start / stop switches, hand-off-auto switch, pilot lamps

Standard equipment enclosure Regenerative drive/braking 240/120VAC input 90V DC armature voltage output Potentiometer speed control Adjustable acceleration/deceleration/IR comp/max speed Red pilot lamp, panel mount, 120V Electric brake Fail-safe operation Single-phase and 240/460V 3-phase control circuits NEMA 56 double-face Mounting standards Manual release with automatic reset Electrical signaling components 120VAC strobe-type status lights for paint/bake/cool process Process paint cool down blower 115V, 60 Hz, PSC direct drive blower, 2450 RPM CFM @ 0.000-In SP 150 Process sensors Proximity switch, capacitive, 0.125 - 1.0" (3-25mm) range, NO output mode Fiber-optic photoelectric switch, thru beam, NPN-SPST form Process programmable logic controller Inputs: 9 DC sinking or sourcing with diagnostic LEDs Outputs: 7 AC relay with diagnostic LEDs Input power requirements: 100-240VAC Front panel LED indicators HMI connector for direct front panel plug-in mounting Expansion port for expansion modules Communications port RS-232 or RS-485 adapter Cartridge connector for optional memory or clock cartridge Program capacity: 27,000 bytes, 4500 steps RAM backup: lithium battery Backup duration: 30 days Instruction words: 35 basic and 46 advanced Self-diagnostic functions Accessories Computer link cable for connecting to a compatible computer to provide the following functions: Monitoring of operating and I/O status Monitoring/updating CPU module data Uploading/downloading user programs 9-position I/O simulator Programming software on CD-ROM Printed user’s manual INDUSTRIAL LIGHTING COMPONENTS

Variable frequency drive

208/240V 3-phase input Standard equipment enclosure Programming keypad Digital readout of programming parameters Analog, 10V, 0-60 Hz panel mounted speed control Acceleration/deceleration/current boost control Voltage/current/alarm monitoring RS485 mod bus Red pilot lamp, panel mounted, 240V 3-position For-Off-Rev selector switch with legend plate

Low bay: 120/277VAC 175W, (H x W) 11.5" x 12.5" (292mm x 318mm) enclosed reflector with lamp High bay: 120/208/240/277VAC, 250W metal halide lamp (H x W) 21" x 18" (533mm x 457mm) Emergency: 120/277VAC, 10.8W @ 90 minutes output with 2 lamp heads, thermoplastic housing, 6V battery and charger Floodlight: 120VAC, 70W HPS stem-mount lamp with die-cast aluminum housing, hinged door with toolless latch Hazardous location: 300W incandescent glass globe, copper-free aluminum pendant mounted, explosion-proof, corrosion resistant Fluorescent task: 120/277 VAC, 32W, general duty lamps with 48" x 12" x 4" (1219mm x 305mm x 102mm) fixture , reflector and electronic ballast.

Industrial lighting controllers 2 pole rotary cam switch 120V 3-pole lighting contactor 120V 4-pole lighting contactor 120 VAC power relay DPST-NO 3-position switch, spring return to center OFF MANUFACTURING MECHANICAL COMPONENTS Process conveyor 96" L x 6” W (152mm x 2438mm) flat belt-type mounted on a 2.5'' (63.5mm) H, ruggedduty, hard-black-anodized aluminum frame Standard 0.60'' (1.5mm) above-belt side fences Integral, direct-drive, 0.50" (13mm) side-mount drive input shaft Leveling-type hold down brackets Belt tensioning device Speed reducer Type: right angle Drive ratio: 60:1 Mounting: NEMA 56 C-face Housing: cast iron Bearings: ball bearing on input shaft, tapered roller bearings on output shaft Gearing: hardened alloy steel worm, hardened forged bronze worm gear Lubrication: oil sump supplied full Seals: spring loaded, double lip Configured to mount in tandem with the 56 C-face motor and 56 C-face brake forming a drive train Chain drive Drive input sprocket: #40 chain, 14-tooth, 0.625" (16mm) bore with keyway Drive output sprocket #40 chain, 20-tooth, with 0.50" (13mm) split tapered bushing and keyway Chain: #40, 0.50" x 120" (13mm x 3048mm) pitch 5 chain links, 5 offset links 0.50" (13mm) rigid shaft coupling with keyway Chain guard Steel sheet metal covering full front, back, and sides Safety equipment: 1 each NEMA-1, plunger-type, 2PDT, safety switch with 10-foot (3-meter) covered, 3 conductor electrical cord

Process parts feeder Feeder tube and base: 3.5” x 3.5” x 3.0” (89mm x 89mm x 76mm), clear polycarbonate Parts feeder ramp: aluminum, black finish Pneumatic cylinder, 1.25“ (32mm) bore, 4.0” (102mm) stroke, double acting, pivot/end mount, with two mounted flow controls and mounting bracket 60 unfinished process parts included Process paint tunnel Material: 12 ga painted HRS Dimensions: (L x W x H) 48.0" x 6.0” x 6.5” (1219mm x 152mm x 165mm) Pre-drilled and punched for component mounting FAULT INSERTION/TROUBLESHOOTING SYSTEM A configurable and programmable fault insertion system installed as a complete system integrated into the completed cell Fault initiating and timing is either preset or actuated by wireless remote control 120 faults and related troubleshooting scenarios including: shorted/open/miswired components or wiring intermittent faults blown circuit fuses/electrical overloads/imbalance mechanical misalignment improper component lubrication equipment vibration improper pneumatic pressure/flow Up to 4 faults may run simultaneously DOCUMENTATION/OPERATING INSTRUCTIONS Supplied for each task in standard industry format: work orders and operating procedures electrical schematics and mechanical drawings observable and measurable performance standards maintenance supervisor signoff /assessment All documentation deliverable via LearnMate

(800) 221-2763

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Electromechanical Maintenance Cell Skills Acquired Basic Maintenance Cell Cell Frame

1600-ZA01

Work Order 1: Assemble the Base Work Order 2: Assemble & Install the Conveyor Mount Support Assembly Work Order 3: Install Pull Box, End & Feeder Tube Supports Work Order 4: Install Crossbars & Top Members Work Order 5: Inspect & Align Completed Frame Enclosures Work Order 6: Install Load Center Work Order 7: Install Cable Trays Work Order 8: Install Wireway Work Order 9: Install Pull Boxes Work Order 10: Install Equipment Enclosures Work Order 11: Install Safety Disconnects Work Order 12: Install Fuse Box & Station Transformer Conduit & Fittings Work Order 13: Cut & Ream Conduit Work Order 14: Install Flexible Metal Conduit Work Order 15: Install EMT Conduit Low Voltage & Circuit Protection Work Order 16: Wire & Connect Main Power Cord Work Order 17: Install & Connect Circuit Breakers Work Order 18: Install Equipment Grounds Work Order 19: Wire Fuse Box Work Order 20: Wire Station Transformer Work Order 21: Perform Megohmmeter Tests

Conveyor, Drive & Control Conveyor

1600-ZA02

Work Order 1: Install Conveyor Work Order 2: Install Conveyor Drive Components Work Order 3: Install & Align Conveyor Drive Chain Work Order 4: Install Conveyor Drive Safety Guard Conveyor Controls Work Order 5: Install & Connect Conveyor Drive Controls Work Order 6: Install Emergency Stop Circuits

Work Order 7: Perform Circuit Continuity Tests Work Order 8: Megger Test Conveyor Drive Work Order 9: Test & Troubleshoot Conveyor Drive Predictive/Preventive Maintenance Work Order 10: Lubricate Conveyor Drive Work Order 11: Verify Conveyor Alignment Work Order 12: Verify Drive Chain Alignment Work Order 13: Obtain Vibration Profiles

Part Manipulation Part Manipulation

1600-ZA03

Work Order 1: Install Part Stacker & Feeder Tray Work Order 2: Install Part Kicker Work Order 3: Install Stacker Part Sensor Paint, Bake & Cool Tunnel

Industrial Lighting Circuits 1600-ZA04 Industrial Lighting Circuits Work Order 1: Install Fluorescent Task Lighting Work Order 2: Install Low Bay Lighting Work Order 3: Install High Bay Lighting Work Order 4: Install Flood Lighting Work Order 5: Install Hazardous Location Lighting Work Order 6: Install Emergency Lighting Work Order 7: Rough-In Lighting Circuits Work Order 8: Megger Test Lighting Circuits Industrial Power Circuits Work Order 9: Install Wiring Devices Work Order 10: Rough-In Wiring Device Circuits Work Order 11: Megger Test Power Circuits Work Order 12: Wire Lighting & Lighting Control Work Order 13: Install & Test GFCI Circuit Work Order 14: Troubleshoot Lighting & Power System

Variable Frequency Drive

1600-ZA05

Work Order 1: Install Drive Work Order 2: Rough-in Drive Wiring Work Order 3: Megger Test VFD Wires Work Order 4: Program & Test Drive Work Order 4: Install Paint Bake Heaters Work Order 5: Install Tunnel Work Order 6: Install Paint Nozzles Work Order 7: Install Cool Down Blower Work Order 8: Install Part Count Sensor Work Order 9: Install Paint Tunnel Status Indicators Programmable Logic Controller (PLC) Work Order 10: Install PLC Work Order 11: Rough-in PLC power Work Order 12: Program PLC Work Order 13: Connect PLC input Sensor Circuits Work Order 14: Connect PLC Output Device Circuits Work Order 15: Troubleshoot Paint, Bake & Cool System

DC Motor Drive

1600-ZA06

Work Order 1: Measure & Remove AC Motor Work Order 2: Install DC Motor Work Order 3: Install DC Drive Work Order 4: Rough-in DC Drive Wiring Work Order 5: Set Up & Test DC Drive (Manual - jumpers) Work Order 6: Finalize Drive Wiring & Installation Work Order 7: Troubleshoot DC Drive System

Fault Insertion System

1600-ZA07

Work Order 1: Install Fault Insertion Sub Panel Work Order 2: Rough-In Power Circuit Work Order 3: Rough-In Fault Insertion Wiring Work Order 4: Install & Configure Triggered Faults Work Order 5: Test Triggered Fault System

About intelitek Our Mission

intelitek’s mission is to improve student outcomes in education by transforming the classroom for schools, colleges, universities and industrial training. Through our proven innovations in curriculum, lab equipment, classroom management technology, assessments, professional development and teacher training, intelitek seeks to engage students, empower instructors and support administrators in the quest to equip learners of all types with relevant skills. intelitek is committed to putting the best technology in the hands of educators to prepare a wider range of students with career- and college-ready skills and the desire to use such skills to improve the world around them.

Our Programs

From Mathematics to Mechatronics, Engineering to Agriculture, intelitek has a program to fit your STEM education needs. Built on the power of the LearnMate® e-learning platform, intelitek’s blended-learning programs deliver comprehensive, standards-based instruction via hands-on activities and compelling online curriculum.

For more information, contact intelitek or visit www.intelitek.com.

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At intelitek, we provide far more than lab equipment and curriculum. Each program we implement is a partnership fully backed by our sustained support and professional development. Everything we provide is for the purpose of an improved educational outcome for all those invested in education, from students and parents to teachers and administrators.

© intelitek, inc. All specifications and available courses subject to change without notice. All trademarks are property of their respective owners.

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