Instructor: Jeremie Hedges (757)651-1007 Contact Hours: 72 hours Prerequisites: None Electrical Controls Syllabus Course Description: This course is designed to present a blend of electrical theory and practice suitable for the apprentice level or experienced technician who wishes to upgrade his or her knowledge and skills. Students will be provided with a sound foundation in electrical safety and theory, the operational function of electrical control devices, interpreting schematics and wiring diagrams, and troubleshooting methods. The mastery of this material will reduce downtime and expenses caused by equipment failures and increase the overall efficiency of their facility. Text/Reference: Electricity for Refrigeration, Heating and Air-Conditioning (ERHA) 40th Anniversary, Russell E. Smith. Electricity 9 th edition Course Outline: Module 1 Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module 10 Module 11 Module 12 Module 13 Electrical Safety & Theory: ERHA Chapters 1 & 2 (3hr Lecture) Electrical Circuits & Meters: ERHA Chapters 3 & 4 (3hr Lecture / 3hr Lab) Wiring & Schematic Diagrams: ERHA Chapters 5 & 6 (3hr Lecture / 3hr Lab) AC Power and Installation: ERHA Chapters 7 & 8 (3hr Lecture); Electric Motors: ERHA Chapters 9 & 10 (3hr Lecture / 3hr Lab) Mid-term: (3hr Review / 3hr Exam) Electrical Controls ERHA Chapters 11 & 12 (3hr Lecture / 1.5hr Lab) Electronic & Heating Controls: ERHA Chapters 13 & 14 (3hr Lecture / 1.5hr Lab) Troubleshooting Electrical Controls: ERHA Chapter 15 (3hr Lecture / 3hr Lab) Residential AC Control Systems: ERHA Chapter 16 (3hr Lecture / 3hr Lab) Commercial AC Control Systems: ERHA Chapter 17 (3hr Lecture / 3hr Lab) Troubleshooting HVAC Controls: ERHA Chapter 16 (3hr Lecture / 3hr Lab) Certification: (3hr Review / 6hr Exam / Lab) Page 1 of 10
Module 1 Electrical Safety & Theory It is impossible for a service technician to adequately troubleshoot systems with the electrical power turned off, so it is imperative to use safe procedures when the power is on. The technician must be knowledgeable in electrical theory to be able to diagnose and repair residential / commercial appliances and HVAC systems properly. Although this unit cannot cover all there is to know about electricity, it will provide an excellent foundation for technicians. explain the effect of electric current on the human body understand the injuries that are possible from an electrical shock know the basic procedures in the event of an electrical shock understand the importance of grounding tools and appliances safely use electrical hand tools and electric meters explain Ohm s law follow the principles of safety when installing and servicing heating and air-conditioning equipment. briefly explain the atomic theory and its relationship to physical objects and electron flow explain the flow of electrons and how it is accomplished explain electrical potential, current flow, and resistance and how each is measured explain electrical power and how it is measured calculate the potential, current, and resistance of an electrical circuit using Ohm s law Module 2 Electrical Circuits & Meters Any electrical system utilized in the industry is composed of various types of circuits. Each type is designed to do a specific task within the system. This module will address some of the more common types of circuits used in modern electrical control systems. In addition to circuits, this module will also instruct students on the proper selection and use of electric meters to identify electrical characteristics and troubleshoot systems. Technicians must be able to interpret system circuits and how to properly utilize electrical meters to do an effective job of installing and servicing equipment. explain the concepts of a basic electric circuit describe the use of the volt-ohm meter and clamp-on ammeter in the heating, cooling, and refrigeration industry explain the characteristics of a series circuit explain the operation of the basic analog meter explain the characteristics of a parallel circuit explain the operation of a digital volt-ohm meter explain the relationship and characteristics of the current, resistance, and electromotive force in a series circuit explain the relationship and characteristics of the current, resistance, and electromotive force in a parallel circuit describe how series-parallel circuits are utilized in the air-conditioning industry give the advantages and disadvantages of the analog and digital meters describe the conditions of resistance that can exist in an electrical circuit in reference to continuity describe the source of energy for the operation of the analog voltmeter, ammeter, and ohmmeter Page 2 of 10
Module 3 Wiring & Schematic Diagrams Because of the complexity of today s commercial and residential appliances and HVAC&R systems, technicians have to be able to read and interpret all kinds of wiring diagrams. Electrical diagrams contain a wealth of information about the electrical installation and operation of the equipment. This module will provide students with in depth, hands-on experience reading and interpreting various wiring and schematic diagrams. identify the symbols of common loads used in read and interpret the schematic of a heating, cooling, and refrigeration systems dehumidifier explain the purpose of relays and contactors in read and interpret the schematic of a window air heating, cooling, and refrigeration systems conditioner identify the symbols of relays and contactors in read and interpret the schematic of a walk-in heating, cooling, and refrigeration systems cooler identify the symbols of switches in heating, cooling, read and interpret the schematic of a commercial and refrigeration systems freezer identify the different types of wiring diagrams used read and interpret the schematics of heat pumps in the industry and the purpose of each with defrost boards and defrost timers read simple and advanced schematic diagrams read and interpret most diagrams found in the refrigeration, heating, and air-conditioning industry Module 4 AC Power and Installation Due to the wide use of alternating current, it is important for technicians to be familiar with its theory. In addition, technicians should be familiar with the way power is distributed and the many type of voltage-current systems available. Proper installation will also require identifying the circuit servicing the equipment and its size. This module will cover the fundamentals of AC power and the distribution systems from the power plant to the residence as well as typical power panels and conductors that can be found in commercial and residential locations. explain the basic difference between direct and understand the standard wire size as defined by alternating currents the American Wire Gauge (AWG) briefly explain how alternating current is produced give the advantages and disadvantages of copper and aluminum conductors explain the difference between single-phase and three-phase power distribution systems correctly size and install electrical conductors for circuits used in the industry by the National Electrical Code and the manufacturer s instructions explain inductance, reactance, and impedance explain the types, sizes, and enclosures of disconnect switches that are used in the industry explain a basic power distribution system explain the types of electrical panels that are used to distribute electrical power to circuits in the structure identify the common voltage systems install breakers in an electrical breaker panel Page 3 of 10
Module 5 Electric Motors There are many different types of electric motors with different running and starting characteristics. This module will cover most types of motors available today and how they are used in industry. Magnetism, an effect that is essential to the operation of motors, relays, contactors, and other electrical devices, will also be discussed along with a specific focus on single-phase motor starting devices. explain magnetism and the part it plays in the operation of electric motors understand the operation, install, reverse the rotation, if possible, and diagnose problems in a shaded-pole motor understand the purpose of capacitors in the operation of a single-phase motor and be able to explain the difference between a starting and running capacitor correctly diagnose the condition of any capacitor and use capacitor rules and be able to substitute a capacitor if a direct replacement is not available explain the operation, install, troubleshoot, and repair, if possible, capacitor-start-capacitor-run motors understand the operation, install, reverse, and troubleshoot three-phase motors identify and explain the operation of motor starting relays and other starting components that are used on single-phase hermetic compressor motors troubleshoot and install motor starting relays on hermetic compressor motors lubricate and identify the type of bearings used in electric motors identify the type of motor drive used on industry applications calculate the variables in a V-belt drive application to obtain the desired equipment rpm recognize and adjust a V-belt application to the proper tension and alignment Module 6 Midterm Exam In this module, you will be given an opportunity to test your mastery of modules 1 5 of the Electrical Controls course. A three-hour student driven lecture will provide a quick review of the key concepts presented in modules 1 through 5. Testing will be in the form of a written exam consisting of 50 questions covering the fundamental knowledge requirements expected of successfully completing modules 1 through 5. Page 4 of 10
Module 7 Electrical Controls Control systems used on modern commercial and residential appliances as well as HVAC&R systems use many different control components to achieve automatic operation and higher efficiencies. While residential HVAC systems have fewer control components, the commercial HVAC and both residential and commercial appliances have far more complex controls. With more control comes the need for more control components and a greater need for technicians to become familiar with the variety of control components and understand their function so they can diagnose faulty components and perform effective control system troubleshooting. This module will provide an overview of various control components and how to troubleshoot control systems. correctly install a contactor or relay in a control troubleshoot and replace a transformer in a system residential air-conditioning control circuit draw a schematic wiring diagram using contactors install line and low-voltage thermostats on and/or relays to control loads in a control system heating, cooling, and refrigeration equipment understand the types and applications of overloads explain the basic function of a line and lowvoltage thermostat in a control system draw schematic wiring diagrams using the proper overload to protect loads draw schematic diagrams using line and low voltage thermostats and operating and safety controls troubleshoot common types of overloads correctly set the heating anticipators and cooling anticipators, if adjustable, on a residential low voltage control system troubleshoot contactors and relays explain the function and operation of pressure switches Module 8 Electronic & Heating Controls Vast improvements in solid-state components has revolutionized the industry, yielding smaller, more accurate, and more diversified control systems. This module will show that these new control systems are nothing to be intimidated by and still share many similarities to the old conventional control systems. This module also covers the various control systems found on gas, oil and electric heating systems and troubleshooting methods for each system. identify and describe the operation of basic electronic system components describe the function and operation of an electronic defrost board used in a heat pump explain the purpose of the electrical controls in warm air and hydronic heating applications that are necessary to safely operate and maintain the desired temperature in a conditioned space explain the operation of an electric furnace or electric resistance duct heaters and the methods of control that are commonly used draw a wiring diagram of an oil-fired, warm-air describe the operation of an electronic motor protection module used on motors furnace identify electronic control systems used in draw a wiring diagram of a gas-fired, warm-air commercial and industrial equipment and structures furnace troubleshoot electronic defrost modules draw the wiring diagram of an electric furnace understand and troubleshoot basic electronic control systems used in residential conditioned air systems troubleshoot an electric furnace or electric resistance duct heater Page 5 of 10
Module 9 Troubleshooting Electrical Controls Most troubleshooting in a system involves a specific problem that the customer is encountering. Most problems in a system stem from one source. It is the responsibility of the technician to replace or repair this component. Sometimes it is difficult to locate the exact problem in an entire system, this module will help students develop troubleshooting methods to accurately identify system faults. troubleshoot electric motors troubleshoot transformers troubleshoot contactors and relays troubleshoot electric heating controls troubleshoot overloads troubleshoot gas heating controls troubleshoot thermostats troubleshoot oil heating controls troubleshoot pressure switches Module 10 Residential AC Control Systems Many of the problems in residential AC systems can be traced to some electrical problem. Although it is impossible to study all the different control systems used in the industry today, familiarity with the more common systems will enable you to understand special systems because of the similarities of design. In this module students will be presented with the more common residential control systems in both a classroom and lab environment. identify the configuration of the equipment (packaged or split system), the airflow source (air handler or furnace), and the heating source (gas, oil, or electric) identify the electrical components of any residential conditioned air system correctly size the wire, formulate a list of supplies needed for installation, make all electrical connections, operate the system, and complete a check, test, and start procedure of the installation of a packaged unit correctly size the wire, formulate a list of supplies needed for installation, make all electrical connections, operate the system, and complete a check, test, and start procedure of the installation of a split system with a fan coil unit correctly size the wire, formulate a list of supplies needed for installation, make all electrical connections, operate the system, and complete a check, test, and start procedure of the installation of a gas furnace and a condensing unit correctly size the wire, formulate a list of supplies needed for installation, make all electrical connections, operate the system, and complete a check, test, and start procedure of the installation of a split system heat pump Page 6 of 10
Module 11 Commercial AC Control Systems In the commercial and industrial equipment, larger loads are used, which requires greater safety, more than its residential counterparts. The basic control system contains several components common to all control systems, such as compressors, evaporator fan motor, and the condenser fan motor along with their controlling devices. Commercial systems tend to be larger and more complex, in this module we will be looking at the control systems found in these larger systems. understand basic commercial and industrial control circuitry, including compressor, evaporator fan motor, condenser fan motor, and safety control circuits understand control circuits that are used in commercial and industrial equipment like specialized compressor motor circuits, water chiller controls, component interlocks, and anti-short-cycling devices, and others understand the basic circuitry of control systems used on light commercial and commercial and industrial applications identify the methods of control for commercial and industrial systems describe the control loop as it relates to control circuitry explain a basic pneumatic control system explain a basic direct digital control system Module 12 Troubleshooting HVAC Controls The two most important tools available to technicians are the electrical meters and schematic wiring diagrams. A technician must know how to interpret a schematic in order to know how a system should operate. When troubleshooting a technician will have to correctly read electrical test instruments to determine voltage, current and resistance. Troubleshooting skills are developed over time and a technician s ability to diagnose control systems will improve with experience. This module will assist students in developing their own troubleshooting methods to work both safely and efficiently. use the proper safety procedures when troubleshooting HVAC control systems determine and use the correct electrical instrument to check the electrical characteristics (potential, current, and resistance) in an HVAC electrical system troubleshoot any electrical component in an HVAC electrical system isolate electrical circuits that are operating incorrectly by reading electrical wiring diagrams and using electrical meters troubleshoot a line voltage control system troubleshoot a residential packaged unit troubleshoot a residential gas heating and electric air-conditioning split system troubleshoot a heat pump Page 7 of 10
Module 13 Certification In this module, you will be given an opportunity to test your mastery of the electrical controls course material. A three-hour student driven lecture will provide a quick review of the key concepts presented in all of the modules presented in this course. Testing will be two parts, a written exam and a performance based exercise. The written exam will be 100 questions covering the fundamental knowledge requirements expected of an apprentice or journeyman technician. The performance based portion will require you to complete several tasks frequently performed by apprentice or journeyman technicians. Certification will be awarded upon satisfactory completion of the previous 10 modules of instruction and a minimum grade point average of 70%. Page 8 of 10
Instructional Philosophy Class starts at 5:30 pm and ends at 8:30 pm. The days of instruction will be posted on the Blue Crab Appliance Parts training calendar. (Calendars are available at the parts counter and will be provided upon enrollment to any course of instruction.) The number of instructional days per week will vary depending on the length of the module being administered. The practical assessments (labs) are a key area of instruction and provide the students an opportunity to apply concepts learned in the lectures to a hands-on exercise. Students will work both independently and in work groups during practical assessments. Course Grades The grades for this course will be determined as follows: Tests 34% Homework 17% Practical Assessments (Labs) 31% Exams 18% There will be a test after the completion of each module. In the case of classes being called off for any reason on the day of a scheduled test, the test will be given at the next scheduled class meeting. Make up tests may be administered at a time designated by the instructor. Homework will be assigned daily and is considered due at the beginning of the next class meeting. Practical assessments will be assigned a total point value and will be administered as follows: Pass or Fail: Cumulative Points A total point score will be assigned to the assessment. The student must successfully complete the required task with no assistance from the instructor or other students to earn the total point value. If the student fails to perform the objective(s) no points will be awarded. A total point score will be divided among several relevant Job Standards for the assessment being performed. Students will earn points based on the level of proficiency observed by the instructor in each of the job standard categories. The total points earned by the student will then be converted into a percentage grade. See example below: Cumulative Point Example Standards Score Scoring Guidelines Preparation Cannot explain anything about the lab = 0 Can explain everything about the lab = 20 Components Cannot correctly identify any components = 0 Can correctly identify any components = 20 Heating Cycle Cannot correctly trace the heating cycle = 0 Can correctly trace the heating cycle = 20 Cooling Cycle Cannot correctly trace the cooling cycle = 0 Can correctly trace the cooling cycle = 20 Charging Chart Cannot determine if charge is correct = 0 Can determine if charge is correct = 20 Total Max = 200 Pts Page 9 of 10
Course Grades (cont.) Final course grades will be assigned according to the following scale: A 90% or greater B 80% to less than 90% C 70% to less than 80% D 60% to less than 70% F less than 60% Attendance/Tardiness/Disenrollment: Students cannot miss more than 3 days of instruction and tardy hours will be deducted from the student total hours. A minimum of 63 hours is required to receive a certification of completion. Students must give a disenrollment notice 48 hours prior to the start of any course of instruction to receive a 100% refund of the enrollment fee. A 50% refund will be given for any disenrollment occurring no later than the second class convening. Any disenrollment occurring after the second class convening will result in a complete forfeiture of enrollment fees. All disenrollment notifications must be presented in writing. Sales of textbooks and course materials are nonrefundable. Safety Violations: Students are required to adhere to all safety procedures while attending any instruction, whether in a classroom or lab environment. Violations of safety procedures could result in a failure of the performance objective being assessed. Repetitive violations could result in disenrollment from the course of study and forfeiture of all enrollment fees. Page 10 of 10