jobmaster mechatronics & industrial maintenance program

Mechatronics & industrial Maintenance

PROGRAM DESCRIPTION AND COURSE LIBRARY

w w w . i n t e l i t e k . c o m

http://intelitek.com/Products.asp?CategoryID=125&Industrial=&Education=yes&category_str_id=

http://www.intelitek.com

2 [email protected]

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

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

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

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

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.

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:

FLUID POWER

FOUNDATION SKILLS

ELECTROMECHANICAL

AUTOMATION

ELECTRICAL SYSTEMS

MECHANICAL

CAD/CAM/CNC

Basic Power ElectricityElectrical Control Systems

Industrial Power Electronics

CAD/CAMCNC Milling and Turning

Automated Manufacturing Projects

Employability Introduction to Advanced Manufacturing

Introduction to Lean Manufacturing Mathematics

Lockout/Tagout

Conveyor, Drive & Controls Industrial Lighting Circuits Variable Frequency Drive

DC Motor & Drive

Mechanical Training BenchLaser Alignment

Vibration Analysis Bearing Maintenance

Robotics Robotics and Automation Projects

Programmable Logic Controllers (PLCs)Process Control

HydraulicsPneumatics

Electro-pneumatics

Mechanical Measurement & Quality Control Blueprint Reading

Lubrication for Technicians Mechanical Fasteners Hand & Power Tools

Validated by industry . . .

COMPREHENSIVE INDUSTRIAL MAINTENANCE & MECHATRONICS TRAINING!

�� Caterpillar

�� DuPont

�� General�Electric

�� General�Motors

�� Ford

�� U.S.�Steel

JobMaster® Course Library . . . . . . . . . . . . . . . . . .5

Foundations (BA) Series . . . . . . . . . . . . . . . . . . . .6

Electrical Series . . . . . . . . . . . . . . . . . . . . . . . . . . .10

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

Fluid Power Series . . . . . . . . . . . . . . . . . . . . . . . 25

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Automation Series . . . . . . . . . . . . . . . . . . . . . . . .27

Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Programmable Logic Controlers (PLCs) . . . .30

Process Control . . . . . . . . . . . . . . . . . . . . . . . .31

CAD/CAM/CNC Series . . . . . . . . . . . . . . . . . . . . . .32

Mechanical (ME) Series . . . . . . . . . . . . . . . . . . . .35

Electromechanical Maintenance Cell . . . . . . . .38

LEARN MORE INSIDE:

3(800) 221-2763

. . . powered by learnMate®

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 access content anytime, anywhere, and proceed at their own

individualized pace. Robust simulations, interactive animations and videos - all

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

trainees engaged. Tests and quizzes with multiple question types identify skills gaps

for focused training.

�� 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

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

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

� Share resources and collaborate

p o w e r e d b y

LEARNMATE® IS THE DASHBOARD TO YOUR TRAINING PROGRAM, WITH POWERFUL

ADMINISTRATIVE FEATURES AT YOUR FINGERTIPS

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.

JobMaster® is powered by LearnMate®, intelitek’s web-based Learning Management System (LMS). LearnMate® delivers powerful content delivery and classroom management capabilities.


4 [email protected]

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

QUALITY HARDWARENo 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.

JobMaster® Course Library

5(800) 221-2763

Foundations skills p. 6Foundations 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 Course # PageEmployability 3097 6Introduction to Advanced Manufacturing 3096 6Introduction to Lean Manufacturing 3109 6Lockout/Tagout LOTO 7Mathematics 1 BA01A 7Mathematics 2 BA01B 7Blueprint Reading BA02 7Lubrication for Technicians BA03 7Mechanical Fasteners BA04 8Hand Tools BA05 8Power Tools BA06 9Mechanical Measurement & Quality Control 3030 9Mechanical Measurement & QC (Lab) 8014 9

ElEctrical sEriEs p. 10JobMaster® Electrical Series skills-based curriculum presents hands-on activities using industrial-grade electrical components mounted on Flexponent™ panels which attach to the JobMaster® Learning Sta-tion. 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 ElectricityCourse Name Course # PageElectrical Circuits EA01A 13Resistors & Conductors EA01B 13LCR Circuits EA01C 14Motors & Generators EA01D 14

Electrical Control SystemsCourse Name Course # PageElectric Circuit Protection & Monitoring EA02 15Transformers EA03 15Electric Motors EA04 16Electromagnetic Motor Starters EA07 17Relays, Timers, & Time Delay Relays EA08 17Pilot Devices EA09 18Solid-State Starters EA11 18Variable Frequency Drives (VFDs) EA12 19DC Motor Control EA16 19

Industrial Power ElectronicsCourse Name Course # PageOscilloscope EB01A 20Digital Multimeter EB01B 21Hand Held Digital Oscilloscope EB01C 21DC Power Supplies EB02A 22Single-phase & 3-phase Power Supplies EB02B 22Thyristor Electric Motor Drives EB03 23Electronic Timers EB04 24Stepper Motor Drives EB05 24Servo Motor Drives EB06 24

Fluid powEr p. 25JobMaster® Fluid Power courses feature stand-alone desktop training panels providing compre-hensive training in hydraulic and pneumatic skills. Modular components mount on the panels for course activities. The included software for simu-lating 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.

HydraulicsCourse Name Course # PageHydraulics 1: Fundamentals (Virtual) 3024 25Hydraulics 1: Fundamentals (Lab) 8008 25Hydraulics 2: Electro-Hydraulics 3025 25

PneumaticsCourse Name Course # PagePneumatics 1: Fundamentals (Virtual) 3037 Pneumatics 1: Fundamentals (Lab) 8068 26Pneumatics 2: Advanced (Virtual) 3038 Pneumatics 2: Advanced (Lab) 8069 26Pneumatics 3: Electro-Pneumatics 3039 26

automation p. 27Automation 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.

RoboticsCourse Name Course # PageRobotics and Materials Handling 1 8082 27Robotics and Materials Handling 2 8083 28Flexible Manufacturing Systems 8067 28Robotics & Automation Project 7016 29

Programmable Logic Controllers (PLC)Course Name Course # PagePLC 1: Fundamentals (Virtual) 3032 30 PLC 1: Fundamentals (Lab) Micrologix 8009 30PLC 1: Fundamentals (Lab) Allen-Bradley 8079 30PLC 2: Advanced Ladder Logic (Virtual) 3033 30PLC 2: Advanced (Lab) Micrologix 8040 30PLC 2: Advanced (Lab) Allen-Bradley 8080 30PLC 3: PLC-Controlled Pneumatic Systems 3034 30PLC 4: PLC-Controlled Hydraulic Systems 3035 30

Process ControlCourse Name Course # PageProcess Control: Temperature 3041 31Process Control: Flow 3043 31Process Control: Presssure 3044 31Process Control: Level 3045 31

cad/cam/cnc machining p. 32CAD, CAM and CNC courses provide comprehen-sive 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 Course # PageCAM with Mastercam® Milling 3006 32CAM with Mastercam® Turning 3008 32CAD with SolidWorks® 3108 33CNC Milling Technology (Virtual) 3009 33CNC Milling Technology (Lab) 8007 33CNC Turning Technology (Virtual) 3011 34CNC Turning Technology (Lab) 8016 34AMT Project: Four Cavity Mold 7022 34AMT Project: Planetary Gearbox 7023 34

mEchanical systEms p. 35JobMaster® Mechanical Systems features the Mechanical Training Bench, a stand-alone mobile training station providing comprehensive training in mechanical power transmission. This all-in-one solution for mechanical training features industrial hardware and skills-based LearnMate® e-learning curriculum.

Course Name Course # PageMechanical Training Bench ME10 35

Includes:Basic Machines ME01Machine Statics & Dynamics ME02Machine Shafts & Keys ME03Bearings ME04Belt Drives ME05Chain Drives ME06Machine Shaft Couplings ME07Gear Drives ME08Machine Speed Reducers ME09Electric Brakes ME10

Laser Alignment ME11 36Vibration Analysis ME12 37Bearing Service ME13 37

ElEctromEchanical maintEnancE cEll p. 38The 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 Course # PageElectromechanical Maintenance Cell 1600 39Includes:

Basic Maintenance Cell ZA01Conveyor, Drive & Control ZA02Part Manipulation ZA03Industrial Lighting Circuits ZA04Variable Frequency Drive ZA05DC Motor Drive ZA06Fault Insertion System ZA07

COURSE LIBRARY

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

6 [email protected]

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

Materials IncludedOrder #16-3097:

�� LearnMate®�E-learning�Content:�Employability��

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.

Course Outline�� 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��

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��

eMpLoyabiLity introduCtion to advanCed ManufaCturing

introduCtion to Lean ManufaCturing

Career Skills Education Program

Foundation skills Course list

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.

foundations

Foundation�Skills�Courses

Course title Course # Skills Hours*�� Employability 3097 15 15

�� Introduction�to�Advanced�Manufacturing 3096 9 15

�� Introduction�to�Lean�Manufacturing 3109 7 15

�� Industrial�Safety:�Lockout/Tagout LOTO 6 9

��Mathematics�for�Technicians�1� BA01A 9 12

��Mathematics�for�Technicians�2 BA01B 9 14

�� Blueprint�Reading BA02 12 18

�� Lubrication�for�Technicians BA03 15 23

��Mechanical�Fasteners BA04 12 18

�� Hand�Tools BA05 17 25

�� Power�Tools BA06 12 18

��Mechanical�Measurement�and�Quality�Control 3030/8014 15 15

Total: 138 197*Hours are approximate and depend on class structure and teaching strategies.

7(800) 221-2763

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.

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

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

industriaL safety: LoCkout/tagout (Loto)

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:�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

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

MatheMatiCs for teChniCians 2 (ba01b)

foundations

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

bLueprint reading (ba02)

Lubrication for Technicians conveys skills-based curriculum through virtual and hands-

on 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��

LubriCation for teChniCians (ba03)

Mathematics for Technicians 1 conveys skills-based math curriculum through nine virtual

activities. Students gain the fundamental math skills needed for working in a variety of technical and industrial environments.

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

Materials Included

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

MatheMatiCs for

teChniCians 1 (ba01a)

8 [email protected]

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 hardware-based 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

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

hand tooLs (ba05)

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

Materials Included

Order #16-BA04:

�� LearnMate®�E-learning�Content:�Mechanical�Fasteners


�� 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

MeChaniCaL fasteners (ba04)

9(800) 221-2763

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

Power Tools delivers twelve skills-based 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 IncludedOrder #16-BA06:

�� LearnMate®�E-learning�Content:�Power�Tools


�� 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

foundations

MeChaniCaL MeasureMent and QuaLity ControLpower tooLs (ba06)

Mechanical Measurement and Quality Control with lab hardware

10 [email protected]

HOW TO BUILD YOUR ELECTRICAL SERIES TRAINING PROGRAM:

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.

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.

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.

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

The ultimate flexibility in electrical maintenance skills training!

eleCtriCal series Course list

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

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.

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.

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

3 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.

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

Electrical Sytems HardwareLearning Station LS00

Single-phase power control panel PC04

Three-phase power control panel PC06

International step-down transformer PC09

Portable panel storage unit PPSU

Basic Power ElectricityElectrical Circuits EA01A

Resistors & Conductors EA01B

LCR Circuits EA01C

Motors & Generators EA01D

Electrical Control SystemsElectric 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 ElectronicsOscilloscope 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

Electrical Series OverviewTotal hours of instruction* 325

Total critical skills taught 214

Total Flexponent panels 75

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

11(800) 221-2763

portabLe paneL storage

unit (ppsu)The Portable Panel Storage Unit stores up to 50 Flexponent™ panels.

Materials Included

Order #10-PPSU-0200 � Portable panel storage unit

Hardware Specifications�� Frame�Construction:

�� Material:�� Anodized�aluminum�U-shaped�frame�� Overall�size:� 76”H�X�44.25”W�X�32”D�� 1930mm�x�1120mm�x�813mm

�� Casters�:� 4”�(102�mm)�swiveling�and�locking

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.

Materials Required (sold separately) � Power Control Panels(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.

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

Hardware Specifications�� Frame�Construction:

�� 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:�� Assembled�weight:� 150�lbs�(68�kg)�� Shipping�weight:�� 245�lbs�(112�kg)

eLeCtriCaL series hardware

JobMaster® Learning station (Ls00)

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:

� JobMaster® Learning Station � Power Control Panels � Flexponent Panels

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

�All wiring is terminated with crimped ferrules, like those found in industry. � The JobMaster® learning station includes frame-mounted industry-standard conduit, allowing students to learn effective wiring practices when wiring from panel to panel.


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 single-phase 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.

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)

�� 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

eLeCtriCaL series hardware

power ControL paneLs (pC04 & pC06)

All Flexponent™ panels are constructed of non-conductive, high density polyethylene with industry-standard recessed and insulated terminal strip connections.

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)

fLexponent™ paneLs

13(800) 221-2763

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 #10-PC09-0000) 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

�� Panel�E152:�Adjustable�Power�Supply

Hardware SpecificationsDigital Multimeter

True-rmsCAT�III�600�V�safety�ratedAC/DC�volts,�millivolts,�ampsContinuityResistanceDiode�testCapacitanceHz�(V�or�A�input)

Panel E040: Switch, Lamp and BuzzerPanel�type:�Single1� 87dB�Piezo�pulse�buzzer1� 12V�jumbo�lamp1� SPST�toggle�switch1� DPDT�toggle�switch1� NO�pushbutton�switch1� NC�push�button�switch

Panel E045: Sources of ElectricityPanel�type:�Single1� Encapsulated�PV�cell1� J-type�surface�thermocouple1� Battery�box4� D-cell�batteries

Panel E047: Heat and Light SourcePanel�type:�Single1� Heat�gun1� Flashlight

Panel E151: Series/Parallel Lamp CircuitsPanel�type:�Single6� Miniature�bulb�sockets3� [email protected]�bulbs3� [email protected]�bulbs

Panel E152: Adjustable Power SupplyPanel�type:�Single1� 8V/16V/24V�transformer1� 1000uF�50V�20%�axial-lead�electrolytic�capacitor1� 4A�50PIV�bridge�rectifier1� 100-ohm�rheostat

basiC power eLeCtriCity

eLeCtriCaL CirCuits:(ea01a)

Resistors and Conductors (EA01B) teaches circuit troubleshooting and testing skills including measuring resistance, calculating wire size and determining losses in a wire. The hands-on 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



�� 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 SpecificationsPanel E042: Resistance

Panel�Type:� Double1� Wire�gauge,�US�standard1� Resistance�coils�package1� Rheostat,�100ohm1� 5K-ohm�linear�taper�potentiometer1� 10K-ohm�linear�taper�potentiometer1� 50K-ohm�linear�taper�potentiometer1� Knob,�hexagon1� Resistor,�wire�wound,�10ohm,�5%,�5W,�ceramic1� Resistor,�wire�wound,�400ohm,�5%,�5W1� Resistor,�wire�wound,�900ohm,�5%,�5W1� Resistor,�wire�wound,�10kohm,�5%,�5W,�ceramic1� Resistor,�carbon�film,�15kohm,�5%,�1/4W

resistors & ConduCtors

(ea01b)With 45 total skills and 11 total Flexponent panels, Basic Power Electricity teaches the introductory electrical skills essential for entry level maintenance technicians.


Basic�Power�Electricity�Courses

Course title Course # Skills Hours* Panels�� Electrical�Circuits EA01A 14 21 5

�� Resistors�and�Conductors EA01B 9 14 1

�� LCR�Circuits EA01C 14 21 5

��Motors�and�Generators EA01D 8 12 0

Total: 45 68 11


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 inter-active content for eight additional hands-on activi-ties 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



�� Prerequisite�courses:�� LCR�Circuits�(EA01C)� � Order�#16-EA01C

Materials Included

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

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



�� 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 SpecificationsPanel E029: Magnetism

Panel�type:�Single1� Current�meter,�100-0-100,�3.5”�x�3.5”

1� Mini�compass,�1-1/2”�diameter

Panel E043: CapacitancePanel�type:�Single1� Start�capacitor,�88-106MFD,�110-125V1� Capacitor,�100uf,�50V,�axial,�aluminum1� Capacitor,�2200uf,�25V,�axial,�aluminum1� Capacitor,�3.3uf,�10V,�axial,�ceramic1� Capacitor,�47uf,�25V,�axial,�aluminum1� Run�capacitor,�12.5�MFD,�370V

Panel E044: inductancePanel�type:�Single1� Primary-secondary�coil2� Bar�magnets,�2”

Panel E057: Motor/GeneratorPanel�type:�Single1� Motor/Generator1� Cover,�clear,�3.5”�depth

Panel E150: Relay/ContactorPanel�type:�Single1� Contactor,�mini,�6A,�24V1� Relay,�8�pin�DPDT1� Socket,�relay,�8�pin1� Solenoid,�24V,�box�frame

basiC power eLeCtriCity

LCr CirCuits

(ea01C)Motors and generators

(ea01d)

15(800) 221-2763

eLeCtriCaL ControL systeMs

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 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


�� Digital�Multimeter�(Fluke�Model�115�or�equivalent)�� Prerequisite�courses:

�� Electromagnetic�Motor�Starters�(EA07)� Order�#16-EA07

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 SpecificationsPanel E019 Capacitor-Start Motor

Panel�type:�Double1�� 1-phase�motor,�.08hp,�1725rpm2�� Fault�switch,�4A,�250V�push-on/

push-off�momentary

Panel E022 Manual StarterPanel�type:�Single1�� Single-phase�fractional�horsepower�starter�(FHP)1�� Thermal�overload�unit�(0.41�to�16�A)�with�pilot�light1�� Non-reversing�manual�starter�with�bimetallic�

thermal�trip�and�magnetic�trip2�� Fault�switch,�4A,�250V��

push-on/push-off�momentary

Panel E030 Circuit Overload Protection & Monitoring

Panel�type:� Double1� Relay,�overload1� Circuit�breaker,�2A1� 3-Phase�line�monitor3�� Midget�fuse�2A1� Midget�fuse�block,�30A,�3-pole

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



�� 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

Hardware SpecificationsPanel E003: Three-Phase Transformer

Panel�type�Double1� Midget�fuse�2A1� Midget�fuse�block,�30A3� 0.05kVA,�50/60�Hz,�Step-down�transformer

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.


Electrical�Control�Systems�Courses

Course title Course # Skills Hours* Panels�� Electric�Circuit�Protection�&�Monitoring EA02 10 15 3

�� Transformers EA03 8 12 1

�� Electric�Motors EA04 14 21 10

�� Electromagnetic�Motor�Starters� EA07 8 12 9

�� Relays,�Timers,�&�Time�Delay�Relays EA08 8 12 2

�� Pilot�Devices EA09 10 15 4

�� Solid-State�Starters EA11 5 8 1

�� Variable�Frequency�Drives�(VFDs) EA12 6 9 2

�� DC�Motor�Control EA16 8 12 7

Total: 77 116 39


Electric Motors (EA04) presents a wide array of hands-on activities using industrial motors, including three-phase, split-phase and capacitor-start 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 Capacitor-Start 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



�� 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

Materials Included

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

�� 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

Hardware SpecificationsPanel E007: SCR Speed Controller

Panel�type:�Single1� 115V�DC�SCR�speed�control2� Fault�switch,�4A,�250V�push-on/push-off�

momentary

Panel E012: TransformerPanel�type:�Single1� Midget�fuse�2A1� Midget�fuse�block,�30A1� Transformer,�110V,�230�to�115V1� Transformer�finger�guard2� Fault�switch,�4A,�250V�push-on/push-off�

momentary

Panel E027 : Shaded-Pole MotorPanel�type:�Single1� Shaded-pole�motor,�1/20�hp1� Fault�switch:�4A,�250V�push-on/push-off�

momentary

Panel E154 : Lamps and SwitchesPanel�type:�Single1� 125V�raised�indicator�light,�RED1� 125V�raised�indicator�light,�AMBER1� 125V�raised�indicator�light,�GREEN3� Switches,�toggle,�SPST

1� Switch,�toggle,�3PST,�On/Off

Panel E156 : Dissectible MotorPanel�type:�Single1� 3-phase�motor,�.13hp,�1725�rpm,�disabled

Panel E010: Three-Phase MotorPanel�type:�Double1� 3-phase�motor,�.13hp,�1725�rpm3� Fault�switch,�4A,�250V�push-on/


Panel E019: Capacitor-Start MotorPanel�type:�Double1� 1-phase�motor,�.08hp,�1725rpm2� Fault�switch,�4A,�250V�push-on/


Panel E034 : DC MotorPanel�type:�Double1� Motor,�90VDC,�.13hp1� Fault�switch:�4A,�250V�push-on/


Panel E065 : Split-Phase MotorPanel�type:�Double1� Motor,�split�phase,�NEMA�frame�422� Fault�switch,�4A,�250V�push-on/


Panel E066 : Adjustable Motor LoadPanel�type:�Double1� Brake,�magnetic�particle,�0.6-35�

lb-in1� Power�supply,�0-24VDC�output,�

220V�AC�input1� Bracket,�adjustable�torque�brake�mounting1� Coupling�body,�jaw�type,�size�L050,�1/2”�bore1� Coupling�body,�jaw�type,�size�L050,�3/8”�bore1� Coupling�insert,�jaw�type,�size�L0501� Relay,�solid�state,�10sec�delay1� Relay,�solid�state,�.1�To�100�min�delay1� NO�pushbutton�switch

eLeCtriC Motors (ea04)eLeCtriCaL ControL systeMs

17(800) 221-2763

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 three-phase 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



�� 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 SpecificationsPanel E002: START-STOP Control

Panel�type:�Single1� Switch,�pushbutton,�momentary,�black,�NO�w/contact�block1� Switch,�pushbutton,�momentary,�red,�NC�w/contact�block2� Fault�switch,�4A,�250V�push-on/push-off�momentary

Panel E004: Single Magnetic StarterPanel�type:�Single1� Contactor,�9A,�43mm1� AUX�Contact�1NO/1NC1� Relay,�thermal�overload,�0.8-1.2A2� Fault�switch,�4A,�250V�push-on/push-off�momentary

Panel E005 : START-REVERSE-STOP SwitchPanel�type:�Single1� Switch,�pushbutton,�momentary,�red�LED,�NC�w/contact�block1� Switch,�pushbutton,�momentary,�green�LED,�NO�w/contact�

block1� Switch,�pushbutton,�momentary,�yellow�LED,�NO�w/contact�

block2� Fault�switch,�4A,�250V�push-on/push-off�momentary

Panel E006 : Reversing Magnetic StarterPanel�type:�Single2� Contactor,�9A,�43mm2� AUX�contact�2NO/2NC1� Relay,�thermal�overload,�0.8-1.2A1� Interlock�unit1� Reversing�unit�load�side2� Fault�switch,�4A,�250V�push-on/push-off�momentary

Panel E010: Three-Phase MotorPanel�type:�Double1� 3-phase�motor,�.13hp,�1725�rpm2� Fault�switch,�4A,�250V��


Panel E012: TransformerPanel�type:�Single1� Midget�fuse�2A1� Midget�fuse�block,�30A1� Transformer,�110V,�230�to�115V1� Transformer�finger�guard2� Fault�switch,�4A,�250V�push-on/push-off�momentary

Panel E016 : Analog RelayPanel�type:�Single1� Relay,�120V�2PDT�15A�LED�Test�PB1� Relay,�socket1� Timer�multi-mode�2PDT,�100-240V�0.05S-60H1� Relay,�socket�mount

Panel E154 : Lamps and SwitchesPanel�type:�Single1� 125V�raised�indicator�light,�red1� 125V�raised�indicator�light,�amber1� 125V�raised�indicator�light,�green3� Switches,�toggle,�SPST1� Switch,�toggle,�3PST,�on/off

Panel E155: HOA SwitchPanel�type:�Single1� Switch,�3�pos,�maintained�contact,�black2� Fault�switch,�4A,�250V�push-on/push-off�momentary

eLeCtroMagnetiC Motor starters (ea07)eLeCtriCaL ControL systeMs

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



�� 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 SpecificationsPanel E017: Digital Relay

Panel�type:�Single4� Fault�switch,�4A,�250V,��

push-on/push-off�momentary1� Relay,�120V�2PDT�15A�LED�Test�PB1� Socket�relay1� Time�delay�relay,�DPDT,�multi-function1� Socket�relay,�11�pin�octal

Panel E041: Electric TimerPanel�type:�Single1� Timer�mechanism,�electronic

reLays, tiMers & tiMe deLay reLays (ea08)


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.

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

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

� Skill 10: Performing Preventive Maintenance



�� Digital�Multimeter�(Fluke�Model�115�or�equivalent)�� Prerequisite�Courses

�� Electromagnetic�Motor�Starters�(EA07)�� Order�#16-EA07

Materials Included

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

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

Hardware SpecificationsPanel E011: Limit Switch

Panel�type:�Single2� Limit�switch,�snap�action,�one-way�lever4� Fault�switch,�4A,�250V,��


Panel E018: Liquid Level and Pressure Switch

Panel�type:�Double1� Pressure�gauge,�60�psi,�1-1/2�dia1� Pressure�switch,�NEMA�1�enclosed,�40-100�PSIG2� Liquid�level�switch,�1/4”�x�1/2”�NPT1� Liquid�level�switch,�float,�1/4”�NPT4� Fault�switch,�4A,�250V,�push-on/push-off�momentary

Panel E126: Proximity & Photoelectric Switch

Panel�type:�Double1� Switch,�fiber�optic�photoelectric1� Switch,�proximity,�34mm,�120VAC1� Switch,�magnetic�reed1� Photoelectric�sensor,�12-240VDC,�w/6ft�cable1� Proximity�sensor,�12mm�dia,�24VDC,�NO4� Fault�switch,�4A,�250V,�push-on/push-off�momentary

Panel E153: AC/DC CircuitPanel�type:�Single1� Transformer,�24V�output,�40�VA�rating1� Encapsulated�solar�cell,�0.45V/200mA1� Bridge�rectifier,�4A,�50PIV1� Light�bulb�,�24V,�w/socket

eLeCtriCaL ControL systeMs

piLot deviCes (ea09)

Solid-State Starters (EA11) guides trainees through installing, operating and troubleshooting solid-state 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



�� 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 SpecificationsPanel E024: Solid-State Starter

Panel�type:�Single1� Solid-state�soft�starter,�1/2HP,�100-240V�control�

voltage,�200-208V�3PH,�3A�output2� Fault�switch,�4A,�250V�push-on/push-off�

momentary

soLid-state starters (ea11)

19(800) 221-2763

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



�� Digital�multimeter�(Fluke�Model�115�or�equivalent)�� Prerequisite�courses:


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

Hardware SpecificationsPanel E067: Variable Frequency Drive

Panel�type:�Single1� AC�adjustable�drive,�115V,�0.5hp,��

1�phase�in�3�phase�out

Panel E002: START-STOP ControlPanel�type:�Single1� Switch,�pushbutton,�momentary,�black,��

NO�w/contact�block1� Switch,�pushbutton,�momentary,�red,��

NC�w/contact�block2� Fault�switch,�4A,�250V,�push-on/push-off�

momentary

variabLe freQuenCy drives (ea12)eLeCtriCaL ControL systeMs

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 hands-on 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 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



�� Digital�multimeter�(Fluke�Model�115�or�equivalent)�� Prerequisite�courses:


Materials Included

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

�� 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 SpecificationsPanel E007: SCR Speed Controller

Panel�type:�Single1� 115V�DC�SCR�speed�control2� Fault�switch,�4A,�250V�push-on/push-off�

momentary

Panel E017: Digital RelayPanel�type:�Single1� Relay,�120V�2PDT�15A�LED�test�PB1� Socket�relay1� Time�delay�relay,�DPDT,�multi-function1� Socket�relay,�11�pin�octal4� Fault�switch,�4A,�250V�push-on/push-off�

momentary

Panel E025: F-O-R Switch and PotentiometerPanel�type:�Single1� Toggle�switch,�SPDT,�On-Off-On,�contact�rating�

125V/15A,�250V/10A1� Potentiometer,�linear,�5k�ohm,�1/2�w

Panel E034: DC MotorPanel�type:�Double1� Motor,�90VDC,�.13hp1� Fault�switch:�4A,�250V�push-on/


Panel E038: PWM Motor ControlPanel�type:�Single1� Pulse�Width�Modulated�(PWM)�speed�control,�

115VAC�input,�1�HP,�10A,�0-130VDC�output

Panel E048: Inertial LoadPanel�type:�Single1� Rotor,�balanced,�4”�diameter,�1141�steel1� Toggle�shaft�coupling,�5/8”�bore1� Flanged�bearing�and�bearing�mount

Panel E071: Regenerative Four Quadrant DC DrivePanel�type:�Single1� 4-Quadrant�regenerative�DC�drive,�115V/230V�input,�

0.75HP/1.5HP,�90V/180VDC�armature

dC Motor ControL (ea16)


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.

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

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


Materials Included

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

�� Panel�E087�Adjustable�Power�Supply�� Panel�E153�AC/DC�Circuit�

�� Oscilloscope�(BK�Precision�Model�2120B�or�equivalent)

Hardware SpecificationsPanel E087: Adjustable Power Supply

Panel�type:�Single

1� Adjustable�power�supply,�3-12V�@�2A

Panel E153: AC/DC CircuitPanel�type:�Single1� Transformer,�24v�output,�40�VA�rating1� Encapsulated�solar�cell,�0.45V/200mA1� Bridge�rectifier,�4A,�50PIV1� Candelabra�socket1� Lightbulb,�24Vs

Oscilloscope

30�MHz�dual�traceDual�or�single�trace�operation5�mV/div�sensitivityCompact�low�profile

osCiLLosCope (eb01a)

industriaL power eLeCtroniCs

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.


Industrial�Power�Electronics�Courses

Course title Course # Skills Hours* Panels�� Oscilloscope EB01A 8 12 2

�� Digital�Multimeter� EB01B 17 26 2

�� Hand�Held�Digital�Oscilloscope EB01C 8 12 2

�� DC�Power�Supplies EB02A 11 17 3

�� Single-phase�&�3-phase�Power�Supplies EB02B 13 20 3

�� Thyristor�Electric�Motor�Drives EB03 15 23 8

�� Electronic�Timers EB04 7 11 1

�� Stepper�Motor�Drives EB05 7 11 1

�� Servo�Motor�Drives EB06 6 9 1

Total: 92 141 23

21(800) 221-2763

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.

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



Materials Included

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

�� Panel�E087:�Adjustable�Power�Supply�� Panel�E153:�AC/DC�Circuit

�� Hand-held�Digital�Oscilloscope

Hardware SpecificationsPanel E087: Adjustable Power Supply

Panel�type:�Single

1� Adjustable�power�supply,�3-12V�@�2A

Panel E153: AC/DC CircuitPanel�type:�Single1� Transformer,�24v�output,�40�VA�rating1� Encapsulated�solar�cell,�0.45V/200mA1� Bridge�rectifier,�4A,�50PIV1� Candelabra�socket1� Lightbulb,�24Vs

Hand-held Digital Oscilloscope5MHz�Bandwidth25MS/s�(dual�channel);�50MS/s�(single�channel)�max.�

sample�rate�per�channel512�single�shot;�256�all�other�modes�record�lengthSingle�shot,�roll,�normal�sample�mode50mV�max�vertical�sensitivity600V�DC�or�AC�rms�max�input�voltageAuto,�normal,�single�trigger�modesChannel�A,�B,�external�trigger�sourceAC,�DC�trigger�coupling1μS�to�5S�timebase1MΩ�input�impedanceCompact�low�profile

hand-heLd digitaL osCiLLosCope (eb01C)


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.

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

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



�� Prerequisite�courses�� 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 SpecificationsDigital Multimeter

True-rmsCAT�III�600�V�safety�ratedAC/DC�volts,�millivolts,�ampsContinuityResistanceDiode�TestCapacitanceHz�(V�or�A�input)

Panel E052: ResistorsPanel�type:�Single2� Composition,�470Kohm,�10%,�2W,�ceramic1� Ceramic�power�resistor�180ohm,�5%,�5W1� Ceramic�power�resistor�330ohm,�5%,�5W1� Ceramic�power�resistor�470ohm,�5%,�5W1� Ceramic�power�resistor�680ohm,�5%,�10W1� Ceramic�power�resistor�900ohm,�5%,�8W1� Ceramic�power�resistor�1.2Kohm,�5%,�5W1� Ceramic�power�resistor�2.7Kohm,�5%,�10W1� Ceramic�power�resistor�3.3Kohm,�5%,�5W1� Ceramic�power�resistor�6Kohm,�5%,�5W1� Ceramic�power�resistor�10Kohm,�5%,�5W1� 47ohm�resistor

Panel E055: Filters/CapacitorsPanel�type:�Single1� Capacitor,�2.2Uf,�50V,�axial,�aluminum1� Capacitor,�10uf,�50V,�axial,�aluminum1� Capacitor,�22uf,�50V,�axial,�aluminum1� Capacitor,�100uf,�50V,�axial,�aluminum1� Capacitor,�220uf,�50V,�axial,�aluminum1� Capacitor,�470uf,�50V,�axial,�aluminum2� Capacitor,�1000uf,�50V,�axial,�aluminum1� Capacitor,�150uf,�10V,�axial,�aluminum1� Inductor,�high�current,�27uH,�10%,�4.8A,�Axial

digitaL MuLtiMeter (eb01b)


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 Three-Phase Bridge Rectifier � Skill 13: Troubleshooting a Three-Phase Bridge Rectifier

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


�� Prerequisite�courses�� DC�Power�Supplies�(EB02A)� 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

Hardware SpecificationsPanel E049: Zener Diode

Panel�type:�Single1� Zener�diode,�15V,�170mA1� Heatsink,�TO-3,�76.2mm2� Fault�switch,�4A,�250V�push-on/� �


Panel E050: Regulated Power SupplyPanel�type:�Single1� Adjustable�voltage�power�supply2� Fault�switch,�4A,�250V�push-on/� �


Panel E053: Three-Phase Bridge RectifierPanel�type:�Single1� Bridge�rectifier,�3P,�1200V,�60A2� Fault�switch,�4A,�250V�push-on/� �


singLe-phase and three-phase power suppLies (eb02b)


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 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 Single-Phase Bridge Rectifier



�� Prerequisite�courses�� Digital�Multimeter�(EB01B)� Order�#16-EB01B

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�E062:�Diode�Rectifiers

Hardware SpecificationsPanel E039: Single-Phase Bridge Rectifier

Panel�type:�Single1� Bridge�rectifier,�25A,�200V1� Heatsink,�TO-3,�76.2mm2� Fault�switch,�4A,�250V,�push-on/push-off�

momentary

Panel E061: Low-voltage TransformerPanel�type:�Single1� Transformer,�bobbins,�115V�to�24V,�96A1� Midget�fuse�block,�30A1� Fuse,�midget,�10A,�fast�acting2� Fault�switch,�4A,�250V,�push-on/push-off�

momentary

Panel E062: Diode RectifiersPanel�type:�Single2� Recovery�rectifier,�16A,�1.23V1� Heatsink,�TO-3,�76.2mm2� Fault�switch,�4A,�250V,�push-on/push-off�

momentary

dC power suppLies (eb02a)

23(800) 221-2763

Thyristor Electric Motor Drives (EB03) brings students in contact with the same industrial-grade 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 Trigger-controlled 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 DIAC-Controlled 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



�� 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 SpecificationsPanel E034 : DC Motor

Panel�type:�Double1� Motor,�90VDC,�.13hp1� Fault�switch:�4A,�250V�push-on/


Panel E081: SCRPanel�type:�Single1� Heatsink,�TO-3,�76.2mm1� SCR�thyristor,�25A2� Fault�switch,�4A,�250V��


Panel E082: Full-Wave SCR DrivePanel�type:�Single1� Speed�control,�DC�115V,�SCR2� Fault�switch,�4A,�250V��


Panel E083: TRIACPanel�type:�Single1� Heatsink,�TO-3,�76.2mm1� TRIAC,�15A,�600V2� Fault�switch,�4A,�250V��


Panel E084: DIAC Adjustable ResistorsPanel�type:�Single1� DIAC,�36V1� Capacitor,�0.1uf,�600VDC,�radial,��

metallized�polyester1� 50K-ohm�linear�potentiometer�0.125�shaft1� 500K-ohm�linear�potentiometer�0.125�shaft

Panel E085: TRIAC with Schmidt TriggerPanel�type:�Single1� Speed�control,�TRIAC1� Switch,�toggle,�DPDT,�flat�lever

Panel E088: Pulse Width Modulation (PWM) Motor DriverPanel�type:�Single1� Speed�control,�PWM

Panel E157: Universal AC/DC Motor and PMDC MotorPanel�type:�Single1� AC/DC�motor,�1/15hp,�5000rpm1� DC�Motor,�12/24V,�1/44hp�@�12�VDC,�1/18hp�@�

24VDC,�1800rpm�@12�VDC,�4300rpm�@24�VDC2� Fault�switch,�4A,�250V��

push-on/push-off�momentary�

thyristor eLeCtriC Motor drives (eb03)industriaL power eLeCtroniCs


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



�� 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 SpecificationsPanel E089: Timers and Triggers

Panel�type:�Single1� Timer1� Potentiometer1� NO�pushbutton�switch

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



�� Prerequisite�courses�� Electronic�Timers�(EB04)� � Order�#16-EB04

Materials Included

Order #16-EB05:�� LearnMate®�E-learning�Content:�Stepper�Motor�Drives�(EB05)�� Teachers'�Guide�� (1)�Flexponent™�panel:

�� Panel�E090:�Stepper�Motor�and�Drive

Hardware SpecificationsPanel E090: Stepper Motor and Drive

Panel�type:�Single1� Stepper�motor1� Stepper�drive1� NO�pushbutton�switch1� Potentiometer1� Dial1� IC�test�clip,�16-position2� Fault�switch,�4A,�250V,�push-on/push-off�

momentary

Servo Motor Drives (EB06) guides students through six additional skills with an industrial-grade 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.

Skills Acquired � Skill 1: Demonstrating Closed-Loop Servo Motor Control Principles � Skill 2: Demonstrating Closed-Loop Servo Motor 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



�� 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

Hardware SpecificationsPanel E091: Servo Motor and Drive

Panel�type:�Single1� Servo�motor1� Servo�drive1� NO�pushbutton�switch1� Potentiometer1� Dial1� IC�test�clip,�16-position

eLeCtroniC tiMers (eb04) stepper Motor drives (eb05) servo Motor drives (eb06)industriaL power eLeCtroniCs

25(800) 221-2763

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

Materials Included

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

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

hydrauLiCs 1: fundaMentaLs

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.

Fluid power series Course listFluid 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

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

hydrauLiCs 2: eLeCtro-hydrauLiCs

Fluid�Power�Courses

Course title Course # Hours*�� Hydraulics�1:�Fundamentals�(Virtual) 3024 15

�� Hydraulics�1:�Fundamentals�(Lab) 8008 15

�� Hydraulics�2:�Electro-Hydraulics 3025 15

�� Pneumatics�1:�Fundamentals�(Virtual) 3037 15

�� Pneumatics�1:�Fundamentals�(Lab) 8068 15

�� Pneumatics�2:�Advanced�(Virtual) 3038 15

�� Pneumatics�2:�Advanced�(Lab) 8069 15

�� Pneumatics�3:�Electro-Pneumatics 3039 15

Total: 120


Hydraulics with HydraFlex training panel


pneuMatiCs

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-pneuMatiCsSkills 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


�� Pneumatics�2

Materials Included

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

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

Materials Included

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

Skills Acquired �Activity 1: Getting Started �Activity 2: The Logic Function AND �Activity 3: Implementing AND in a Pneumatic Circuit �Activity 4: The Toggle Valve �Activity 5: Using AND to Build a Fully Automatic 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 �Activity 12: Opposing Control Signals �Activity 13: Timing Diagrams �Activity 14: Using a Single Pilot Valve to Prevent Opposing Control Signals �Activity 15: Using A Single Pilot Valve in a Pneumatic Circuit


�� 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

Pneumatics with PneuFlex training panel

27(800) 221-2763

Robotics and Materials Handling with ER4u robot

robotiCs

autoMation Course list

robotiCs and MateriaLs handLing 1Robotics 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


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 � 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

� 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

Automation�Courses

Course title Course # Hours*�� Robotics�and�Materials�Handling�1� 8082 15

�� Robotics�and�Materials�Handling�2� 8083 15

�� Flexible�Manufacturing�Systems� 8067 15

�� Robotics�and�Automation��Technology�Project

7016/��7018

n/a

�� PLC�1:�Fundamentals�(Virtual) 3032 15

�� PLC�1:�Fundamentals�(Lab)�Micrologix 8009 15

�� PLC�1:�Fundamentals�(Lab)�Allen-Bradley

8079 15

�� PLC�2:�Advanced�Ladder�Logic�(Virtual)� 3033 15

�� PLC�2:�Advanced�(Lab)�Micrologix 8040 15

�� PLC�2:�Advanced�(Lab)�Allen-Bradley 8080 15

�� PLC�3:�PLC-Controlled�Pneumatic�Systems� 3034 15

�� PLC�4:�PLC-Controlled�Hydraulic�Systems� 3035 15

�� Process�Control:�Temperature 3041 15

�� Process�Control:�Flow 3043 15

�� Process�Control:�Pressure 3044 15

�� Process�Control:�Level 3045 15

Total: 225+

The Automation Courses feature stand-alone curriculum that focuses on automated manufacturing skills and concepts, including:

� Robotics � Process Control � Programmable Logic Controllers (PLC)

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.

For PLC instruction, choose from virtual or hardware labs.

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

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


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


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 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.

�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

robotiCs and MateriaLs handLing 2

robotiCs

Skills Acquired

29(800) 221-2763

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!

Order #16-7016 (all-inclusive):

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

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

�Misc supplies for project

Order #16-7018 (add-on�package):

Materials Required (sold separately)

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

robotiCs and autoMation teChnoLogy proJeCt

robotiCs

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.


prograMMabLe LogiC ControLLers (pLCs)

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 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

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

Materials Required (sold separately) � Prerequisite courses

� PLC 1: Fundamentals of Ladder Logic


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

� Teachers guide

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 Spring-Return Valve �Activity 6: Fully Automatic Operation �Activity 7: Fully Automatic Operation with a 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


� PLC 2: Advanced Ladder Logic � Pneumatics 3


Materials Included � LearnMate® E-Learning Content: PLC Technology 3: PLC-Controlled Pneumatic Systems � Teachers guide

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.

Skills Acquired �Activity 1: Getting Started �Activity 2: Using a 4/2 Sol-Sol Valve to Control a Double-Acting Cylinder �Activity 3: Using a 4/2 Sol-Spring Valve to 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

�Activity 11: Sequential Operation with Two Double-Acting Cylinders and a Delay �Activity 12: Sequential Operation with Three Double-Acting Cylinders and a Delay �Activity 13: Variable Timers �Activity 14: Variable Counters �Activity 15: Project: Port Soil Removal System


� PLC 2: Advanced Ladder Logic � Hydraulics 2


Materials Included � LearnMate® E-Learning Content: PLC Technology 4: PLC-Controlled Hydraulic Systems � Teachers guide

pLC 4: pLC-ControLLed hydrauLiC systeMs

31(800) 221-2763

proCess ControL

Skills Acquired �Activity 1: Introduction to Process Control �Activity 2: Introduction to ProcessMotion Simulation Software �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 Constant �Activity 8: Controlling the Temperature System Using Open Loop Control �Activity 9: Introduction to On-Off Control �Activity 10: On-Off Control - Tasks �Activity 11: Controlling the Temperature System Using On-Off Control �Activity 12: Proportional Control �Activity 13: First Order Systems Under Proportional Control �Activity 14: Controlling the Temperature System Using Proportional Control �Activity 15: Proportional Integral Control �Activity 16: Controlling the Temperature System Using Proportional Integral Control �Activity 17: PID Control �Activity 18: Controlling the Temperature System 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

Skills Acquired �Activity 1: Introduction to Process Control �Activity 2: Introduction to ProcessMotion Simulation Software �Activity 3: Block Diagrams and Gain �Activity 4: The System Block Diagram and Final Control Element Gain �Activity 5: Calculating Process Gain �Activity 6: First Order Systems �Activity 7: The Flow System Time Constant �Activity 8: Controlling the Flow System Using Open Loop Control �Activity 9: Introduction to On-Off Control �Activity 10: On-Off Control - Tasks �Activity 11: Controlling the Flow System Using On-Off Control �Activity 12: Proportional Control �Activity 13: First Order Systems Under Proportional Control �Activity 14: Controlling the Flow 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 �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 Flow � ProcessMotion simulation software

Skills Acquired �Activity 1: Introduction to Process Control �Activity 2: Introduction to ProcessMotion Simulation Software �Activity 3: Block Diagrams and Gain �Activity 4: Calculating Process Gain �Activity 5: Calculating the Final Control Element 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 � ProcessMotion simulation software

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

�Activity 11: Controlling the Level System Using 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

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

Materials Included

Order #16-3045: � LearnMate® E-Learning Content: Process Control Level � ProcessMotion simulation software

proCess ControL:teMperature

proCess ControL: LeveL

proCess ControL:fLow

proCess ControL:pressure

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.


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

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

Materials Required (sold separately) �Mastercam® software

Materials Included

Order #16-3006: � LearnMate® E-Learning Content: Computer-Aided Manufacturing for Mastercam® Milling

Computer-Aided Manufacturing for Mastercam® Turning

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

Materials Required (sold separately) �Mastercam® software

Materials Included

Order #16-3008: � LearnMate® E-Learning Content: Computer-Aided Manufacturing for Mastercam® Turning

Cad/CaM/CnC ManufaCturing

The CAD/CAM/CNC Manufacturing series is stand-alone 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 Course list

CoMputer-aided ManufaCturing for MasterCaM®

CAD/CAM/CNC�Manufacturing�Courses

Course title Course # Hours*�� CAM�Milling�with�Mastercam® 3006 15

�� CAM�Turning�with�Mastercam® 3008 15

�� CAD�with�SolidWorks® 3108 15

�� CNC�Milling�Technology�(Virtual) 3009 15

�� CNC�Milling�Technology�(Lab) 8007 15

�� CNC�Turning�Technology�(Virtual) 3011 15

�� CNC�Turning��Technology�(Lab) 8016 15

�� Automated�Manufacturing�Technology�Project:�Four�Cavity�Mold

7022 n/a

�� Automated�Manufacturing�Technology�Project:�Planetary�Gearbox

7023 n/a

Total: 105+

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

33(800) 221-2763


CoMputer-aided design with soLidworks®

CnC MiLLing teChnoLogy

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 fast-tracks 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: Computer-aided Design (CAD) with SolidWorks

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


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 � 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

� 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



CnC turning teChnoLogy

autoMated ManufaCturing teChnoLogy (aMt) proJeCts

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


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

intelitek’s Advanced Manufacturing Technology (AMT) projects replicate the

automated manufacturing process. These well-designed 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

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

35(800) 221-2763

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� Order�#16-ME12�� Laser�Alignment�Tools� Order�#16-ME11�� Bearing�Service�Cart� Order�#16-ME13

MeChaniCaL training benCh (Me10)MeChaniCaL systeMs

MeChaniCal systeMs series Course list

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

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 Course # Skills Hours*��Mechanical��Training�Bench ME10 63 95

�� Laser�Alignment ME11 4 6

�� Vibration�Analysis ME12 11 17

�� Bearing�Service ME13 12 18

Total: 90 136*Hours are approximate and depend on class structure and teaching strategies.


�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

�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

�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

MeChaniCaL systeMs

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

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 (Me11)MeChaniCaL training benCh (Me10) (Continued)

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

Skills Acquired

37(800) 221-2763

MeChaniCaL systeMs

bearing serviCe (Me13)

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 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

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

Materials Included

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 (Me12)

Vibration Analysis Tools (ME12) shown with the Mechanical

Training Bench (ME10)

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


Optional Accessories�� Two-student�add-on� Order�#10-ME13��(factory�hardware-only�option)


The ultimate capstone to any industrial maintenance mechatronics program

eleCtroMeChaniCal MaintenanCe Cell

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.

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.

“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

Electromechanical�Maintenance�Cell�Courses

Course title Course # Skills Hours*�� Basic�Maintenance�Cell ZA01 21 32

�� Conveyor,�Drive�&�Controls ZA02 13 20

�� Part�Manipulation ZA03 15 23

�� Industrial�Lighting�Circuits ZA04 14 21

�� Variable�Frequency�Drive ZA05 4 6

�� DC�Motor�&�Drive ZA06 7 11

�� Fault�Insertion�System ZA07 5 8

Total: 79 121


39(800) 221-2763

eLeCtroMeChaniCaL MaintenanCe CeLL

Order #16-1600:�� Electromechanical�Maintenance�Cell�(ZA01-ZA07)�E-learning�Course�and�Teachers’�Guide�� JobMaster®�Electromechanical�Maintenance�Cell

Hardware SpecificationsMECHANICAL 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�installationWireways:�NEMA-1�standard�16-gauge�steel,�4"�x�4"�(102mm�x�102mm),�with�hinged�cover,�knockouts�and�end�closure�capsCable trays, ladder-style: Aluminum,�(LxWxD)�144"�x�12"�x�4"�(3658mm�x�305mm�x�102mm),�with�90-degree�turndownCable 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�coverSafety disconnectsGeneral�duty,�3-phase,�3-pole,�240V,�30A�cartridge-style�fuse�safety�disconnectsQuick-make,�quick-break�operating�mechanism�provides�for�OSHA�standard�lockout/tagout�procedures�and�meets�UL�98�standardsMain load centerNEMA-1�load�center�supplies�12�1-pole�circuits125�amp,�3-phase,�main�breakerFront�cover�with�hinged�door�and�2-and�3-pole�breakersStation transformerType:�Indoor/outdoor,�wall�mountedInput:�208/240V�single�phaseOutput:�120/110V�at�1�kVAConduit�and�components0.75”�(19mm)�EMT0.75"�(19mm)�flexible�metal0.50"�(13mm)�flexible,�liquid-tightSteel�bodies,�fittings,�and�clampsStation/building Wire14�AWG�Type�TFFN�building�wire,�UL�listed,�stranded,�PVC�insulation�and�a�nylon�jacket

ELECTRICAL PROCESS COMPONENTSAC motor: 208/240V,�3-phase,�1/3�HP�(0.25�kW),�1725�rpm,�1.8�FLA,�56�C-face,�TEFC,�with�a�rigid�mounting�baseDC motor:�90V,�0.25�HP�(0.18�kW),�TENV,�1725�rpm,�3.0�FLA,�56�-face,�with�a�rigid�mounting�baseMotor controllers: Motor�contactor,�overload�relay,�station�transformer,�pushbutton�start�/�stop�switches,�hand-off-auto�switch,�pilot�lamps

Variable frequency drive

208/240V�3-phase�inputStandard�equipment�enclosureProgramming�keypadDigital�readout�of�programming�parametersAnalog,�10V,�0-60�Hz�panel�mounted�speed�controlAcceleration/deceleration/current�boost�controlVoltage/current/alarm�monitoringRS485�mod�busRed�pilot�lamp,�panel�mounted,�240V3-position�For-Off-Rev�selector�switch�with�legend�plate

DC drive

Standard�equipment�enclosureRegenerative�drive/braking240/120VAC�input90V�DC�armature�voltage�outputPotentiometer�speed�controlAdjustable�acceleration/deceleration/IR�comp/max�speedRed�pilot�lamp,�panel�mount,�120VElectric brakeFail-safe�operationSingle-phase�and�240/460V�3-phase�control�circuitsNEMA�56�double-face�Mounting�standardsManual�release�with�automatic�resetElectrical signaling components120VAC�strobe-type�status�lights�for�paint/bake/cool�processProcess�paint�cool�down�blower115V,�60�Hz,�PSC�direct�drive�blower,�2450�RPMCFM�@�0.000-In�SP�150Process sensorsProximity�switch,�capacitive,�0.125�-�1.0"�(3-25mm)�range,��NO�output�modeFiber-optic�photoelectric�switch,�thru�beam,�NPN-SPST�formProcess programmable logic controllerInputs:�9�DC�sinking�or�sourcing�with�diagnostic�LEDsOutputs:�7�AC�relay�with�diagnostic�LEDsInput�power�requirements:�100-240VACFront�panel�LED�indicatorsHMI�connector�for�direct�front�panel�plug-in�mountingExpansion�port�for�expansion�modulesCommunications�port�RS-232�or�RS-485�adapterCartridge�connector�for�optional�memory�or�clock�cartridgeProgram�capacity:�27,000�bytes,�4500�stepsRAM�backup:�lithium�batteryBackup�duration:�30�daysInstruction�words:�35�basic�and�46�advancedSelf-diagnostic�functionsAccessoriesComputer�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�simulatorProgramming�software�on�CD-ROMPrinted�user’s�manual

INDUSTRIAL LIGHTING COMPONENTS

Low bay: 120/277VAC�175W,�(H�x�W)�11.5"�x�12.5"�(292mm�x�318mm)�enclosed�reflector�with�lampHigh 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�chargerFloodlight:�120VAC,�70W�HPS�stem-mount�lamp�with�die-cast�aluminum�housing,�hinged�door�with�toolless�latchHazardous location:�300W�incandescent�glass�globe,�copper-free�aluminum�pendant�mounted,�explosion-proof,�corrosion�resistantFluorescent 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 controllers2�pole�rotary�cam�switch120V�3-pole�lighting�contactor120V�4-pole�lighting�contactor120�VAC�power�relay�DPST-NO3-position�switch,�spring�return�to�center�OFF

MANUFACTURING MECHANICAL COMPONENTSProcess conveyor96"�L�x�6”�W�(152mm�x�2438mm)�flat�belt-type�mounted�on�a�2.5''�(63.5mm)�H,�rugged-duty,�hard-black-anodized�aluminum�frameStandard�0.60''�(1.5mm)�above-belt�side�fencesIntegral,�direct-drive,�0.50"�(13mm)�side-mount�drive�input�shaftLeveling-type�hold�down�bracketsBelt�tensioning�deviceSpeed reducerType:�right�angleDrive�ratio:�60:1Mounting:�NEMA�56�C-faceHousing:�cast�ironBearings:�ball�bearing�on�input�shaft,�tapered�roller�bearings�on�output�shaftGearing:�hardened�alloy�steel�worm,�hardened�forged�bronze�worm�gearLubrication:�oil�sump�supplied�fullSeals:�spring�loaded,�double�lipConfigured�to�mount�in�tandem�with�the�56�C-face�motor�and�56�C-face�brake�forming�a�drive�trainChain driveDrive�input�sprocket:�#40�chain,�14-tooth,�0.625"�(16mm)�bore�with�keywayDrive�output�sprocket�#40�chain,�20-tooth,�with�0.50"�(13mm)�split�tapered�bushing�and�keywayChain:�#40,�0.50"�x�120"�(13mm�x�3048mm)�pitch5�chain�links,�5�offset�links0.50"�(13mm)�rigid�shaft�coupling�with�keywayChain guardSteel�sheet�metal�covering�full�front,�back,�and�sidesSafety�equipment:�1�each�NEMA-1,�plunger-type,�2PDT,�safety�switch�with�10-foot�(3-meter)�covered,�3�conductor�electrical�cord

Process parts feederFeeder�tube�and�base:�3.5”�x�3.5”�x�3.0”�(89mm�x�89mm�x�76mm),�clear�polycarbonateParts�feeder�ramp:�aluminum,�black�finishPneumatic�cylinder,�1.25“�(32mm)�bore,�4.0”�(102mm)�stroke,�double�acting,�pivot/end�mount,�with�two�mounted�flow�controls�and�mounting�bracket60�unfinished�process�parts�includedProcess paint tunnelMaterial:�12�ga�painted�HRSDimensions:�(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 SYSTEMA�configurable�and�programmable�fault�insertion�system�installed�as�a�complete�system�integrated�into�the�completed�cellFault�initiating�and�timing�is�either�preset�or�actuated�by�wireless�remote�control120�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 INSTRUCTIONSSupplied�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

Materials Included

Our�Missionintelitek’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�ProgramsFrom 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.

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.

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

www.facebook.com/intelitek

Basic Maintenance Cell 1600-ZA01 �Cell Frame

�� 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 1600-ZA02 �Conveyor

�� 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 1600-ZA03 � Part Manipulation

�� 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

�� 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

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

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

Skills Acquired

eLeCtroMeChaniCaL MaintenanCe CeLL

about inteLitek

© intelitek, inc . All specifications and available courses subject to change without notice . All trademarks are property of their respective owners . 35-BR01-PJIM Rev-F

http://www.intelitek.com


http://facebook.com/intelitek

jobmaster mechatronics & industrial maintenance program

Documents

industrial training

jobmaster training program

skillsbased training

fluid power series

electrical series program

new skills

basic power ea01 series

electrical series hardware