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Instructional Materials for Industrial Skills:
Industrial Electrical and 
Electronic Maintenance

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EMN011    
AC/DC THEORY
Video
Tape One contains an introduction to electricity, voltage, and units of measurement used for electricity.  It discusses voltage, current and resistance; Ohm’s Law -- the relationship of work and power; and kilowatt hours.

Tape Two discusses alternating current (AC) and direct current (DC); types of circuits; and finding total resistance and current in a series circuit.  It also includes the characteristics of current and voltage in a series circuit; the characteristics of current and voltage in a parallel circuit; finding total resistance of parallel and series-parallel circuits; and the common causes of circuit failure.

Tape Three describes magnetism; magnetic fields; magnetism and electricity; induced voltage; sine waves; resistance and inductance; and capacitance.

Tape Four AC/DC Theory
Three-Phase Voltage Systems, Wye Connections, Delta Connections, Transformers, Transformer Operation, Motors, AC Induction Motors.

Four 1 hour Videos, 1 student workbook, 1 instructor guide.  Also available in Spanish.

EEM005 
AC MOTORS
Video
Explains the operation of three-phase and single-phase AC motors.  The lesson explains the differences between synchronous and induction motors, and why single-phase motors need start circuits.  21 minutes.

EEM007 
AC POWER GENERATION AND TRANSMISSION
Video
This program examines the relationships between electricity and magnetism, and explains how electromagnets, alternators, and transformers work.  Employees will be shown how alternators produce alternating voltage and current, and transformers step AC  voltage up or down.  Viewers will be introduced to transformer calculations, and power transmission systems, including three-phase.  Also available in Spanish.  22 minutes

EMN015    
BATTERIES
Video
Talks about DC power circuits, battery cells, safety procedures, inspection and cleaning, removing corrosion, battery measurements, and review.

1 hour Video, 1 student workbook, 1 instructor guide, transparencies.  Also available in Spanish.

EEM011 
BASIC ELECTRONICS 1
Video
This video shows trainees how to solve for unknown voltages, currents, resistances, impedances, inductances, and capacitances in RL, RC, and RLC circuits.  The unit also explains how to calculate the phase angle of any series or parallel circuit and the resonant frequency of an RLC circuit.

Includes 1 workbook and 1 instructor’s guide.  Available in Portuguese and Spanish.  1 hour.

EEM012 
BASIC ELECTRONICS 2
Video
This video introduces the basic construction of semiconductor diodes—the control of current flow through a diode and the use of diodes as half-wave and full-wave rectifiers.  The unit also demonstrates how to identify the cathode end of various types of diodes, how to use a diode manufacturer’s data book to select a properly rated replacement diode, and how to use a multimeter to test diodes to determine if they are good or bad.

Includes 1 workbook and 1 instructor’s guide.  Also available in Portuguese and Spanish.  1 hour.

EMN017    
CONTROL EQUIPMENT
Video
Tape One discusses an introduction to troubleshooting, ruling out problems, troubleshooting circuit switches, introduction to removing and replacing parts, checking if a circuit is dead, checking for continuity, removing and installing parts, and poles and throws.

Tape Two illustrates an introduction to limit switches, finding the cause of the problem, re-placing the contact block and testing the switch, introduction to torque switches, adjustment and testing of a torque switch, setting the open rotor on the geared limit switch, and setting the closed rotor.

Tape Three examines overload relays, de-energizing a controller, performing a continuity check, overload relay removal, installing and checking a new overload relay, introduction to coils, replacing a coil, ruling out components based on operation, and performing a continuity check to find the problem.

Tape Four demonstrates fuses, installing new fuses, small molded case circuit breakers, replacing a circuit breaker, ground fault circuit breakers, large molded case circuit breakers, testing large molded case circuit breakers.

Tape Five teaches motor starters, troubleshooting coil-operated contactors, auxiliary contacts and removing coil-operated contactors, disassembling coil-operated contactors, reversing magnetic motor starters, control transformers, and operationally testing a control transformer.

Tape Six describes performing an operational test, ruling out portions of the circuit, ruling out components, locating the problem, testing a valve mechanically and electrically, locating the problem, checking for a short circuit, finding a grounded circuit, and finding a ground.

Six 1 hour Videos, 1 student workbook, 1 instructor guide.

EEM019 
CONTROLLERS, INDICATORS,  AND RECORDERS
Video
This program describes common maintenance and troubleshooting tasks associated with these instrument loop components.  Calibration, troubleshooting, and maintenance of a typical analog controller are demonstrated.  Typical indicators such as those found on controllers are shown.  Typical annunciator maintenance is demonstrated.  Typical calibration and maintenance for a variety of recorders is shown.

 ANALOG CONTROLLERS

CONTROLLER CALIBRATION

CONTROLLER TROUBLESHOOTING

INDICATORS AND ANNUNCIATORS

RECORDERS

1 student workbook and 1 instructor’s guide.  30 minutes.

EEM021 
DC GENERATOR MAINTENANCE
Video
This program covers various types of DC generators used in the plant and describes how they function.  Effective maintenance, repair, and operation of these generators are stressed.

Includes 10 student workbooks and 1 instructor’s guide.  Also available in Spanish and Portuguese.

EEM023 
DC MOTORS
Video
Focuses on the switching action of the brushes and commutator in a DC motor, the operating characteristics of different kinds of DC motors, and how DC motors are controlled.  23 minutes.

EEM025 
ELECTRICAL CONNECTIONS
Videos
Tape One discusses conductors, sizes of conductors, insulation, ampacity, making a splice connection, soldering connections, finishing connections, and solderless connections.

Tape Two describes conduit selection, flexible conduit and connectors, hand benders, power benders, using a power bender, installing conduit, offset bends, and installing flexible conduit and wires.

Tape Three explains cable construction, shielding and grounding high voltage cables, removing a cable jacket, terminating insulating shields, final preparations for cable termination, building a stress cone, class 3 terminations, class 2 terminations, and class 1 terminations.

Tape Four talks about terminations and splices, ribbon-shielded cable, cutting a ribbon metallic shield, braided ground straps, preformed stress cones, installing prestretched tubing and stress cone ground connections, heat shrinkable tubing, and molded insulation.

4 1-hour Videos, 1 workbook, 1 instructor’s guide, transparencies.  Also available in Spanish.

EMN023     
ELECTRICAL EQUIPMENT
Video
This program includes circuit breaker operation, racking breakers, ground trucks and relays, control fuses and racking low voltage breakers, disconnects, and key interlocks and pole use.

1 hour Video, 1 student workbook, 1 instructor’s guide, transparencies.

EMN024 
ELECTRICAL MAINTENANCE  AND INSPECTION
Video Series

This series of twelve videos (EMN024A-EMN024L) shows plant workers and supervisors how and what to inspect to optimize maintenance expense.  It will teach you how to reduce machinery failures and unscheduled outages so you can improve equipment reliability and increase run time.  On-site demonstrations at actual production facilities and computerized animation will teach you how to:

EMN024A PART ONE
BASIC ELECTRICAL SAFETY
Video
Covers electrical injuries, types of electrical hazards, common electrical accidents, and guidelines on working safely near electricity.

EMN024B PART TWO
THE VALUE OF INSPECTION
Video
Explains the types of preventive maintenance, benefits of inspection and maintenance, and condition-based maintenance methods.

EMN024C 
PART THREE
NEC COMPLIANCE INSPECTIONS
Video
Describes service requirements, common mistakes, safe working distances, grounding, wire sizes and types, equipment protection, and circuit breakers and fuses.

EMN024D 
PART FOUR
HAZARDOUS  ENVIRONMENTS
Video
Reviews NEC environment guidelines, categories of hazardous environments, types of equipment approved for use, equipment marking, and common problems.

EMN024E 
PART FIVE
ELECTRICAL PROTECTIVE SYSTEMS:  INSPECTION AND   TESTING
Video
Outlines the different types of protective systems and how to test them.  Methods include:  engineering analysis, engineering studies, harmonic analysis, condition and serviceability inspections, and ground mat analysis.

EMN024F PART SIX
CIRCUIT BREAKERS:  INSPECTION AND TESTING
Video
Illustrates the different types of circuit breakers and inspection techniques.  Shows how to test them using contact resistance measurements, primary injection tests, high potential tests, and more.

EMN024G 
PART SEVEN
TRANSFORMERS:  INSPECTION AND TESTING
Video
Covers dry-type, liquid-filled, and instrument transformers.  Explains why transformers fail and how to safely inspect them.

EMN024H 
PART EIGHT
SWITCHGEAR: INSPECTION AND TESTING
Video
Describes the panel board and metalclad switchgear.  Shows how to inspect them using mechanical, visual, and electrical testing.

EMN024I 
PART NINE
ROTATING EQUIPMENT:  INSPECTION AND TESTING
Video
Explains how to extend the life of generators and motors.  Also describes in-service inspections, current and voltage tests, vibration analysis, and insulation resistance testing.

EMN024J 
PART TEN
PROTECTIVE RELAYS:  INSPECTION AND TESTING
Video
Shows how instantaneous and built-in delay relays work.  Explains how to inspect and maintain relays using as-found tests, visual and mechanical inspection, and as-left testing.

EMN024K 
PART ELEVEN
SAFETY INSPECTIONS
Video
Explains how to conduct inspections according to OSHA standards.  Also covers installation inspections, safe distance requirements, wiring design and protection inspections, and electrical safety-related work practices.

EMN024L 
PART TWELVE
CONDITION-BASED MAINTENANCE
Video
Explains the theory of condition-based and predictive maintenance and shows how to create a real-world performance baseline to tailor a program to fit your company.

EEM029 
ELECTRICAL PRINT READING
Videos
Tape One describes an introduction to schematic diagrams, using device designations and numbers for symbols, additional uses of schematics, reading schematic diagrams, additional information found on schematics, and using schematics when modifying circuits.

Tape Two gives an introduction to wiring diagrams, using wiring diagrams when modifying circuits, additional information on wiring diagrams, single line drawings, building electrical diagrams, and use of electrical diagrams when troubleshooting.

2 Videos, 1 workbook, 1 instructor’s guide, transparencies.  Also available in Spanish.

ESA017 
ELECTRICAL SAFETY
Video
This video describes the many hazards that you will encounter when working with electricity.  Electric shock, electrical fires, the amount of current needed to cause death, protection of electrical instruments and solid-state devices are all detailed.  Both in-shop and on-the-job situations are described.  This program should be viewed by anyone who will be exposed to electricity — almost a general education subject.  22 minutes.

ESA019 
ELECTRICAL SAFETY
Video
This is an OSHA compliance safety training program.  It explains how electricity works and demonstrates safe work practices.  It defines fuses, circuit breakers, outlets, plugs and grounding.  It discusses lock-out/tag-out and electrical emergencies.

Includes a Presenter’s Guide, a poster and 15 Employee Booklets.  14 minutes.

EMN025 
PROTECTIVE RELAYS
Video
This program gives an introduction to protective relays, relay circuits, types of protective relays, electromagnetic relays, relay maintenance, relay removal and inspection, relay calibration, and relay reinstallation.

1 hour Video, 1 student workbook, 1 instructor’s guide, transparencies.  Also available in Spanish.

EMN031     
SOLID-STATE DEVICES
Video
Tape One details the crystal, forward and reverse bias, diode codes and symbols, operating characteristic curves, rectification and zener diodes.

Tape Two explains electric circuit power supply, half-wave rectifiers, full-wave rectifiers, bridge rectifiers and filters.

Tape Three covers transistors, bipolar junction transistors, current flow through a transistor, transistors in circuits, checking transistor operation and SCR’s and TRIAC’s.

Tape Four demonstrates an introduction to the oscilloscope, setting up an oscilloscope, the coupling switch, vertical amplifier controls, horizontal amplifier controls, triggering controls, oscilloscope probes, troubleshooting a circuit, printed circuit assemblies and repairing printed circuit assemblies.

4 Videos, 1 student workbook, 1 instructor’s guide, transparencies.  Also available in Spanish.

EMN033     
SWITCHGEAR
Video
Tape One presents circuit breakers, circuit breaker contacts, control circuits, circuit breaker connections, racking a breaker, circuit breaker disassembly and inspection, and testing breaker contacts.

Tape Two describes checking main contact pressure, checking main contact resistance, additional breaker tests, checking the control circuits, lubricating the disconnects, circuit breaker reinstallation, final tests, and inspecting bus work.

2 hour Videos, 1 student workbook, 1 instructor’s guide, transparencies.  Also available in Spanish.

EMN035     
TRANSFORMERS
Video
Presents an introduction to transformers, de-energizing and grounding, testing for combustible gases, testing winding resistance, drawing an oil sample, performing a dielectric test, and drawing an air-free oil sample.

1 hour Video, 1 student workbook, 1 instructor’s guide,  transparencies.  Also available in Spanish.

Maintenance Management  Mechanical Maintenance 
Industrial Electrical and Electronic Maintenance  Manufacturing 
Basic Instrumentation Process  Industrial Controls Controllers 
Welding Fluid Power, Hydraulics and Pneumatics

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