ELECTRICAL TECHNOLOGY ASSOCIATE DIPLOMA

RECOMMENDED PRACTICE EQUIPMENT

(version 2016/17)

UNIT 09 DEVELOP ELECTRICAL CONTROL CIRCUITS

0. PROCEDURE
1. MAIN UNIT CONTENT AND PRACTICE ANALYSIS.
Determine what content needs to be covered and practiced.
2. IDENTIFICATION OF ALIGNED MAIN SPECIFIC EQUIPMENTS.
Determine what typology of training systems is required for
intended practice.
3. DESCRIPTION/SPECIFICATION OF EQUIPMENT FOR PURPOSES OF
ORIENTATION.
Determine basic characteristics and composition of identified
training systems.
4. QUANTITIES AND OTHER ORIENTATIONS FOR CONFIGURATION OF
PRACTICE SPACES.
Suggest quantities, capacity, acquisition priorities and learning
spaces arrangements (labs, workshops) for program
implementation.

1. MAIN UNIT CONTENT AND PRACTICE ANALYSIS

1
2

TOPICS/LEARNING
OUTCOMES
UNDERSTAND BASIC
RELAYS

Connecting a basic relay circuit, using a circuit diagram as a guide.

Make systematic checking of the circuit.

RELAY CIRCUITS AND

Provide further practice at connecting basic relay circuits (more

complex), using a circuit diagrams as a guide. Learn to select
components and complete diagrams.
Connecting relay circuits which incorporate remote start-stop
control and electrical interlocking, using a circuit diagram as a
guide.
Select components, complete diagrams.
Test voltages in points of the circuit and make basic fault finding.
Connect and test a circuit that includes a time delay relay and
associated control equipment (no power load required, no
contactors).
Complete diagrams, select components, test voltages and make
basic fault finding.
Connect and test a circuit that includes contactors, power load(s)
to be powered and associated control and protection equipment.
Select components, complete diagrams, test voltages and basic
fault finding.
Security (using thermal units and associated contacts).
Connect and test a circuit that includes jog control of an electric
motor and associated control equipment, using a circuit diagram
as a guide.
Select components, complete diagrams, basic fault finding,
security (isolation switches, thermal units)
Connect and test operating features of a range of detectors (limit,
proximity, level, reed, photoelectric cells, etc.)
Design an electrical control circuit from a written description of the
circuit operation (technical specification) and select appropriate
components for the circuit.
Program the control solution in a programmable relay.
Connect the circuit and use circuit checking techniques to ensure
the circuit is wired correctly and that it works according to the
specification.
Basic fault finding in programmable systems. Select detection
technologies and detectors. Draw control schematics.
Program a programmable relay (small capacity PLC) and to note

DRAWING
REMOTE STOP-START

CTRL AND
INTERLOCKING

PRACTICE TYPOLOGY

TIME DELAY RELAYS

CONTACTORS

JOGGING AND
INTERLOCKING

CONTROL DEVICES

PROGRAMMABLE

(basically monitor and confirm) the operation of the relay.

Including:

Program various functions (input and outputs, combinational

circuits).

Program an elemental basic stop-start control.

Safely connect the circuit.

Direct programming or downloading the program to the relay.

Test the connected circuit for correct operation.

Observe and report certain operations of the circuit.

RELAYS

3-P INDUCTION
MOTOR STARTERS

1
0

3-P INDUCTION
MOTOR STARTERS
REDUCED VOLTAGE

1
1

3-P INDUCTION
MOTOR STARTERS

REVERS. & BRAKING

1
2

3-P INDUCTION
MOTOR STARTERS
SPEED CONTROL

Provide further practice at programming a smart-relay. Particularly,

in using timers/(counters) in programmable relays.
Convert control circuits in ladder diagrams. Interpret ladder
diagrams.
Transfer programs.
Monitor programs and change circuits or performance conditions
(on and off-line).
Basic fault finding/program debugging.
Connect detectors (limit switches, etc.), dialog devices (start/stop
buttons) and loads.
Control a small automated process (traffic lights, elevator, control
tanks, etc).
Connect a three-phase DOL starter and a three-phase DOL
reversing starter and to examine their operation.
Connect a range of variations of a DOL starter (using delays or
using secondary resistances in a slip-ring induction motor, etc.).
Interpret, complete and modify motor starter diagrams. Fault
finding in DOL motor maneuvers.
Analyze the operating principles of the star-delta, autotransformer, primary resistance and electronic soft starters.
Compare motor starters and select.
Connect motor starter power and control circuits for correct
operation (star-delta starter and maybe others).
Measure starting current and torque of selected motor starters.
Interpret, complete and modify motor starter diagrams. Fault
finding in star-delta motor maneuvers. Measurements.
To examine the operation of induction motor reversing and motor
braking circuits.
Compare motor braking techniques: plugging circuit, dynamic
braking, regenerative braking, mechanical braking, etc.
Connect motor reversing and braking maneuvers and compare
performances. Select the most suitable technique according to
practical scenarios.
Interpret, complete and modify motor starter diagrams. Fault
finding in reversing and braking motor maneuvers. Measurements.
Analyze common types of speed control methods used on threephase motors. Including, the operating principles of pole changing,
secondary resistance speed control or variable voltage/ variable
frequency drives.
Connect and run a speed controller (AC variable frequency drive)
with a motor.
Determine the acceleration and deceleration times for an AC
variable frequency
drive. Carry out load and no load tests on an VFD.
Configure basic operating modes and parameters of an AC motor
VFD.
Interpret, complete and modify motor starter diagrams. Fault
finding in motor speed control. Measurements of speed, current,
voltage, torque, frequency.

2. IDENTIFICATION OF ALIGNED MAIN SPECIFIC EQUIPMENTS

Generic
Equipments
Main Topic Units

(1)
ELECTRICAL
CONTROL
WIRING PANEL

(2)

(3)

PROGRAM.

INDUST.

RELAY

DETECTORS

TRAINING

TRAINING

SYSTEM

SYSTEM

UNDERSTAND
BASIC RELAYS

RELAY
CIRCUITS AND
DRAWING

REMOTE STOPSTART CTRL

AND
INTERLOCKING

TIME DELAY
RELAYS

CONTACTORS

JOGGING AND
INTERLOCKING

CONTROL
DEVICES

PROGRAMMAB
LE RELAYS

3-P INDUCTION
MOTOR
STARTERS

1
0
1
1
1
2

(4)
MOTOR
STARTER
BENCH

3-P INDUCTION
MOTOR
STARTERS
REDUCED
3-P INDUCTION
MOTOR
STARTERS
REVERS. &
3-P INDUCTION
MOTOR
STARTERS
SPEED

Major specific training equipments identified for this unit are:

1. ELECTRICAL CONTROL WIRING PANEL
2. PROGRAMMABLE RELAY TRAINING SYSTEM
3. INDUSTRY DETECTORS TRAINING SYSTEM
4. MOTOR STARTER BENCH
Important note: all names above are generic denominations of
educational equipment, independent of commercial brands or providers.
Also, the equipments are broad concepts; accordingly, they are not
necessarily independent or autonomous. Instead, they may integrate some
elements from other related educational equipment or come completed with
other equipments to be fully functional in the learning context of the Unit.
See following descriptions.
5.
4

3.DESCRIPTION OF EQUIPMENTS FOR PURPOSES OF ORIENTATION

Note:
All identified equipments are generic, covering a wide range of designs,
structural compositions and specific denominations. Refer to illustrations
and sites of potential providers to clarify concepts and, eventually, to
select equipments after having added more accuracy to the desired
product concept.
1. ELECTRICAL CONTROL WIRING PANEL
DESCRIPTION/(BASIC SPECIFICATION)
GENERAL:

Many practical design and configurations may be

appropriate for this training system.

The simplest consist of a standard wiring Panel installed

vertically or horizontally in a kind of support.

On the wiring panel other standard elements can be

installed/ removed flexibly, such as DIN rails, wiring
ducts, power and protection modules and other
mounting accessories.

The whole structure is portable (to put on a workbench

or table, etc.).

More sophisticated configurations are real electrical

cabinets where bare wiring panels can be integrated
once mounted.

Another solution is a (probably) multipurpose wiring

table or wiring workbench with ready power supply and
protections to make easier the wiring work (of different
electrical installations) and to increase/optimize the
capacity. That is, possibility of more than one student
working simultaneously.

Obviously, the wiring panel must be completed with

electrical control components and other elements if its
to be fully functional.

ILLUSTRATION

SUGGESTED STRUCTURE/COMPOSITION:

To be fully functional, this training system encompass

and/or integrates (make use of elements of other
related equipments) generically:

WIRING PANEL, SUPPORT AND ACCESSORIES.

A selection of:

ELECTRICAL CONTROL COMPONENTS for wiring.

ELECTRICAL MACHINES AND OTHER LOADS

INSTRUMENTS

TOOL SET
From the content/practice analysis and to orientate:
WIRING PANEL, SUPPORT AND ACCESSORIES.

See general description above.

SELECTION OF ELECTRICAL CONTROL COMPONENTS:

The selection should be made based on the typology of

systems and circuits planned in the Unit:

Relays with different number of contacts.

Control relays.

Pushbuttons.

Jog buttons (double pole job button).

Lamps and signalization.

Circuit breakers.

Time delay (on, off) relays.

Contactors.

Blocks of auxiliary contacts.

Thermal overload units.

Circuit breakers for power and control circuits.

Motor isolators (switches).

MORE EXAMPLES AND POTENTIAL

PROVIDERS
Alecop Equipments:
www.alecop.com
References:

Workstation with power supply and

perforated grid panel for 4
students.
(Ref. No name. Its the existing
workstation in Muhayil)

Electrical cabinets mounting kit

(with cabinet and a flexible
selection of components) (Ref.:
9EQPANNINCE). Probably this
equipment its more intended for
Unit 13 Diploma level).

Other providers:

Schneider Electric:
(English catalogue of training
systems)

Detectors/sensors.
Others (for example: functional blocks, microPLC, starters, etc.).
In addition:

Electrical wires of different sizes (hook-up wires,

power wires, different insulations, colors, etc.),

wire numbers (cable markers),

Mounting accessories and assorted screws.

DIN rails, wiring ducts for managing cables, wire

connectors, etc.

www2.schneiderelectric.com/documents/trainingworkstations/didactic-solutionscatalogue-2015_EN.pdf
(Spanish catalogue of training
systems)
www.schneiderelectric.es/es/work/services/training
/isef/training-equipment/edindustry/ed-industry.jsp

MOTORS AND LOADS:

Single phase fan motor. Mains electricity supply or

reduced (24Vac with appropriate power supply).

3-phase asynchronous motor. Mains electricity supply or

reduced.

Other loads:

Heating device with thermostat.

Rheostats and others.

INSTRUMENTS:

Multimeter.

Tachometer.
TOOL KIT:

A selection of basic hand tools for cutting, stripping,

terminating cables. Pliers, screwdrivers, scissors, wirestripers, etc. Some could be specific of wiring work but
this is not mandatory (an electrician tool kit for students
is enough).

2. PROGRAMMABLE RELAY TRAINING SYSTEM

DESCRIPTION/(BASIC SPECIFICATION)
GENERAL:

Any PLC (Programmable Logic Controller) of small

capacity is perfectly appropriate for supporting the
prescribed introductory course to programming control
circuits in this Unit. Small capacity means a little
number of relay I/O, not or limited expansion, not
analogue inputs, reduced instructions set and the like.

The Unit should be programmable both directly (by

means of keypad, LCD display) and/or with PC (via
programming/monitoring software, interface cable).
Essentially in ladder language (software) and mnemonics
(keypad).

Firstly, its preferred that the PLC basic Unit be adapted

for practice and demonstrations. To do this, several
designs are possible. For example:

Fully integrated in a case.

Fully integrated in a panel (panel-mounted PLC).

With terminal simulation that can be either applied

or removed when needed.
In any of these cases the PLC is presented typically with
readily accessible inputs (switches or buttons), outputs
(output pilot lights, etc.), connections of power supply,
using of banana jack terminals, protections, supplies (to
power output relays and detectors, etc.).

At the same time, may be interesting that Micro-PLC can

be used just as an additional component for real wiring
work. For example, for integration in cabinets and
industrial control circuits. For this kind of goal a bare
micro-PLC with no educational adaptations is better
suited than, for example, a panel-mounted PLC.

SUGGESTED STRUCTURE/COMPOSITION:

To be fully functional, this training system encompass

and/or integrates (make use of elements of other
related equipments) generically:

PROGRAMMABLE RELAY TRAINING SYSTEM AND

ILLUSTRATION

ACCESORIES
COMPLEMENTS

From the content/practice analysis and to orientate:

PROGRAMMABLE RELAY TRAINING SYSTEM AND ACCESORIES

See general description above.

Accessories can be PC connection cable, programming

software, keypad, expansion modules or cards/units
(expandable micro-PLCs).
COMPLEMENTS

A range of elements conceived basically for practice

facilitation. Including:

External panels:

Contactor panels.

Detector panels.

Input and output cards for testing purposes

(with buttons and switches, test lights,
simple moving parts, simple simulated
processes, etc.).

Wiring panel or cabinet with micro-PLC(s)

for assembling and integration in control
circuit.

Loads. Including motors, lamps and others specific

loads.

Simplified industrial processes and automated

products with moving parts or other real effects. For
example:

Industrial process.

Traffic lights.

Elevator.

Tank (level control).

Drive belt.

Software:

Simulated industrial processes that can be

controlled by external PLC

PLC simulators. For practicing

programming, testing and debugging
programs prior to transfer for real control.

Software:

Simulated industrial processes that can be

controlled by simulated PLC.

Instrumentation.
Hand-tools.

MORE EXAMPLES AND POTENTIAL

PROVIDERS

Alecop practice equipment:

www.alecop.com
www.smctraining.com/
http://w5.siemens.com/spain/web/es/ind
ustry/automatizacion/sce_educacion/sol
uciones/Pages/default.aspx
(Ref.No name. In Muhayil there is
available a micro-PLC LOGO! From
SIEMENS. Specifically, a Aula de
Formacin LOGO which encompasses 5
LOGO! Units, software and a
communications cable for connection
PLC-PC

Other providers:

Schneider Electric:
www2.schneiderelectric.com/documents/trainingworkstations/didactic-solutionscatalogue-2015_EN.pdf

Allen Bradley/Rockwell Automation:

www.rockwellautomation.com

Festo Didactic:
www.festo-didactic.com

Siemens:
w3.siemens.com/mcms/programma
ble-logiccontroller/en/Pages/default.aspx

Many others: LG; Omron, etc.

3. INDUSTRIAL DETECTOR TRAINING SYSTEM

DESCRIPTION/(BASIC SPECIFICATION)
GENERAL:

Any specific and adapted training solution intended to

learn and tho show (demonstrate) about the different
technologies used in industrial detection, such as:

Photoelectric sensors (thru-beam, reflex, optic fiber,

background suppression, etc.),

Inductive and capacitive sensors for detecting

different materials,

Detection of linear or rotary movement by different

limit (mechanical) switches.

Some others detectors/sensors and/or technologies.

ILLUSTRATION

Some product designs are valid. For example:

Case mounted trainer.

Panel mounted trainer.

Modular trainer and connections board.

In any case, setting up sensors (mounting

demonstrative or analysis experiments, etc.), making
adjustments to operating parameters and debugging a
detection system should be feasible.

SUGGESTED STRUCTURE/COMPOSITION:

To be fully functional, this training system encompass

and/or integrates (make use of elements of other
related equipments) generically:

INDUSTRIAL DETECTOR TRAINING SYSTEM

EXTENSIONS AND ACCESORIES
MORE EXAMPLES AND POTENTIAL
PROVIDERS

From the content/practice analysis and to orientate:

INDUSRIAL DETECTOR TRAINING SYSTEM

See general description above.

EXTENSIONS AND ACCESORIES

More types of detectors or technologies.

More types of testing applications and experiments.

Connection to a PC.

Accompanying multimedia lessons.

Outputs and inputs for integration (with a PLC, etc.).

Adjusting tools, instruments, etc.

Alecop practice equipment:

www.alecop.com
www.smctraining.com/
(Ref. No name. To choose. This
equipment doesnt exist specifically in
the Mondragon Colleges. However, a
simple approach can be get through the
Alecops motor starter bench)

Schneider Electric:
www2.schneiderelectric.com/documents/trainingworkstations/didactic-solutionscatalogue-2015_EN.pdf

Lucas Nlle
www.lucasnuelle.com/316/apg/3320/SensorTechnology-with-UniTrain-I-.htm

Amatrol:
www.amatrol.com/coursepage/portableelectronic-sensors-learning-system-990sn1/

4. MOTOR STARTER BENCH

DESCRIPTION/(BASIC SPECIFICATION)
GENERAL:

Any specific and adapted training solution intended to

study the various electromechanical and electronic
motor starter standard solutions. In general:

Starting techniques at full voltage (DOL).

Reduced voltage starters.

Reversing and braking techniques.

Speed control techniques of asynchronous motors.

These equipments are conceived for:

analyzing, creating and modifying a selection

(typically essential) of various motor starter
diagrams,

getting to know the equipment and the differences

in implementation,

experimenting with control variations and

techniques,

building power control equipment,

discovering the variable speed drive and other

sophisticated (electronic) motor control devices

etc.

These equipments may support a wide practice scope

depending on the adopted focus:

Number of motor starting and control techniques.

ILLUSTRATION

Typology of electrical machines (AC motors, DC

motors, special motors, etc.).

In this Unit the focus is put just on induction motors 3phase. This including squirrel cage motor, wounded rotor
and multiple poles motor. More specially, a single phase
motor (other types of electrical machines are studied in
other Units).
For these equipments some modular (control
modules), flexible (scalable or expandable) and twoside designs (control and power parts) are typical.
To more clarity, the equipment integrates basically a
series of control modules, electrical machines and
accessories. The control modules contain contactors,
pushbuttons, relays, thermal protections, panel
instruments and the like to build fast, secure and
isolated control parts using banana jack connectors (a
design variation is a contactor panel). The control
modules are inserted or removed in a supporting frame.
From here, the connections to the power part are made.
The motors and applied loads fit together and are fixed
in a bed put apart.
Power supply for modules and controlling signals for/from
external components can be managed thanks to special
functionalities integrated to the supporting structure.
Inertia wheels, brakes and other regulated loads
(dynamometers, eddy brakes, etc.) are coupled to
motors in order to practicing controls under different
operating conditions (loaded/no loaded, etc.).
Theses equipments can be very specific but more
frequently they are expandable starting with a basic or
core configuration adding other functional components
or integrating other functional kits. For example, soft
starters, variable speeds drive with its accessories or
more types of electrical machines and associated
controls, instrumentation, braking devices, etc.
These equipments are educational systems. One notable
adaptation is that they can work either at reduced
voltage with reduced power machines and at mains
supply. The first version is to reduced risks and costs.
The real work with huge power machines is left for
practicing in advanced learning stages or in on the job
training. The second version is to effectively practice
with the real maneuvers and securities even in the
school place (motors of low or medium powers).
In some cases, these equipments, in the simpler versions
are basically wiring panels. This is the case when control
elements or electronic drives are barely adapted and
wires and cables must be prepared and connected as it
happens in real maneuvers.

Alecop practice equipment:

www.alecop.com
http://w5.siemens.com/spain/web/es/ind
ustry/automatizacion/sce_educacion/sol
uciones/Pages/default.aspx
Ref.:In Muhayil exist these equipments:
From Alecop: 9EQMT332SE (motor
starter bench), 9EQM281 (electric motor
test bench with brake system, etc), a
selection of AC motors (1P, 3P and
variable speed) and accessories
(instruments, etc.).

From SIEMENS: Kit SCE Pack motor (5 AC

3-phase motors) and Kit speed control (5
variable frequency drives with soft and
accesories9.

Schneider Electric:
www2.schneiderelectric.com/sites/corporate/en/products
-services/training-workstations/energycontrol/motor-starter-modular-offer.page
www2.schneiderelectric.com/documents/productservices/en/trainingworkstations/energy-control/motorstarter-packs.pdf

Lucas Nlle
www.lucasnuelle.com/316/apg/4993/EDT-51-1Motor-management-relays-1kW.htm
www.lucasnuelle.com/316/apg/5068/Frequencyconverter-Lenze-8400-3phase.htm

www.lucasnuelle.com/316/apg/4978/EDT-17-1Smooth-starting-three-phase-machines1kW.htm

Amatrol:
www.amatrol.com/coursepage/85-mt5/
Lab Volt/Festo Didactic:

www.labvolt.com/solutions/6_power_ene
rgy/59-804500_control_of_industrial_motors_training
_system

10

4.QUANTITIES AND OTHER ORIENTATIONS FOR CONFIGURATION OF

PRACTICE SPACES
Notes:
Assumption 1. The standard classroom group is 20 Students.
Assumption 2. The equipments are equally intended for practice
(student) and demonstrations (teaching).
Assumptions 3. All equipments are essential. All should be present at
least as a minimum if the Unit practice plan is to be met.

ORIENTATIONS:

This Unit should be imparted in the Electricity Workshop.

List of associated equipments:
EQUIPMENT

Better

QUANTITY
Good
Minimu
m

NOTES

ELECTRICAL
CONTROL
WIRING
PANEL

20

10

PROGRAM
RELAY
TRAINING
SYSTEM

10

5-6

1-2

INDUSTRY
DETECTORS
TRAINING
SYSTEM

2-3

MOTOR
STARTER
BENCH

5-6

3-4

1-2

11

Basic composition:

Wiring Panel.

Selection of components.

Accessories.
Better. 1 Wiring panel per student.
Good. 1 Wiring panel per couple of
students.
Minimum. 1 Wiring panel per couple of
students in a semi group.
Basic composition:

Micro-PLC and accessories for

programming.

Simple process simulation and/or testing

boards.

Accessories.
Better. 1 Micro PLC per couple of students
+ a variety of application boards.
Good. 1 Micro PLC per three students + a
variety of application boards.
Minimum. 1 Micro PLC per classroom + some
application boards.
Basic composition:

Detectors training system.

Accessories.
Better. 1 Detector training system per 2-3
students in a semi group.
Good. 1 Detector training system per 3-4
students in a semi group
Minimum. 1 Detector training system per
classroom.
Basic composition:

Control board/panel with basic control

modules, for direct and basic starting
maneuvers.

A range of AC motors with brake

systems and loads.

Variable speed drive, soft starters and

other electronic systems.

Accessories.
Better. 1 Motor starter bench per 2-3
students in a semi group + electronic drives
for ac motors + accessories.
Good. 1 Motor starter bench per 3-4
students in a semi group + electronic drives
for ac motors + accessories.

Minimum. 1 Motor starter bench full per

classroom.

Workshop arrangements for delivering the course:

This illustrative course sequence can orientate either about the

number of equipments required or how to optimize the use of already
existing resources:

Images and diagrams:

12

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