Choose a fuse type for a motor circuit with high inrush current. Course 6: Control Circuits – Relays, Timers & Sensors Focus: Industrial control logic, timing relays, proximity/photo sensors, and basic ladder logic.

Design a conveyor start/stop with a 5-second delayed start. Course 7: Variable Frequency Drives (VFDs) – Setup & Troubleshooting Focus: VFD components, programming, motor protection, and common faults.

| Segment | Topic | Key Demo | |---------|-------|-----------| | 1 | Contactors – coil, contacts, arc chutes, enclosure types | Open a NEMA contactor | | 2 | Manual motor starters – toggle & pushbutton | Wire a simple start/stop circuit | | 3 | Magnetic motor starter – 3-pole contactor + overload relay | Assemble a starter on a DIN rail | | 4 | Overload relays – thermal (bimetallic) vs. electronic | Trip test with a heat gun | | 5 | Selecting starter size based on motor HP & voltage | Sizing exercise for a 25 HP motor |

Troubleshoot a contactor that chatters when energized. Course 5: Overcurrent Protection – Fuses & Circuit Breakers Focus: Fuse types, breaker trip curves, selective coordination, and short-circuit ratings.

| Segment | Topic | Key Demo | |---------|-------|-----------| | 1 | Digital multimeter (DMM) basics: V, A, Ω, continuity | Measure line voltage (120V/480V) | | 2 | Clamp meter – measuring current without breaking circuit | Measure motor FLA in a panel | | 3 | Insulation resistance tester (megohmmeter) | Test motor winding insulation | | 4 | Non-contact voltage tester & solenoid tester | Verify absence of voltage | | 5 | Understanding test lead categories (CAT III / CAT IV) | Compare meters for industrial use |

| Segment | Topic | Key Demo | |---------|-------|-----------| | 1 | One-line diagrams vs. wiring diagrams vs. ladder logic | Trace power from utility to motor | | 2 | Wire numbering & terminal strip labeling | Follow a wire from page 3 to page 10 | | 3 | Finding an open circuit – step-by-step voltage method | Locate a broken wire in a control loop | | 4 | Finding a short circuit – resistance method | Blown fuse investigation | | 5 | Ground fault location using a megohmmeter | Isolate a wet motor winding |

| Segment | Topic | Key Demo | |---------|-------|-----------| | 1 | NFPA 79 (Industrial Machinery) – key requirements | Panel labeling, wire colors | | 2 | Panel layout – component spacing, heat dissipation, wireways | Redesign a crowded panel | | 3 | Grounding & bonding – ground bar, shielded cable termination | PE terminal to backplane connection | | 4 | Wire types (MTW, THHN, TFFN) & ampacity tables | Select wire for a 30A circuit | | 5 | Short-circuit current rating (SCCR) of an assembled panel | Nameplate calculation example |