Electrical Control Equipment

Electrical Control Equipment

Electrical Control Equipment

Who are these courses for?

This program is ideal for training electricians and technicians in instrumentation and electronics, equipping them with essential skills for installing, maintaining, and troubleshooting electrical control systems. It also addresses the multi-craft training needs of process and manufacturing facilities, ensuring personnel are proficient in adhering to national electrical code standards and effectively managing electrical control equipment.

Fuses and Circuit Breakers

Prerequisites:

Learners should have a solid understanding of  AC/DC theory, electrical safety,  basic electrical schematics, and be comfortable using hand tools and electronic test instruments. Recommended prior exposure to motor control circuits or control panels will enhance understanding.

Description:

This lesson examines the operation and maintenance of fuses and circuit breakers as essential components of electrical control equipment in industrial power distribution and motor control systems. It covers procedures for selecting appropriate devices (including molded case, multiple, ground fault, and short-circuit protection circuit breakers), installing, removing, and maintaining these components, testing them, and interpreting characteristic trip curves. Emphasis is placed on maintaining safe electrical installations by following national electrical safety standards and codes, properly de-energizing electrical equipment to prevent hazards, and ensuring their effective roles in power distribution systems.

Objectives:
  • Define the functions of fuses and circuit breakers in protecting electrical control systems against overloads, short circuits, and ground faults.
  • Choose the right fuse or breaker type (molded case, multiple, ground fault) based on capacity, current rating, and application, according to electrical codes.
  • Properly de-energize control equipment before performing maintenance to ensure adherence to safety and code standards.
  • Install and replace fuses and circuit breakers correctly within control panels and power distribution networks.
  • Interpret characteristic trip curves to select protection devices that fit motor control requirements.
  • Explain the operation of small, molded case circuit breakers within power distribution networks.
  • Reset and maintain circuit breaker panels safely, ensuring reliable power supply and system uptime.
  • Learn how circuit breakers detect issues and how to maintain breaker panels.
  • Install a circuit breaker and identify one that is a multiple.
  • Use a characteristic trip curve to interpret test results.
  • Identify, install, and test ground fault circuit breakers, understanding their auxiliary contacts and their role in system safety.

Fuses and Circuit Breakers

Prerequisites:

Learners should have a solid understanding of  AC/DC theory, electrical safety,  basic electrical schematics, and be comfortable using hand tools and electronic test instruments. Recommended prior exposure to motor control circuits or control panels will enhance understanding.

Description:

This lesson examines the operation and maintenance of fuses and circuit breakers as essential components of electrical control equipment in industrial power distribution and motor control systems. It covers procedures for selecting appropriate devices (including molded case, multiple, ground fault, and short-circuit protection circuit breakers), installing, removing, and maintaining these components, testing them, and interpreting characteristic trip curves. Emphasis is placed on maintaining safe electrical installations by following national electrical safety standards and codes, properly de-energizing electrical equipment to prevent hazards, and ensuring their effective roles in power distribution systems.

Objectives:
  • Define the functions of fuses and circuit breakers in protecting electrical control systems against overloads, short circuits, and ground faults.
  • Choose the right fuse or breaker type (molded case, multiple, ground fault) based on capacity, current rating, and application, according to electrical codes.
  • Properly de-energize control equipment before performing maintenance to ensure adherence to safety and code standards.
  • Install and replace fuses and circuit breakers correctly within control panels and power distribution networks.
  • Interpret characteristic trip curves to select protection devices that fit motor control requirements.
  • Explain the operation of small, molded case circuit breakers within power distribution networks.
  • Reset and maintain circuit breaker panels safely, ensuring reliable power supply and system uptime.
  • Learn how circuit breakers detect issues and how to maintain breaker panels.
  • Install a circuit breaker and identify one that is a multiple.
  • Use a characteristic trip curve to interpret test results.
  • Identify, install, and test ground fault circuit breakers, understanding their auxiliary contacts and their role in system safety.

Limit switches

Prerequisites:

Learners should already understand AC/DC theory, electrical schematics, and electrical safety. Prior experience using test instruments is required. Familiarity with control panels, motor control circuits, or auxiliary contact configurations will be helpful.

Description:

This lesson examines the operation, selection, and maintenance of limit switches as critical components in electrical control equipment, control panels, and electrical systems. It covers how limit switches work, where they are used, and how they interface with motor starters, relays, and control circuits. Topics include maintaining, troubleshooting, adjusting, and repairing limit switches while following electrical codes and standards. The lesson also addresses safety best practices, environmental considerations, and strategies for ensuring proper electrical installations and effective problem-solving in various work environments.

Objectives:
  • Explain the role of limit switches in motor control circuits and electrical control systems.
  • Identify different types of limit switches (lever, roller, plunger, whisker, geared) and their actuator styles.
  • Visually recognize various limit switches and know their uses.
  • Visually inspect limit switches for wear or damage and assess their suitability for control equipment.
  • Recognize photoelectric and proximity switch alternatives and how they integrate into control circuits.
  • Maintain and repair photoelectric and proximity switches safely.
  • Follow safety guidelines and code requirements when replacing or repairing switches, including de-energizing control panels.
  • Correctly install, adjust, and calibrate lever-actuated and geared limit switches in various work environments.
  • Understand the internal function of a lever-actuated limit switch and its role in control circuits.
  • Maintain, troubleshoot, repair, and adjust lever-actuated limit switches in various work environments.
  • Identify and fix common issues in these switches.
  • Explain the internal function of geared limit switches and torque switches in control circuits.

Limit switches

Prerequisites:

Learners should already understand AC/DC theory, electrical schematics, and electrical safety. Prior experience using test instruments is required. Familiarity with control panels, motor control circuits, or auxiliary contact configurations will be helpful.

Description:

This lesson examines the operation, selection, and maintenance of limit switches as critical components in electrical control equipment, control panels, and electrical systems. It covers how limit switches work, where they are used, and how they interface with motor starters, relays, and control circuits. Topics include maintaining, troubleshooting, adjusting, and repairing limit switches while following electrical codes and standards. The lesson also addresses safety best practices, environmental considerations, and strategies for ensuring proper electrical installations and effective problem-solving in various work environments.

Objectives:
  • Explain the role of limit switches in motor control circuits and electrical control systems.
  • Identify different types of limit switches (lever, roller, plunger, whisker, geared) and their actuator styles.
  • Visually recognize various limit switches and know their uses.
  • Visually inspect limit switches for wear or damage and assess their suitability for control equipment.
  • Recognize photoelectric and proximity switch alternatives and how they integrate into control circuits.
  • Maintain and repair photoelectric and proximity switches safely.
  • Follow safety guidelines and code requirements when replacing or repairing switches, including de-energizing control panels.
  • Correctly install, adjust, and calibrate lever-actuated and geared limit switches in various work environments.
  • Understand the internal function of a lever-actuated limit switch and its role in control circuits.
  • Maintain, troubleshoot, repair, and adjust lever-actuated limit switches in various work environments.
  • Identify and fix common issues in these switches.
  • Explain the internal function of geared limit switches and torque switches in control circuits.

Switches, Coils, and Overloads

Prerequisites:

Learners should be familiar with AC/DC theory, electrical safety, and reading electrical prints. Must know basic electrical connections and how to use electrical test instruments. A basic understanding of the operation of control circuits (including switches, relays, and power supply systems) and overload protection is recommended.

Description:

This lesson explores switches, coils, and overload relays as core components of electrical control equipment and electrical control systems. It explains the types and operations of switches, including push-button, selector, rotary, and momentary versus maintained types as well as the function of coils and the operation of thermal and magnetic overload relays. The lesson covers their roles in power supply, power distribution, and preserving motor health, while providing procedures for testing and replacing coils, verifying de-energized circuits, interpreting connection and circuit diagrams, and diagnosing malfunctions using manufacturer’s literature. Emphasis is placed on developing technical skills, adhering to electrical codes, and ensuring safety to prevent failures in power distribution and control panels.

Objectives:
  • Explain what types of switches are used in industry and know how to tell if they are functioning properly.
  • Test coils and replace overload relays in control panels, following electrical codes.
  • Understand coil operations in relays and how coil failures impact motor control circuits.
  • Explain what poles and throws mean in switches.
  • Describe how momentary and maintained push-button switches operate.
  • Understand how selector switches function and where they are used.
  • Read and interpret rotary switch connection diagrams, auxiliary contacts, and pole/throw designations.
  • Perform continuity checks on push-button switches to ensure they work properly.
  • Learn how to check coils for overheating and breaks in the wire winding.
  • Explain how overload relays protect motors in electrical systems.
  • Describe how bimetallic thermal overload relays work in power distribution.
  • Understand how melting-alloy thermal overload relays function and store heat.
  • Identify magnetic and electronic overload relays.
  • Describe the common problems of thermal overload relays.
  • Install thermal overload relays in starters, following electrical codes.

Switches, Coils, and Overloads

Prerequisites:

Learners should be familiar with AC/DC theory, electrical safety, and reading electrical prints. Must know basic electrical connections and how to use electrical test instruments. A basic understanding of the operation of control circuits (including switches, relays, and power supply systems) and overload protection is recommended.

Description:

This lesson explores switches, coils, and overload relays as core components of electrical control equipment and electrical control systems. It explains the types and operations of switches, including push-button, selector, rotary, and momentary versus maintained types as well as the function of coils and the operation of thermal and magnetic overload relays. The lesson covers their roles in power supply, power distribution, and preserving motor health, while providing procedures for testing and replacing coils, verifying de-energized circuits, interpreting connection and circuit diagrams, and diagnosing malfunctions using manufacturer’s literature. Emphasis is placed on developing technical skills, adhering to electrical codes, and ensuring safety to prevent failures in power distribution and control panels.

Objectives:
  • Explain what types of switches are used in industry and know how to tell if they are functioning properly.
  • Test coils and replace overload relays in control panels, following electrical codes.
  • Understand coil operations in relays and how coil failures impact motor control circuits.
  • Explain what poles and throws mean in switches.
  • Describe how momentary and maintained push-button switches operate.
  • Understand how selector switches function and where they are used.
  • Read and interpret rotary switch connection diagrams, auxiliary contacts, and pole/throw designations.
  • Perform continuity checks on push-button switches to ensure they work properly.
  • Learn how to check coils for overheating and breaks in the wire winding.
  • Explain how overload relays protect motors in electrical systems.
  • Describe how bimetallic thermal overload relays work in power distribution.
  • Understand how melting-alloy thermal overload relays function and store heat.
  • Identify magnetic and electronic overload relays.
  • Describe the common problems of thermal overload relays.
  • Install thermal overload relays in starters, following electrical codes.

Magnetic Starters

Prerequisites:

Learners should have foundational knowledge of AC/DC theory, electrical safety, and reading electrical prints. Must understand basic electrical connections, have experience properly using test instruments, and ideally have worked with switches, overload relays, or motor control circuits in control panels.

Description:

This lesson dives deep into magnetic starters within electrical control equipment and control systems. It covers their components (contactor, coil, overload protection), their operation, and how they integrate with motor control circuits in industrial and commercial power distribution systems. Learners will practice interpreting schematic diagrams and manufacturer literature, conducting safety-centered troubleshooting, and performing installations and maintenance. Emphasis is placed on problem-solving skills, following national electrical codes, correctly de-energizing equipment, and using auxiliary contacts and mechanical/electrical interlocks to ensure safe and reliable control equipment performance.

Objectives:
  • Understand the role and operation of magnetic motor starters in motor control and electrical control systems.
  • Describe electromagnets and their role in the functioning of contactors within control panels.
  • Differentiate between contactors and magnetic starters, including the functions of their coils, overload relays, and auxiliary contacts.
  • Identify components of magnetic starters and examine how they protect against electrical faults and overload conditions.
  • Test and replace magnetic starters safely, applying technical skills in control panels and power supply installations.
  • Perform sensory inspections to detect issues in magnetic motor starters.
  • Interpret schematic diagrams involving magnetic starters, contac­tor coil wiring, and mechanical/electrical interlocks.
  • Test armatures to ensure proper operation within electrical installations.
  • Disassemble and reassemble magnetic starter assemblies safely following code-compliant procedures.
  • Explain the purpose of interlocks and how mechanical and electrical interlocks function incontrol systems.
  • Explain reversing magnetic starters, including wiring for reversing starters and how to select the correct starter type for motor applications.

Magnetic Starters

Prerequisites:

Learners should have foundational knowledge of AC/DC theory, electrical safety, and reading electrical prints. Must understand basic electrical connections, have experience properly using test instruments, and ideally have worked with switches, overload relays, or motor control circuits in control panels.

Description:

This lesson dives deep into magnetic starters within electrical control equipment and control systems. It covers their components (contactor, coil, overload protection), their operation, and how they integrate with motor control circuits in industrial and commercial power distribution systems. Learners will practice interpreting schematic diagrams and manufacturer literature, conducting safety-centered troubleshooting, and performing installations and maintenance. Emphasis is placed on problem-solving skills, following national electrical codes, correctly de-energizing equipment, and using auxiliary contacts and mechanical/electrical interlocks to ensure safe and reliable control equipment performance.

Objectives:
  • Understand the role and operation of magnetic motor starters in motor control and electrical control systems.
  • Describe electromagnets and their role in the functioning of contactors within control panels.
  • Differentiate between contactors and magnetic starters, including the functions of their coils, overload relays, and auxiliary contacts.
  • Identify components of magnetic starters and examine how they protect against electrical faults and overload conditions.
  • Test and replace magnetic starters safely, applying technical skills in control panels and power supply installations.
  • Perform sensory inspections to detect issues in magnetic motor starters.
  • Interpret schematic diagrams involving magnetic starters, contac­tor coil wiring, and mechanical/electrical interlocks.
  • Test armatures to ensure proper operation within electrical installations.
  • Disassemble and reassemble magnetic starter assemblies safely following code-compliant procedures.
  • Explain the purpose of interlocks and how mechanical and electrical interlocks function incontrol systems.
  • Explain reversing magnetic starters, including wiring for reversing starters and how to select the correct starter type for motor applications.

Troubleshooting Electrical Control Circuits

Prerequisites:

This lesson is designed for learners with a good working foundation in AC and DC theory, electrical safety, electrical schematics, and the proper use of electrical test instruments. An understanding of the operation of control circuits and components, such as switches, relays, fuses, circuit breakers, motor starters, contactors, and control transformers is also recommended.

Description:

This lesson presents a systematic approach to troubleshooting electrical control circuits, guiding participants in gathering and verifying symptom information, using schematic and wiring diagrams to identify issues, and applying test instruments to isolate problem areas. It emphasizes developing strong problem-solving skills to diagnose faults and resolve malfunctions, execute safe corrective actions, and maintain power integrity. Learners will practice de-energizing control equipment and ensuring electrical installations are safe and reliable, with a strong focus on adherence to electrical codes and compliance with U.S. NEC and UL standards across diverse work environments.

Objectives:
  • Develop a logical and systematic strategy for troubleshooting control circuits in motor control systems in various work environments.
  • Gather diagnostic information accurately, using schematic diagrams, wiring diagrams, and observing operational symptoms.
  • Use test instruments (voltmeter, ohmmeter, continuity tester, etc.) to verify circuit integrity and identify faults.
  • Verify problem symptoms by performing electrical and mechanical operational checks, applying technical skills.
  • Isolate and diagnose problems within electrical control systems (e.g., faulty relay coils, broken contacts, overload relay trips, auxiliary contact failures).
  • Replace or repair defective components safely, ensuring adherence to electrical codes and standards during installations.
  • Confirm successful repair / replacement by verifying restored operation and safe electrical connections.
  • Communicate findings and troubleshooting steps effectively to maintenance teams or supervisors, enhancing future reliability and minimizing downtime.
  • Ensure safe work practices: proper de-energizing, lock-out/tag-out, verifying absence of voltage before work begins.

Troubleshooting Electrical Control Circuits

Prerequisites:

This lesson is designed for learners with a good working foundation in AC and DC theory, electrical safety, electrical schematics, and the proper use of electrical test instruments. An understanding of the operation of control circuits and components, such as switches, relays, fuses, circuit breakers, motor starters, contactors, and control transformers is also recommended.

Description:

This lesson presents a systematic approach to troubleshooting electrical control circuits, guiding participants in gathering and verifying symptom information, using schematic and wiring diagrams to identify issues, and applying test instruments to isolate problem areas. It emphasizes developing strong problem-solving skills to diagnose faults and resolve malfunctions, execute safe corrective actions, and maintain power integrity. Learners will practice de-energizing control equipment and ensuring electrical installations are safe and reliable, with a strong focus on adherence to electrical codes and compliance with U.S. NEC and UL standards across diverse work environments.

Objectives:
  • Develop a logical and systematic strategy for troubleshooting control circuits in motor control systems in various work environments.
  • Gather diagnostic information accurately, using schematic diagrams, wiring diagrams, and observing operational symptoms.
  • Use test instruments (voltmeter, ohmmeter, continuity tester, etc.) to verify circuit integrity and identify faults.
  • Verify problem symptoms by performing electrical and mechanical operational checks, applying technical skills.
  • Isolate and diagnose problems within electrical control systems (e.g., faulty relay coils, broken contacts, overload relay trips, auxiliary contact failures).
  • Replace or repair defective components safely, ensuring adherence to electrical codes and standards during installations.
  • Confirm successful repair / replacement by verifying restored operation and safe electrical connections.
  • Communicate findings and troubleshooting steps effectively to maintenance teams or supervisors, enhancing future reliability and minimizing downtime.
  • Ensure safe work practices: proper de-energizing, lock-out/tag-out, verifying absence of voltage before work begins.

Inverters: Operation and Maintenance

Prerequisites:

Learners should already understand AC/DC theory, AC motor theory, electrical safety, reading electrical prints, and the proper use of electrical test instruments. Prior exposure to control circuits, motor starters, and overload relays will aid in understanding inverter behavior.

Description:

This lesson covers the operation, maintenance, and fault diagnosis of inverters (variable-frequency drives, also called inverter drives) as vital components of electrical control equipment and control systems. Topics include inverter functions (PAM, PWM, open-loop, closed-loop, vector control), how inverters compensate for motor slip, calculating synchronous speed, identifying common malfunctions, and best practices for working with inverters, including safety, proper de-energizing, thermal considerations, and environmental impacts. Emphasis is placed on maintaining efficient power supply and power distribution, ensuring that electrical installations comply with U.S. electrical codes and standards for reliability and safety.

Objectives:
  • State the functions and parts of inverter (drive) units in electrical control systems.
  • Describe how PAM (Pulse Amplitude Modulation) and PWM (Pulse Width Modulation) inverters differ and how they are used in varying applications.
  • Review the operation of a typical induction motor and explain how to calculate synchronous speed and motor slip.
  • Explain how inverters compensate for slip and how they help maintain motor control and efficiency.
  • Describe the three types of inverter drives (open‐loop / closed-loop / flux vector control) and how they deliver control over speed and torque.
  • Explain how variable-torque applications can conserve energy when using appropriate inverter settings and how soft starting is implemented.
  • Identify environmental and installation conditions (such as temperature, ventilation, cabling) that affect inverter performance, and describe safety precautions when working with drives.
  • Diagnose common inverter errors and faults (over-temperature, overload, harmonic distortion, control board errors) and interpret typical error messages.

Inverters: Operation and Maintenance

Prerequisites:

Learners should already understand AC/DC theory, AC motor theory, electrical safety, reading electrical prints, and the proper use of electrical test instruments. Prior exposure to control circuits, motor starters, and overload relays will aid in understanding inverter behavior.

Description:

This lesson covers the operation, maintenance, and fault diagnosis of inverters (variable-frequency drives, also called inverter drives) as vital components of electrical control equipment and control systems. Topics include inverter functions (PAM, PWM, open-loop, closed-loop, vector control), how inverters compensate for motor slip, calculating synchronous speed, identifying common malfunctions, and best practices for working with inverters, including safety, proper de-energizing, thermal considerations, and environmental impacts. Emphasis is placed on maintaining efficient power supply and power distribution, ensuring that electrical installations comply with U.S. electrical codes and standards for reliability and safety.

Objectives:
  • State the functions and parts of inverter (drive) units in electrical control systems.
  • Describe how PAM (Pulse Amplitude Modulation) and PWM (Pulse Width Modulation) inverters differ and how they are used in varying applications.
  • Review the operation of a typical induction motor and explain how to calculate synchronous speed and motor slip.
  • Explain how inverters compensate for slip and how they help maintain motor control and efficiency.
  • Describe the three types of inverter drives (open‐loop / closed-loop / flux vector control) and how they deliver control over speed and torque.
  • Explain how variable-torque applications can conserve energy when using appropriate inverter settings and how soft starting is implemented.
  • Identify environmental and installation conditions (such as temperature, ventilation, cabling) that affect inverter performance, and describe safety precautions when working with drives.
  • Diagnose common inverter errors and faults (over-temperature, overload, harmonic distortion, control board errors) and interpret typical error messages.

Introduction to VFDs

Prerequisites:

This lesson is designed for participants familiar with AC and DC theory, electrical safety, electrical schematics, control systems, and the proper use of hand tools and test instruments.

Description:

This lesson covers various types of Variable Frequency Drives (VFDs) including their operation and applications. This lesson explains the benefits of each type of VFD and the key factors to consider when selecting a VFD for a particular application. Troubleshooting techniques used when repairing VFDs are described.

Objectives:
  • Describe the operation of a variable frequency drive
  • Identify the three main types of VFD
  • Identify the proper applications of VFDs
  • Describe the benefits and possible drawbacks of VFD implementation in a system
  • Demonstrate common troubleshooting techniques when diagnosing a faulty VFD

Introduction to VFDs

Prerequisites:

This lesson is designed for participants familiar with AC and DC theory, electrical safety, electrical schematics, control systems, and the proper use of hand tools and test instruments.

Description:

This lesson covers various types of Variable Frequency Drives (VFDs) including their operation and applications. This lesson explains the benefits of each type of VFD and the key factors to consider when selecting a VFD for a particular application. Troubleshooting techniques used when repairing VFDs are described.

Objectives:
  • Describe the operation of a variable frequency drive
  • Identify the three main types of VFD
  • Identify the proper applications of VFDs
  • Describe the benefits and possible drawbacks of VFD implementation in a system
  • Demonstrate common troubleshooting techniques when diagnosing a faulty VFD

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How can your maintenance team master industrial electrical control equipment?

ITC Learning’s online industrial training provides technicians and maintenance teams with the practical skills needed to safely maintain, troubleshoot, and repair critical control systems. By focusing on real-world plant-floor applications like VFDs, limit switches, and magnetic starters, this training directly reduces mean-time-to-repair (MTTR) and improves overall facility reliability.

Aligning Electrical Control Maintenance with NFPA 70B and 70E Standards

Effective maintenance of electrical control equipment is no longer just a best practice; it is a code requirement. Our courses provide the foundational awareness needed to align your facility’s Electrical Maintenance Program (EMP) with NFPA 70B standards, including scheduled inspections of magnetic starters and circuit breakers. By training learners on NFPA 70E safe work practices—such as establishing approach boundaries and selecting proper PPE before interacting with energized control circuits—you reduce the risk of arc flash incidents and ensure workforce safety.

Reducing Downtime Through Rapid Control Circuit Troubleshooting

Unplanned downtime often stems from simple control failures that technicians lack the confidence to diagnose quickly. ITC’s training transitions your team from reactive “trial and error” to logical, production-aware troubleshooting. By mastering the tracing of power through schematics and verifying three-phase balance in motor controllers, your crew can significantly cut downtime and improve site reliability.

Feature Business ImpactEstimated ROI Implementation Time
ITC Learning Online TrainingReduces MTTR via job-ready troubleshooting skills.1.3x to 3x return within 18 months.Immediate; SCORM-compliant rollout.
Traditional Off-Site ClassesHigh travel costs and production disruption.Slowed by high overhead and rigid schedules.Weeks to months for scheduling.
Generic E-Learning MarketplacesPurely academic; lacks plant-floor applicability.Low; fails to address specific craft gaps.Instant, but low retention.

Frequently Asked Questions

  • Does this training cover variable frequency drives (VFDs) and inverters?

    Yes. The series includes dedicated courses on the operation, maintenance, and troubleshooting of VFDs and inverters to ensure technicians can support modern automated systems.

  • Can these courses help our facility meet OSHA and NEC requirements?

    While the training focuses on maintenance tasks, it is built with compliance in mind, aligning awareness to the National Electrical Code (NEC) and safety procedures like Lockout/Tagout (LOTO) and PPE selection.

  • How do these electrical control assessments identify specific skill gaps?

    Each course includes a 20-question skills assessment that establishes a technical baseline, allowing managers to pinpoint exactly where a learner needs upskilling in control logic or equipment repair.

  • Is this training appropriate for cross-training mechanical technicians?

    Absolutely. Many organizations use these modular lessons to build multi-craft capacity, giving mechanics the foundational electrical knowledge to safely troubleshoot control circuits.

  • Can we integrate these courses into our existing LMS?

    Yes. All ITC Learning content is SCORM-compliant and designed for seamless integration into your current platform, or you can use our full-featured hosted portal.

Fuses and Circuit Breakers

Prerequisites:

Learners should have a solid understanding of  AC/DC theory, electrical safety,  basic electrical schematics, and be comfortable using hand tools and electronic test instruments. Recommended prior exposure to motor control circuits or control panels will enhance understanding.

Description:

This lesson examines the operation and maintenance of fuses and circuit breakers as essential components of electrical control equipment in industrial power distribution and motor control systems. It covers procedures for selecting appropriate devices (including molded case, multiple, ground fault, and short-circuit protection circuit breakers), installing, removing, and maintaining these components, testing them, and interpreting characteristic trip curves. Emphasis is placed on maintaining safe electrical installations by following national electrical safety standards and codes, properly de-energizing electrical equipment to prevent hazards, and ensuring their effective roles in power distribution systems.

Objectives:
  • Define the functions of fuses and circuit breakers in protecting electrical control systems against overloads, short circuits, and ground faults.
  • Choose the right fuse or breaker type (molded case, multiple, ground fault) based on capacity, current rating, and application, according to electrical codes.
  • Properly de-energize control equipment before performing maintenance to ensure adherence to safety and code standards.
  • Install and replace fuses and circuit breakers correctly within control panels and power distribution networks.
  • Interpret characteristic trip curves to select protection devices that fit motor control requirements.
  • Explain the operation of small, molded case circuit breakers within power distribution networks.
  • Reset and maintain circuit breaker panels safely, ensuring reliable power supply and system uptime.
  • Learn how circuit breakers detect issues and how to maintain breaker panels.
  • Install a circuit breaker and identify one that is a multiple.
  • Use a characteristic trip curve to interpret test results.
  • Identify, install, and test ground fault circuit breakers, understanding their auxiliary contacts and their role in system safety.

Fuses and Circuit Breakers

Prerequisites:

Learners should have a solid understanding of  AC/DC theory, electrical safety,  basic electrical schematics, and be comfortable using hand tools and electronic test instruments. Recommended prior exposure to motor control circuits or control panels will enhance understanding.

Description:

This lesson examines the operation and maintenance of fuses and circuit breakers as essential components of electrical control equipment in industrial power distribution and motor control systems. It covers procedures for selecting appropriate devices (including molded case, multiple, ground fault, and short-circuit protection circuit breakers), installing, removing, and maintaining these components, testing them, and interpreting characteristic trip curves. Emphasis is placed on maintaining safe electrical installations by following national electrical safety standards and codes, properly de-energizing electrical equipment to prevent hazards, and ensuring their effective roles in power distribution systems.

Objectives:
  • Define the functions of fuses and circuit breakers in protecting electrical control systems against overloads, short circuits, and ground faults.
  • Choose the right fuse or breaker type (molded case, multiple, ground fault) based on capacity, current rating, and application, according to electrical codes.
  • Properly de-energize control equipment before performing maintenance to ensure adherence to safety and code standards.
  • Install and replace fuses and circuit breakers correctly within control panels and power distribution networks.
  • Interpret characteristic trip curves to select protection devices that fit motor control requirements.
  • Explain the operation of small, molded case circuit breakers within power distribution networks.
  • Reset and maintain circuit breaker panels safely, ensuring reliable power supply and system uptime.
  • Learn how circuit breakers detect issues and how to maintain breaker panels.
  • Install a circuit breaker and identify one that is a multiple.
  • Use a characteristic trip curve to interpret test results.
  • Identify, install, and test ground fault circuit breakers, understanding their auxiliary contacts and their role in system safety.

Limit switches

Prerequisites:

Learners should already understand AC/DC theory, electrical schematics, and electrical safety. Prior experience using test instruments is required. Familiarity with control panels, motor control circuits, or auxiliary contact configurations will be helpful.

Description:

This lesson examines the operation, selection, and maintenance of limit switches as critical components in electrical control equipment, control panels, and electrical systems. It covers how limit switches work, where they are used, and how they interface with motor starters, relays, and control circuits. Topics include maintaining, troubleshooting, adjusting, and repairing limit switches while following electrical codes and standards. The lesson also addresses safety best practices, environmental considerations, and strategies for ensuring proper electrical installations and effective problem-solving in various work environments.

Objectives:
  • Explain the role of limit switches in motor control circuits and electrical control systems.
  • Identify different types of limit switches (lever, roller, plunger, whisker, geared) and their actuator styles.
  • Visually recognize various limit switches and know their uses.
  • Visually inspect limit switches for wear or damage and assess their suitability for control equipment.
  • Recognize photoelectric and proximity switch alternatives and how they integrate into control circuits.
  • Maintain and repair photoelectric and proximity switches safely.
  • Follow safety guidelines and code requirements when replacing or repairing switches, including de-energizing control panels.
  • Correctly install, adjust, and calibrate lever-actuated and geared limit switches in various work environments.
  • Understand the internal function of a lever-actuated limit switch and its role in control circuits.
  • Maintain, troubleshoot, repair, and adjust lever-actuated limit switches in various work environments.
  • Identify and fix common issues in these switches.
  • Explain the internal function of geared limit switches and torque switches in control circuits.

Limit switches

Prerequisites:

Learners should already understand AC/DC theory, electrical schematics, and electrical safety. Prior experience using test instruments is required. Familiarity with control panels, motor control circuits, or auxiliary contact configurations will be helpful.

Description:

This lesson examines the operation, selection, and maintenance of limit switches as critical components in electrical control equipment, control panels, and electrical systems. It covers how limit switches work, where they are used, and how they interface with motor starters, relays, and control circuits. Topics include maintaining, troubleshooting, adjusting, and repairing limit switches while following electrical codes and standards. The lesson also addresses safety best practices, environmental considerations, and strategies for ensuring proper electrical installations and effective problem-solving in various work environments.

Objectives:
  • Explain the role of limit switches in motor control circuits and electrical control systems.
  • Identify different types of limit switches (lever, roller, plunger, whisker, geared) and their actuator styles.
  • Visually recognize various limit switches and know their uses.
  • Visually inspect limit switches for wear or damage and assess their suitability for control equipment.
  • Recognize photoelectric and proximity switch alternatives and how they integrate into control circuits.
  • Maintain and repair photoelectric and proximity switches safely.
  • Follow safety guidelines and code requirements when replacing or repairing switches, including de-energizing control panels.
  • Correctly install, adjust, and calibrate lever-actuated and geared limit switches in various work environments.
  • Understand the internal function of a lever-actuated limit switch and its role in control circuits.
  • Maintain, troubleshoot, repair, and adjust lever-actuated limit switches in various work environments.
  • Identify and fix common issues in these switches.
  • Explain the internal function of geared limit switches and torque switches in control circuits.

Switches, Coils, and Overloads

Prerequisites:

Learners should be familiar with AC/DC theory, electrical safety, and reading electrical prints. Must know basic electrical connections and how to use electrical test instruments. A basic understanding of the operation of control circuits (including switches, relays, and power supply systems) and overload protection is recommended.

Description:

This lesson explores switches, coils, and overload relays as core components of electrical control equipment and electrical control systems. It explains the types and operations of switches, including push-button, selector, rotary, and momentary versus maintained types as well as the function of coils and the operation of thermal and magnetic overload relays. The lesson covers their roles in power supply, power distribution, and preserving motor health, while providing procedures for testing and replacing coils, verifying de-energized circuits, interpreting connection and circuit diagrams, and diagnosing malfunctions using manufacturer’s literature. Emphasis is placed on developing technical skills, adhering to electrical codes, and ensuring safety to prevent failures in power distribution and control panels.

Objectives:
  • Explain what types of switches are used in industry and know how to tell if they are functioning properly.
  • Test coils and replace overload relays in control panels, following electrical codes.
  • Understand coil operations in relays and how coil failures impact motor control circuits.
  • Explain what poles and throws mean in switches.
  • Describe how momentary and maintained push-button switches operate.
  • Understand how selector switches function and where they are used.
  • Read and interpret rotary switch connection diagrams, auxiliary contacts, and pole/throw designations.
  • Perform continuity checks on push-button switches to ensure they work properly.
  • Learn how to check coils for overheating and breaks in the wire winding.
  • Explain how overload relays protect motors in electrical systems.
  • Describe how bimetallic thermal overload relays work in power distribution.
  • Understand how melting-alloy thermal overload relays function and store heat.
  • Identify magnetic and electronic overload relays.
  • Describe the common problems of thermal overload relays.
  • Install thermal overload relays in starters, following electrical codes.

Switches, Coils, and Overloads

Prerequisites:

Learners should be familiar with AC/DC theory, electrical safety, and reading electrical prints. Must know basic electrical connections and how to use electrical test instruments. A basic understanding of the operation of control circuits (including switches, relays, and power supply systems) and overload protection is recommended.

Description:

This lesson explores switches, coils, and overload relays as core components of electrical control equipment and electrical control systems. It explains the types and operations of switches, including push-button, selector, rotary, and momentary versus maintained types as well as the function of coils and the operation of thermal and magnetic overload relays. The lesson covers their roles in power supply, power distribution, and preserving motor health, while providing procedures for testing and replacing coils, verifying de-energized circuits, interpreting connection and circuit diagrams, and diagnosing malfunctions using manufacturer’s literature. Emphasis is placed on developing technical skills, adhering to electrical codes, and ensuring safety to prevent failures in power distribution and control panels.

Objectives:
  • Explain what types of switches are used in industry and know how to tell if they are functioning properly.
  • Test coils and replace overload relays in control panels, following electrical codes.
  • Understand coil operations in relays and how coil failures impact motor control circuits.
  • Explain what poles and throws mean in switches.
  • Describe how momentary and maintained push-button switches operate.
  • Understand how selector switches function and where they are used.
  • Read and interpret rotary switch connection diagrams, auxiliary contacts, and pole/throw designations.
  • Perform continuity checks on push-button switches to ensure they work properly.
  • Learn how to check coils for overheating and breaks in the wire winding.
  • Explain how overload relays protect motors in electrical systems.
  • Describe how bimetallic thermal overload relays work in power distribution.
  • Understand how melting-alloy thermal overload relays function and store heat.
  • Identify magnetic and electronic overload relays.
  • Describe the common problems of thermal overload relays.
  • Install thermal overload relays in starters, following electrical codes.

Magnetic Starters

Prerequisites:

Learners should have foundational knowledge of AC/DC theory, electrical safety, and reading electrical prints. Must understand basic electrical connections, have experience properly using test instruments, and ideally have worked with switches, overload relays, or motor control circuits in control panels.

Description:

This lesson dives deep into magnetic starters within electrical control equipment and control systems. It covers their components (contactor, coil, overload protection), their operation, and how they integrate with motor control circuits in industrial and commercial power distribution systems. Learners will practice interpreting schematic diagrams and manufacturer literature, conducting safety-centered troubleshooting, and performing installations and maintenance. Emphasis is placed on problem-solving skills, following national electrical codes, correctly de-energizing equipment, and using auxiliary contacts and mechanical/electrical interlocks to ensure safe and reliable control equipment performance.

Objectives:
  • Understand the role and operation of magnetic motor starters in motor control and electrical control systems.
  • Describe electromagnets and their role in the functioning of contactors within control panels.
  • Differentiate between contactors and magnetic starters, including the functions of their coils, overload relays, and auxiliary contacts.
  • Identify components of magnetic starters and examine how they protect against electrical faults and overload conditions.
  • Test and replace magnetic starters safely, applying technical skills in control panels and power supply installations.
  • Perform sensory inspections to detect issues in magnetic motor starters.
  • Interpret schematic diagrams involving magnetic starters, contac­tor coil wiring, and mechanical/electrical interlocks.
  • Test armatures to ensure proper operation within electrical installations.
  • Disassemble and reassemble magnetic starter assemblies safely following code-compliant procedures.
  • Explain the purpose of interlocks and how mechanical and electrical interlocks function incontrol systems.
  • Explain reversing magnetic starters, including wiring for reversing starters and how to select the correct starter type for motor applications.

Magnetic Starters

Prerequisites:

Learners should have foundational knowledge of AC/DC theory, electrical safety, and reading electrical prints. Must understand basic electrical connections, have experience properly using test instruments, and ideally have worked with switches, overload relays, or motor control circuits in control panels.

Description:

This lesson dives deep into magnetic starters within electrical control equipment and control systems. It covers their components (contactor, coil, overload protection), their operation, and how they integrate with motor control circuits in industrial and commercial power distribution systems. Learners will practice interpreting schematic diagrams and manufacturer literature, conducting safety-centered troubleshooting, and performing installations and maintenance. Emphasis is placed on problem-solving skills, following national electrical codes, correctly de-energizing equipment, and using auxiliary contacts and mechanical/electrical interlocks to ensure safe and reliable control equipment performance.

Objectives:
  • Understand the role and operation of magnetic motor starters in motor control and electrical control systems.
  • Describe electromagnets and their role in the functioning of contactors within control panels.
  • Differentiate between contactors and magnetic starters, including the functions of their coils, overload relays, and auxiliary contacts.
  • Identify components of magnetic starters and examine how they protect against electrical faults and overload conditions.
  • Test and replace magnetic starters safely, applying technical skills in control panels and power supply installations.
  • Perform sensory inspections to detect issues in magnetic motor starters.
  • Interpret schematic diagrams involving magnetic starters, contac­tor coil wiring, and mechanical/electrical interlocks.
  • Test armatures to ensure proper operation within electrical installations.
  • Disassemble and reassemble magnetic starter assemblies safely following code-compliant procedures.
  • Explain the purpose of interlocks and how mechanical and electrical interlocks function incontrol systems.
  • Explain reversing magnetic starters, including wiring for reversing starters and how to select the correct starter type for motor applications.

Troubleshooting Electrical Control Circuits

Prerequisites:

This lesson is designed for learners with a good working foundation in AC and DC theory, electrical safety, electrical schematics, and the proper use of electrical test instruments. An understanding of the operation of control circuits and components, such as switches, relays, fuses, circuit breakers, motor starters, contactors, and control transformers is also recommended.

Description:

This lesson presents a systematic approach to troubleshooting electrical control circuits, guiding participants in gathering and verifying symptom information, using schematic and wiring diagrams to identify issues, and applying test instruments to isolate problem areas. It emphasizes developing strong problem-solving skills to diagnose faults and resolve malfunctions, execute safe corrective actions, and maintain power integrity. Learners will practice de-energizing control equipment and ensuring electrical installations are safe and reliable, with a strong focus on adherence to electrical codes and compliance with U.S. NEC and UL standards across diverse work environments.

Objectives:
  • Develop a logical and systematic strategy for troubleshooting control circuits in motor control systems in various work environments.
  • Gather diagnostic information accurately, using schematic diagrams, wiring diagrams, and observing operational symptoms.
  • Use test instruments (voltmeter, ohmmeter, continuity tester, etc.) to verify circuit integrity and identify faults.
  • Verify problem symptoms by performing electrical and mechanical operational checks, applying technical skills.
  • Isolate and diagnose problems within electrical control systems (e.g., faulty relay coils, broken contacts, overload relay trips, auxiliary contact failures).
  • Replace or repair defective components safely, ensuring adherence to electrical codes and standards during installations.
  • Confirm successful repair / replacement by verifying restored operation and safe electrical connections.
  • Communicate findings and troubleshooting steps effectively to maintenance teams or supervisors, enhancing future reliability and minimizing downtime.
  • Ensure safe work practices: proper de-energizing, lock-out/tag-out, verifying absence of voltage before work begins.

Troubleshooting Electrical Control Circuits

Prerequisites:

This lesson is designed for learners with a good working foundation in AC and DC theory, electrical safety, electrical schematics, and the proper use of electrical test instruments. An understanding of the operation of control circuits and components, such as switches, relays, fuses, circuit breakers, motor starters, contactors, and control transformers is also recommended.

Description:

This lesson presents a systematic approach to troubleshooting electrical control circuits, guiding participants in gathering and verifying symptom information, using schematic and wiring diagrams to identify issues, and applying test instruments to isolate problem areas. It emphasizes developing strong problem-solving skills to diagnose faults and resolve malfunctions, execute safe corrective actions, and maintain power integrity. Learners will practice de-energizing control equipment and ensuring electrical installations are safe and reliable, with a strong focus on adherence to electrical codes and compliance with U.S. NEC and UL standards across diverse work environments.

Objectives:
  • Develop a logical and systematic strategy for troubleshooting control circuits in motor control systems in various work environments.
  • Gather diagnostic information accurately, using schematic diagrams, wiring diagrams, and observing operational symptoms.
  • Use test instruments (voltmeter, ohmmeter, continuity tester, etc.) to verify circuit integrity and identify faults.
  • Verify problem symptoms by performing electrical and mechanical operational checks, applying technical skills.
  • Isolate and diagnose problems within electrical control systems (e.g., faulty relay coils, broken contacts, overload relay trips, auxiliary contact failures).
  • Replace or repair defective components safely, ensuring adherence to electrical codes and standards during installations.
  • Confirm successful repair / replacement by verifying restored operation and safe electrical connections.
  • Communicate findings and troubleshooting steps effectively to maintenance teams or supervisors, enhancing future reliability and minimizing downtime.
  • Ensure safe work practices: proper de-energizing, lock-out/tag-out, verifying absence of voltage before work begins.

Inverters: Operation and Maintenance

Prerequisites:

Learners should already understand AC/DC theory, AC motor theory, electrical safety, reading electrical prints, and the proper use of electrical test instruments. Prior exposure to control circuits, motor starters, and overload relays will aid in understanding inverter behavior.

Description:

This lesson covers the operation, maintenance, and fault diagnosis of inverters (variable-frequency drives, also called inverter drives) as vital components of electrical control equipment and control systems. Topics include inverter functions (PAM, PWM, open-loop, closed-loop, vector control), how inverters compensate for motor slip, calculating synchronous speed, identifying common malfunctions, and best practices for working with inverters, including safety, proper de-energizing, thermal considerations, and environmental impacts. Emphasis is placed on maintaining efficient power supply and power distribution, ensuring that electrical installations comply with U.S. electrical codes and standards for reliability and safety.

Objectives:
  • State the functions and parts of inverter (drive) units in electrical control systems.
  • Describe how PAM (Pulse Amplitude Modulation) and PWM (Pulse Width Modulation) inverters differ and how they are used in varying applications.
  • Review the operation of a typical induction motor and explain how to calculate synchronous speed and motor slip.
  • Explain how inverters compensate for slip and how they help maintain motor control and efficiency.
  • Describe the three types of inverter drives (open‐loop / closed-loop / flux vector control) and how they deliver control over speed and torque.
  • Explain how variable-torque applications can conserve energy when using appropriate inverter settings and how soft starting is implemented.
  • Identify environmental and installation conditions (such as temperature, ventilation, cabling) that affect inverter performance, and describe safety precautions when working with drives.
  • Diagnose common inverter errors and faults (over-temperature, overload, harmonic distortion, control board errors) and interpret typical error messages.

Inverters: Operation and Maintenance

Prerequisites:

Learners should already understand AC/DC theory, AC motor theory, electrical safety, reading electrical prints, and the proper use of electrical test instruments. Prior exposure to control circuits, motor starters, and overload relays will aid in understanding inverter behavior.

Description:

This lesson covers the operation, maintenance, and fault diagnosis of inverters (variable-frequency drives, also called inverter drives) as vital components of electrical control equipment and control systems. Topics include inverter functions (PAM, PWM, open-loop, closed-loop, vector control), how inverters compensate for motor slip, calculating synchronous speed, identifying common malfunctions, and best practices for working with inverters, including safety, proper de-energizing, thermal considerations, and environmental impacts. Emphasis is placed on maintaining efficient power supply and power distribution, ensuring that electrical installations comply with U.S. electrical codes and standards for reliability and safety.

Objectives:
  • State the functions and parts of inverter (drive) units in electrical control systems.
  • Describe how PAM (Pulse Amplitude Modulation) and PWM (Pulse Width Modulation) inverters differ and how they are used in varying applications.
  • Review the operation of a typical induction motor and explain how to calculate synchronous speed and motor slip.
  • Explain how inverters compensate for slip and how they help maintain motor control and efficiency.
  • Describe the three types of inverter drives (open‐loop / closed-loop / flux vector control) and how they deliver control over speed and torque.
  • Explain how variable-torque applications can conserve energy when using appropriate inverter settings and how soft starting is implemented.
  • Identify environmental and installation conditions (such as temperature, ventilation, cabling) that affect inverter performance, and describe safety precautions when working with drives.
  • Diagnose common inverter errors and faults (over-temperature, overload, harmonic distortion, control board errors) and interpret typical error messages.

Introduction to VFDs

Prerequisites:

This lesson is designed for participants familiar with AC and DC theory, electrical safety, electrical schematics, control systems, and the proper use of hand tools and test instruments.

Description:

This lesson covers various types of Variable Frequency Drives (VFDs) including their operation and applications. This lesson explains the benefits of each type of VFD and the key factors to consider when selecting a VFD for a particular application. Troubleshooting techniques used when repairing VFDs are described.

Objectives:
  • Describe the operation of a variable frequency drive
  • Identify the three main types of VFD
  • Identify the proper applications of VFDs
  • Describe the benefits and possible drawbacks of VFD implementation in a system
  • Demonstrate common troubleshooting techniques when diagnosing a faulty VFD

Introduction to VFDs

Prerequisites:

This lesson is designed for participants familiar with AC and DC theory, electrical safety, electrical schematics, control systems, and the proper use of hand tools and test instruments.

Description:

This lesson covers various types of Variable Frequency Drives (VFDs) including their operation and applications. This lesson explains the benefits of each type of VFD and the key factors to consider when selecting a VFD for a particular application. Troubleshooting techniques used when repairing VFDs are described.

Objectives:
  • Describe the operation of a variable frequency drive
  • Identify the three main types of VFD
  • Identify the proper applications of VFDs
  • Describe the benefits and possible drawbacks of VFD implementation in a system
  • Demonstrate common troubleshooting techniques when diagnosing a faulty VFD
Course Overview

This award-winning training program includes six lessons teaching essential skills for installing, maintaining, and repairing electrical control equipment and electrical control systems. Topics include circuit breakers, control panels, limit switches, overload relays, motor starters, inverters, and electrical motor control circuits. The course emphasizes power distribution, safety, de-energizing procedures, and compliance with U.S. electrical code standards.

Who This Course is For?

This program is ideal for training electricians and technicians in instrumentation and electronics, equipping them with essential skills for installing, maintaining, and troubleshooting electrical control systems. It also addresses the multi-craft training needs of process and manufacturing facilities, ensuring personnel are proficient in adhering to national electrical code standards and effectively managing electrical control equipment.

Platforms:  
Number of Courses: 7
How This Course Helps You
Together, these lessons help participants develop the skills and certifications necessary to:

Technical Competence:

Hands-on work with motor starters, overload relays, and inverters to design, install, and maintain electrical control equipment.

Improve Troubleshooting:

Diagnose faults, safely de-energize circuits, and ensure compliance with NEC/UL standards to reduce failures and downtime.

Power Distribution & Efficiency:

Understand power supply protection (circuit breakers, overloads), control panels, and efficient installations for energy savings.

Career Opportunities:

Gain skills in motor control circuits, relay logic, and industrial control systems valued across manufacturing, utilities, and industrial sectors throughout the United States