Motors and Controls

Course Description

ETI1843C — Motors and Controls is a combined lecture and laboratory course (4 credit hours) in the Engineering Technologies / Industrial Systems Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). The course introduces students to the theory, application, installation, and troubleshooting of AC and DC electric motors and the industrial control systems used to operate them. Topics span electromagnetism, single- and three-phase motor operation, manual and automatic motor starters, contactors, overload protection, relay logic, solid-state controls, variable-frequency drives (VFDs), and an introduction to programmable logic controllers (PLCs). Substantial laboratory time is devoted to hands-on wiring, testing, and troubleshooting of motor control circuits using industry-standard components and trainer panels.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Explain the principles of electromagnetism and how they apply to the operation of AC and DC electric motors.
• Identify, interpret, and apply motor nameplate data and manufacturer wiring diagrams for single-phase and three-phase motors.
• Wire, operate, and troubleshoot manual and magnetic motor starters, including full-voltage (across-the-line) starting circuits.
• Design and construct two-wire and three-wire control circuits, including forward/reverse and jogging configurations.
• Select and apply overload protection devices, fuses, and circuit breakers appropriate for a given motor application.
• Interpret and draw ladder (line) diagrams and wiring diagrams for industrial motor control circuits.
• Demonstrate safe work practices in accordance with OSHA standards and lockout/tagout (LOTO) procedures.
• Install and test control relays, contactors, timing relays, and push-button stations in functional motor control circuits.
• Describe the operating principles and wiring of reduced-voltage starting methods (primary resistor, autotransformer, part-winding, wye-delta).
• Explain the theory of operation of variable-frequency drives (VFDs) and configure basic drive parameters for speed control.
• Troubleshoot motor control circuits systematically using digital multimeters, clamp meters, and other test instruments.

Optional Outcomes

The following outcomes may be addressed depending on program emphasis and available equipment:

• Write and execute basic PLC ladder logic programs to control motor circuits (e.g., Allen-Bradley or equivalent platform).
• Analyze and apply motor braking techniques: dynamic braking, DC injection braking, plugging, and friction brakes.
• Identify and describe the operating principles of stepper motors and servo motors used in automation applications.
• Calculate motor torque, speed, and horsepower relationships and apply power factor correction concepts.
• Describe the role of solid-state relays (SSRs), SCRs, and TRIACs in motor control applications.
• Interpret NEC (National Electrical Code) requirements related to motor branch-circuit protection and conductor sizing.

Major Topics

Required Topics

The following content areas are covered at all Florida institutions offering ETI1843C:

• Safety and OSHA Compliance — Electrical safety, PPE, lockout/tagout procedures, and OSHA standards applicable to industrial environments.
• Electromagnetism Review — Magnetic fields, inductance, electromagnetic induction, and their relationship to motor and relay operation.
• Single-Phase AC Motors — Split-phase, capacitor-start, capacitor-run, shaded-pole, and universal motor types; theory, nameplate data, and wiring.
• Three-Phase AC Induction Motors — Construction, rotating magnetic field theory, synchronous speed, slip, torque-speed curves, dual-voltage wiring configurations.
• DC Motors — Series, shunt, compound, and permanent-magnet types; speed/torque characteristics and speed control methods.
• Motor Control Symbols and Diagrams — NEMA and IEC schematic symbols; reading and drawing ladder (line) diagrams and wiring diagrams.
• Manual Motor Starters and Disconnects — Toggle switches, drum switches, manual starters; NEC disconnect requirements.
• Magnetic Motor Starters and Contactors — NEMA size ratings, coil/contact operation, auxiliary contacts, and control wiring.
• Overload Protection — Melting-alloy and bimetallic overload relays, electronic overloads, sizing and installation requirements.
• Two-Wire and Three-Wire Control Circuits — Pilot devices, holding circuits, low-voltage and low-current protection, STOP/START station wiring.
• Reversing Motor Starters — Forward/reverse circuits, mechanical and electrical interlocking methods.
• Jogging and Plugging Circuits — Jog/run selector circuits, plugging relays, anti-plug protection.
• Timing Relays — On-delay and off-delay timers, timing diagram interpretation, timer applications in motor control sequences.
• Reduced-Voltage Starting — Primary resistor, autotransformer, part-winding, and wye-delta starters; purpose and sequencing circuits.
• Variable-Frequency Drives (VFDs) — Principles of operation, basic parameter configuration, speed reference methods, application wiring.
• Motor Circuit Protection — Fuse types, circuit breakers, branch-circuit conductor sizing (NEC Article 430 overview).
• Troubleshooting Motor Control Circuits — Systematic fault-finding procedures, use of DMM, clamp meter, and continuity tester in live and de-energized circuits.

Optional Topics

The following topics may be covered based on program depth, available lab equipment, and instructor discretion:

• PLC Fundamentals — PLC hardware overview, I/O modules, ladder logic programming for basic motor start/stop and sequencing applications.
• Motor Braking Methods — Dynamic braking, DC injection braking, plugging, and friction brake applications.
• Solid-State Starters (Soft Starters) — SCR/TRIAC-based reduced-voltage starting; comparison with VFDs.
• Stepper and Servo Motors — Operating principles, drive circuits, and positioning applications in automated systems.
• Motor Torque and Power Calculations — Calculating HP, torque, synchronous speed, slip, and efficiency from nameplate data.
• Power Factor and Correction — Impact of inductive motor loads on power factor; capacitor correction methods.
• Industrial Control Transformers — Step-down transformer sizing and wiring for control circuits.
• IEC vs. NEMA Standards — Differences in contactor ratings, enclosures, and overload device designations.

Resources & Tools

• Textbook (common adoption): Industrial Motor Control by Stephen Herman (Cengage Learning) — widely used at Florida colleges for ETI-level motor control courses.
• Laboratory Equipment: Motor control trainer panels with NEMA contactors, overload relays, pushbutton stations, timing relays, and three-phase motor simulators; digital multimeters; clamp-on ammeters; variable-frequency drives.
• PLC Software (optional): Allen-Bradley Studio 5000 / RSLogix 500, or equivalent ladder logic simulation software.
• Reference Standards: NFPA 70 (National Electrical Code), NEMA ICS standards, OSHA 29 CFR 1910.147 (Lockout/Tagout).
• Simulation Tools: Electrical circuit simulation software (e.g., FluidSIM, AutoCAD Electrical, or equivalent schematic tools).
• Manufacturer Resources: Rockwell Automation (Allen-Bradley), Siemens, Eaton, and Square D product literature, wiring diagrams, and technical manuals.

Career Pathways

Completion of ETI1843C prepares students for entry-level and advancing roles in industrial and manufacturing environments. This course is a core component of the Industrial Systems Technology A.S. degree and related College Credit Certificates (CCCs) such as Mechatronics.

• Industrial Electrician / Electrical Technician — Installation and maintenance of motor control panels and distribution equipment in manufacturing facilities.
• Electromechanical Technician — Operation, maintenance, and repair of automated electromechanical equipment and assembly systems.
• Maintenance Technician / Maintenance Mechanic — Preventive and corrective maintenance of motors, drives, and control systems in production environments.
• Controls Technician / Automation Technician — Troubleshooting and programming of industrial motor controls and PLC-based systems.
• Manufacturing / Production Technician — Supporting advanced manufacturing operations requiring knowledge of motor-driven equipment.
• Field Service Technician — On-site installation, startup, and repair of motor control equipment for equipment manufacturers and distributors.

This course aligns with skill standards recognized by the Manufacturing Skill Standards Council (MSSC) and supports preparation for industry certifications valued by Florida employers in advanced manufacturing and industrial automation.

Special Information

Industry Certifications

Students completing this course—particularly in conjunction with the full Industrial Systems Technology or Mechatronics program—may be positioned to pursue the following industry-recognized credentials:

• MSSC Certified Production Technician (CPT) — Safety, quality, manufacturing processes, and maintenance modules align with course content.
• NFPA 70E Electrical Safety Certification — Safety content covered in this course (LOTO, arc flash awareness) supports NFPA 70E exam preparation.
• Rockwell Automation (Allen-Bradley) Certifications — PLC and drives content (optional topic) aligns with entry-level RA certification pathways.
• OSHA 10-Hour General Industry Card — OSHA safety content addressed throughout the course supports this credential.

Laboratory Requirement

The "C" lab indicator in the course number (ETI1843C) designates this as a combined lecture and laboratory course meeting in the same location at the same time. Students must satisfactorily complete all laboratory exercises to pass the course. Appropriate closed-toe footwear, safety glasses, and compliance with LOTO procedures are required in the lab at all times.

Program Context

ETI1843C is typically offered as a core course within Florida college Industrial Systems Technology, Mechatronics, and Engineering Technology A.S. degree and certificate programs. The "C" combined lecture-lab format reflects the strong hands-on component essential to workforce preparation in advanced manufacturing. Courses in these programs meet industry standards and align with the Manufacturing Skill Standards Council (MSSC) framework.