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Downloadable Wiring Diagrams and the measurement layout are available at the bottom of this page.
Instructors are always looking for a low cost, hands-on project, that is safer to teach their students about HVAC Electrical Wiring, Components, Thermostats, Thermostat Wiring, and an Intro to Electrical Troubleshooting! This small electrical training board can be built by each student and it allows each student to get some hands-on training. The teacher can provide the step by step instruction and after the project is built, the teacher can set faults into the board for the student to find using their multimeter. The key is to make sure the faults are not visible and to make the students find each problem using the multimeter. The student should NOT pull any connections out to try to find the problem but only find the issue(s) using the multi-meter and explain the issue to the teacher (to prove that they understand) before fixing it. This Electrical Training Board is designed to aid in the instruction and fundamentals of the following:
-Thermostat Wiring -Thermostat Function -Common Electrical Components
-Line Voltage Electrical Wiring -Reading Wiring Diagrams -Intro to Electrical Troubleshooting
The electrical board replicates the thermostat functions of a forced air gas furnace with air conditioning. Instead of using a control board, this board uses electrical relays and switches to perform tasks. The sheet metal base serves as the electrical ground frame and the GFCI is the protection device for the training board. As the teacher moves through the training, the student may add additional components to this board to increase difficulty, such as extra timing mechanisms.
I want to say a special thanks to Packard and DiversiTech for their encouragement in creating this electrical training board and the associated wiring diagrams to benefit HVAC instruction.
Packard Electrical Components Used:
PR380 – Fan Relay SPNC, SPNO 24v coil
POP3 LI'L Popper- 24v circuit breaker 3amp
HS24A343- Heat Sequencer double pole NO
PR340 - General Purpose Switching Relay DPDT 24v coil
C130A – Single Pole Contactor, 24 volt, 30 amp
PF42440 - Multi-Tap Transformer 120, 208, 240v primary, 24v secondary
PTD102 – Delay-On-Make Timer
DiversiTech Tools Used:
FTL3 – alligator test leads
MAG-1 – magnet jumpers
All Other Supplies Used:
(1) 1/2" plywood board that is 18" by 18"
(1 piece) 26 gauge sheet metal 18" by 18" or greater
(10 120v 15amp GFCI plug with cord
(1) 120v 15amp plug with cord
(misc) 16-22 gauge female spade crimp connectors
(misc) 16-22 gauge piggy back female spade crimp connectors
(1) 2" x 4" x 2 1/4" metal electrical box with 1/2" knockouts
(2) 3.5" by 3.5" by 1.5" octagon metal ceiling light box with 1/2" knockouts
(1) 120v shaded pole fan motor (you can find these for free in any old microwave) otherwise use this Fasco motor: C-FRAME MOTOR, 1/150 HP, 115 VOLTS, 3000 RPM, part number K670
(2) small blue wire nuts
(15) 1/4" plastic cable clamps
(1) 3/8" cable strap
(8ft) 14 gauge THHN black stranded wire
(8ft) 14 gauge THHN white stranded wire
(8') 18-6 thermostat wire
(1) duplex receptacle
(2) ceiling light sockets
(2) 120v light bulbs, one red, one blue
(1') 14-2 NMB Romex
(1) Honeywell Pro 3000 thermostat
(misc) 1/4" by 1/2" zip screws
(2) plastic sleeves for electrical box knockouts
(1) NMB 1/2" metal box connector for electrical box knockout
(1) terminal block for the thermostat wires with at least 6 sets of terminals, more terminals allows you to add on later.
Tools Used:
(1) Digital multimeter
(1) Cordless drill
(1) 1/4" magnetic nut driver
(1) 6in1 screwdriver
(1) Wire stripper/crimper
Instructions For Assembly:
To start, give each student a 18" by 18" blank plywood board, a piece of sheet metal 20" by 20", the measurement layout paper, and all electrical components needed for the project (The teacher could also provide a list of the electrical components needed and have the students gather these based on the name of the component, type, and number of poles and throws).
1. The student must cut the metal to 18" by 18", notch the corners in 1/2" and fold each side over with a metal folding tool. The hem can then be flattened down with hand brakes or a sheet metal brake.
