Detailed Contents
Energy ♦ Voltage ♦ Current ♦ Resistance ♦ Ohm's
Law ♦ Series Circuits ♦ Parallel Circuits
♦Series/Parallel Circuits ♦ Power Formula ♦
Power
Hand Tools ♦ Hand Tool Safety ♦ Power-Operated
Tools ♦ Power Tool
Safety ♦ Multimeters ♦ Clamp-on Ammeters ♦
Megohmmeters ♦ Oscilloscopes ♦ Continuity Testers
♦ Voltage Testers ♦ Digital Logic Probes ♦
Phase Sequence Indicators ♦ Ground Resistance
Testers ♦ Receptacle
Testers ♦ Branch Circuit Identifiers ♦ Noncontact
Temperature Probes ♦
Optical Time Domain Reflectometers
Electrical Safety ♦ National Electrical Code® ♦
Qualified Persons ♦
Safety Labels ♦ Electrical Shock ♦ NFPA 70E ♦
Electric Motor Safety ♦
Personal Protective Equipment ♦ Protective Clothing
♦ Arc Blast Protection ♦ Lockout/Tagout ♦ Lockout
Devices ♦ Fire Safety ♦ Confined
Spaces ♦ Overhead Power Line Safety
Language of Control ♦ Pictorial Drawings ♦ Electrical
Symbols and
Abbreviations ♦ Wiring Diagrams ♦ Schematic
Diagrams ♦ Line
Diagrams ♦ Electrical Circuits ♦ Manual Control
Circuits ♦ Automatic
Control Circuits ♦ Magnetic Control Circuits ♦
Printreading
Basic Rules of Line Diagrams ♦ Load Connections ♦
Control Device
Connections ♦ Line Number Reference ♦ Numerical
Cross-Reference
Systems ♦ Wire Reference Numbers ♦
Manufacturer's Terminal Numbers ♦ Line
Diagrams—Signals, Decisions, and Action ♦ Logic
Functions ♦ Common Control Circuits ♦ Control
Circuit Troubleshooting
• a
Magnetism ♦ Electromagnetism ♦ Solenoids ♦
Solenoid Characteristics ♦ Selecting Proper
Solenoids ♦ Solenoid Applications ♦
Troubleshooting Solenoids ♦ DC Generators ♦ DC
Motors ♦ Troubleshooting DC Motors
AC Generators, Transformers, and AC Motors 153
Single-Phase AC Generators ♦ Three-Phase AC
Generators ♦ Voltage
Changes ♦ Transients ♦ Transformer Operation ♦
Transformer Connections ♦ Control Transformers ♦
Transformer Selection ♦ Troubleshooting
Transformers ♦ AC Motors ♦ Single-Phase Motors ♦
Three-Phase Motors ♦ AC Motor Maintenance ♦
Troubleshooting AC Motors
Power Distribution Systems ♦ Generator Phase
Connections ♦ Transformer Installation ♦
Substations ♦ Switchboards ♦ Panelboards and
Branch Circuits ♦ Motor Control Centers ♦ Feeders and Busways ♦
Grounding ♦ Troubleshooting Power Distribution
Systems ♦ Phase
Unbalance ♦ Voltage Unbalance ♦ Single Phasing ♦
Improper
Phase Sequence ♦ Voltage Surges ♦
Troubleshooting Fuses and
Circuit Breakers ♦ Testing Control Transformers
Contactors and Magnetic Motor Starters
Manual Switching ♦ Manual Contactors ♦ Manual
Starters ♦
Magnetic Contactors ♦ Magnetic Motor Starters ♦
Contactor and
Magnetic Motor Starter Modifications ♦ International
Standards ♦
Troubleshooting Contactors and Motor Starters
Motor Drives ♦ Motor Drive Control Circuit ♦
Programming Motor
Drives ♦ DC Motor Drives ♦ AC Motor Drives ♦
Controlling Motor
Speed and Torque ♦ AC Motor Drive, Motor, and Load Test
Industrial Pushbuttons ♦ Selector Switches ♦
Joysticks ♦ Limit Switches ♦
Foot Switches ♦ Daylight Switches ♦ Pressure
Switches ♦ Temperature
Switches ♦ Flow Switches ♦ Smoke/Gas Switches ♦
Level Switches ♦ Wind
Metering ♦ Automated Systems ♦ Troubleshooting
Control Devices ♦
Smart (Intelligent) Input Devices
Reversing Motors Using Manual Starters ♦
Reversing Motors Using Drum Switches ♦ Reversing
Motors Using Magnetic Starters ♦
Magnetic Reversing Starter Applications ♦ PLC
Reversing Circuits
♦ Motor Control Wiring Methods ♦ Troubleshooting
Reversing
Circuits
o
Solid-State Devices and System Integration
Electronic Control Systems and Devices ♦ Diodes, Rectification, and
Power Supplies ♦ Solid-State Power Sources ♦ Input
Devices ♦ Amplification ♦ Processing ♦ Switching
Devices ♦ Communication ♦
Interfacing Solid-State Devices ♦ Output/Display
Devices ♦ Troubleshooting Solid-State Devices
363
409
Timers ♦ Timing Functions ♦ Wiring Diagrams ♦
Multiple Contact
Timers ♦ Timer Applications ♦ Troubleshooting
Timing Circuits ♦
Counters
Relays ♦ Electromechanical Relays (EMRs) ♦ SolidState Relays
(SSRs) ♦ Stand-Alone and Programmable Logic
Relays ♦ Solid-State
Motor Starters ♦ Troubleshooting Relays
Sensing Devices and Controls
Photoelectric Sensors ♦ Photoelectric Control
Applications ♦ Ultrasonic Sensors ♦ Proximity
Sensors ♦ Photoelectric and Proximity
Outputs ♦ Proximity Sensor Installation ♦
Troubleshooting Photoelectric and Proximity
Sensors
467 c h a p t e r
irammable Controllers 503
Programmable Controllers ♦ PLCsand PCs ♦ PLC
Parts ♦ Interfacing
Solid-State Controls ♦ Programming Programmable Timers ♦ PLC
Applications ♦ Programmable Logic Relays (PLRs) ♦
Multiplexing
♦ Troubleshooting PLCs
Reduced-Voltage Starting ♦ DC Motor ReducedVoltage Starting ♦
Reduced-Voltage Starting for Three-Phase Induction
Motors ♦ Primary
Resistor Starting ♦ Autotransformer Starting ♦ PartWinding Starting
♦ Wye-Delta Starting ♦ Solid-State Switches ♦ SolidState Starting
♦ Starting Method Comparison ♦ Troubleshooting
Reduced-Voltage
Starting Circuits
Accelerating and Decelerating Methods 571
Braking ♦ Speed Control ♦ Multispeed Motors ♦ DC Motor Speed
Control ♦ AC Motor Speed Control ♦
Troubleshooting Drive and Motors Circuits
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Preventive and Predictive Maintenance Systems 609
Preventive Maintenance ♦ Work Orders ♦ Alignment
Bearings ♦
Flexible Belt Drives ♦ Preventive Maintenance Tests
Predictive Maintenance
Maintenance Technician Resources ♦
Technical Service Bulletins and Troubleshooting
Reports
Review Question Answer Key 643
Electrical Motor Controls for Integrated Systems, Fourth Edition, is the industry-leading reference for electrical, motor, and mechanical devices and their use in industrial control circuits. This book provides the architecture for acquiring the knowledge and skills required in an advanced manufacturing environment. The book begins with basic electrical and motor theory, builds on circuit fundamentals, and reinforces comprehension through examples of industrial applications.
Special emphasis is placed on the development of troubleshooting skills throughout the book. This book is a practical resource for technicians working in electrical, maintenance, manufacturing, industrial, boiler, and HVAC operations who have some background in electrical theory. Expanded content areas include the following:
Electrical safety, including NFPA® 70E, PPE, arc flash, and arc blast
AC and DC motor drives
Preventive and predictive maintenance systems
The latest in green technology and energy efficiency
Programmable logic relays
Electrical test tools and test instruments
Printreading
The Interactive CD-ROM included with the book is a study aid with the following features:
• Quick Quizzes® that reinforce fundamental concepts, with 10 questions per chapter
• An Illustrated Glossary of industry terms, with links to illustrations, video clips, and animated graphics
• Flash Cards that enable a review of common electrical terms, definitions, and test tools
• Review Questions that reinforce comprehension of motor control concepts, provided in Microsoft® Word format
• Applying Your Knowledge questions that provide interactive motor control exercises
• A Motor Control Library that provides access to interactive motor control resources
• Media Clips that depict electrical and motor control principles through video clips and animated graphics
• Access to ATPeResources.com, which provides a comprehensive array of instructional resources
To obtain information on related training products, visit the American Tech web site at www.go2atp.com
Chapter 1 Electrical Quantities and Circuits
All electrical circuits must have a source of power to produce work. Voltage is the amount of electrical pressure in a circuit. Current is the amount of electrons flowing through an electrical circuit. Current flows through a circuit when a power source is connected to a device that uses electricity.
Resistance limits the flow of current in an electrical circuit.
ENERGY
Energy is used to produce electricity. Energy is the capacity to do work. The two forms of energy are potential energy and kinetic energy. Potential energy is stored energy a body has due to its position, chemical state, or condition. For example, water behind a dam has potential energy because of its position. A battery has potential energy based on its chemical state. A compressed spring has potential energy because of its physical condition. Kinetic energy is the energy of motion. Examples of kinetic energy include falling water, a rotating motor, or a released spring. Kinetic energy is released potential energy. Energy released when water falls through a dam is used to generate electricity. Energy released when a motor is connected to a battery is used to produce a rotating mechanical force. Energy released by a compressed spring is used to apply a braking force on a motor shaft. The sources of energy used to produce electricity are coal, nuclear
power, natural gas, and oil. Wind, solar power, and water also provide energy. These energy sources are used to produce work when converted to electricity, steam, heat, and mechanical force. Some energy sources, such as coal, oil, and natural gas, are consumed in use. Energy sources such as wind, solar power, and water are not consumed in use. See Figure 1-1. Coal is used to produce approximately 50% of the electricity produced, nuclear power approximately 20%, natural gas approximately 18%, and oil approximately 3%. Wind, solar power, and water account for approximately 9% of the electricity produced. Wind and solar power are growing as sources of electricity. Electricity is converted into motion, light, heat, sound, and visual outputs. Approximately 62% of all electricity is converted into rotary motion by motors. Three-phase motors use the largest amount of electricity in commercial and industrial applications. Three-phase motors are used because they are the most energyefficient motors.
Approximately 20% of all electricity is converted into light by lamps. The most common lamp used in residential lighting is the incandescent lamp. The
most common lamps used in commercial and industrial lighting are fluorescent lamps for office installations and high-intensity discharge (HID) lamps for warehouse and factory installations. HID lamps include low-pressure sodium, mercury-vapor, metal-halide, and highpressure sodium lamps. HID lamps are also the most common lamps used for exterior lighting applications. Approximately 18% of all electricity is used to produce heat, linear motion, audible signals, and visual outputs. When the total number of individual electrical loads is considered, this group is the largest group of electricity-using components because it includes a large number of loads that consume very little power compared to motors.
Production of Electricity
Electricity is produced by converting potential energy directly or indirectly into electricity. For example, solar cells convert solar energy directly into electricity. The majority of all electricity is produced indirectly by converting potential energy into electricity using a generator. A generator (alternator)
is a device that converts mechanical energy into electrical energy by means of electromagnetic induction. A generator produces electricity when magnetic lines of force are cut by a rotating wire coil (rotor). The magnetic lines of force are produced by the magnetic field present between the north and south poles of a permanent magnet or electromagnet (stator). As the rotor rotates through the magnetic field, electric current flow is produced through the wire coil(s) of the rotor. See Figure 1-3. Electric current from the wire coil is conducted to the load through slip rings. The voltage produced by a generator depends on the strength of the magnetic field and the rotational speed of the rotor. The stronger the magnetic lines of force and the faster the rotational speed, the higher the voltage produced. The output of a generator may be connected directly to the load, as in a portable generator located on a construction site; connected to transformers; or connected to a rectifier, as in an automobile alternator. In large generator applications, the generator output is connected to transformers. A transformer is an electric device that uses electromagnetism to change voltage from one
level to another or to isolate one voltage from another. Transformers normally step up voltage so power can be transmitted at a lower current level. As AC voltage is increased, current is reduced for any fixed amount of power. Alternating current allows efficient transmission of electrical power between power stations and end users.
Reduced current allows small conductors to be used to conduct electricity. The conductor current rating depends on the wire size, insulation used, conductor temperature rating, and wire type (copper or aluminum). The allowable amount of current a wire may safely carry is listed in National Electrical Code® (NEC®) tables. An AC generator that has only one rotating coil produces a single-phase output. Single-phase generators are used for small power demands, but are not practical or economical for producing large amounts of power. To produce large amounts of power, three single-phase coils are coupled to produce three-phase power. The three separate coils are spaced 120 electrical degrees apart. The individual AC voltage outputs are phase 1 (A), phase 2 (B), and phase 3 (C).
Electrical Abbreviations/Prefixes
Electrical abbreviations are used to simplify the expression of common electrical terms and quantities. An abbreviation is a letter or combination of letters that represents a word. The exact abbreviation used normally depends on the use of the electrical unit. For example, voltage may be abbreviated using a capital letter E or V. A capital letter V is used to indicate voltage quantity because voltage is measured in volts. These abbreviations are often interchanged and both can be used to represent voltage. See Figure 1-5. Prefixes are used to avoid long expressions of units that are smaller or larger than the base unit. A base unit is a number that does not include a metric prefix. To convert between different units, the decimal point is moved to the left or right, depending on the unit. The decimal point is moved to the left and a prefix is added to convert a large base value to a simpler term. For example, 1000 V can be written as 1 kV. The decimal point is moved to the right and a prefix
is added to convert a small base value to a simpler term. For example, .001 V can be written as 1 mV.
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