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Industrial Electricity and Motor Controls, Second Edition
CITATION
Miller, Rex and
Miller, Mark
.
Industrial Electricity and Motor Controls, Second Edition
.
US
: McGraw-Hill Professional, 2013.
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Industrial Electricity and Motor Controls, Second Edition
Authors:
Rex Miller
and
Mark Miller
Published:
August 2013
eISBN:
9780071818704 0071818707
|
ISBN:
9780071818698
Open eBook
Book Description
Table of Contents
Cover
Title Page
Copyright Page
Contents
Preface
About the Authors
Acknowledgments
Introduction: A Quick Review of the Basics
Performance Objectives
What Is Electricity?
Elements and Atoms
Free Electrons
Current Flow
Energy
Electrical Materials
Conductors
Insulators
Semiconductors
Generating Electricity
Voltage and Current
Resistance
Wire Size
Copper versus Aluminum Wire
Circuits
Ohm’s Law
Using Ohm’s Law
Power
Kilowatts
Measuring Electricity
Meters
Other Types of Meters
Controlling Electricity
Switches
Solenoids
Relays
Diodes
Resistors
Resistor Color Code
Review Questions
Chapter 1: Tools and Equipment
Performance Objectives
Hand Tools
Screwdrivers
Pliers
Hammers
Hacksaws
Wrenches
Nut Drivers
Tools for Bearings and Bushings
Solderless Connector Crimper
Soldering Iron
Soldering Gun
Wire Gages
Fuse Puller
Tachometer
Knockout Punch
Fish Tape
Cable Stripper
Cable Cutter
Electrician’s Knives
Other Tools
Electrical Tools
Portable Ammeter and Voltmeter
Megohmmeter
Voltage Tester
Volt-Ohm-Milliammeter (VOM)
Digital Logic Probe
Continuity Tester
Polarized Plug Tester
Recorder
Oscilloscope
Phase Sequence Adapter
Balance Analyzer
Special Tools for Specific Jobs
Printed Circuit Board Puller
Wire Wrap/Unwrap Tool
Conduit Benders
PVC Cutters
Cable Benders
Conduit Reamer
Review Questions
Review Problems
Chapter 2: Safety in the Workplace
Performance Objectives
Electrical Shock
Electrical Safety Measures
Using Ground-Fault Circuit Interrupters
Safety Devices
Circuit Protection
Over currents
Overloads
Short Circuits
Fuses
Electrical Codes
National Electrical Codes
Underwriters Laboratories
Canadian Standards Association
Standards in Other Countries
OSHA
Equipment Standards
OSHA Color Code
Fire Extinguishers
Safe Working Practices
Tool Safety
Using Hammers Properly
Working Clothes
Disconnects
Using Motors and Generators Safely
Grounding
Review Questions
Review Problems
Chapter 3: Symbols
Performance Objectives
Electrical Symbols
Common Switch (Button) Symbols
Standard Wiring Diagram Symbols
Electronic Symbols
Resistor Color Code
Electronic Symbols Compared
Relay Contact Symbols
Line Diagrams, Wiring Diagrams, and Ladder Diagrams
Review Questions
Review Problems
Chapter 4: Control Circuits and Diagrams
Performance Objectives
Wiring Diagrams
Start Circuits
Line Diagram or Ladder Diagram
Undervoltage Release
Two-Wire Control Circuits
Thermostat Control
Undervoltage Protection
Three-Wire Control Circuits
Overcurrent Protection for Control Circuits
Transformers in Control Circuits
Review Questions
Review Problems
Chapter 5: Switches
Performance Objectives
Controlling Electricity
Drum Switch
Easy Conversion
Three-Phase Switching
DC Switching
Float Switches
Flow Switches
Foot Switches
Joystick
Interlock Switches
Mechanical Interlocking
Pushbutton Interlocking
Auxiliary Contact Interlocking
Limit Switches
Types of Limit Switches
Limit Switch Circuits
Pressure Switches
Pushbutton Switches
Safety Switches
Selector Switches
Single-Pole Switches
Start-Stop Switches
Temperature Switches
Toggle Switches
Transistor Switching
Vacuum Switches
Review Questions
Review Problems
Chapter 6: Magnetism and Solenoids
Performance Objectives
Solenoids
Solenoid Valves
Automatic Gas Furnace Solenoid
Construction of Solenoids
Eddy Currents in the Armature and Core
Air Gap and the Armature
Shading Coils
Solenoid Coils
Sealed Current Rating
Coil Voltage
Effects of Voltage Variation
Alternating Current Hum
Review Questions
Review Problems
Chapter 7: Relays
Performance Objectives
Relays
Relay Solenoids
Uses for Relays
Relay Armature
Relay Contacts
Solid-State Relays
Transistor
Surge Protection
Triacs
Silicon-Controlled Rectifiers
Phase-Failure Relays
Solid-State Monitoring Relays
Voltage Relay
Current Relay
Over/Under Relay
Types of Solid-State Relay Switching
Switching Relay Loads
Thermistor Relay
Contact Amplifier Relay
Load Detector and Load Converter Relays
Typical Applications
Thermal Overload Relays
Types of Thermal Overload Relays
Hand-Reset Melting Alloy (NEMA Style)
Bimetallic Overloads (NEMA Style)
Temperature Compensation
Electromagnetic Relays and Motors
Motor Winding Relays
Electromechanical Relays
Relay Operating Characteristics
Contact Life
Contact Construction
Relay Coils
Shock and Vibration
Relays and Altitude
Review Questions
Review Problems
Chapter 8: Electric Motors
Performance Objectives
Motor Classifications
DC Motors
Operating Principles
Counter Electromotive Force
Loads
Types of DC Motors
Series DC Motors
Shunt DC Motors
Compound DC Motors
Types of Armatures
Direction of Rotation
Motor Speed
Armature Reaction
Compensating Windings and Interpoles
DC Motor Starting Resistance
DC Motor Characteristics and Applications
Troubleshooting DC Motors
AC Motors
Types of AC Motors
Series AC Motor
Magnetic Fields in AC Motors
Rotating Magnetic Field: Two-Phase
Two-Phase Waveforms
Rotating Magnetic Field: Three-Phase
Synchronous Motors
Squirrel-Cage Motor
Starting the Synchronous Motor
Induction Motors
Stator Construction
Slip
Single-Phase Induction Motors
Split-Phase Induction Types
Shaded-Pole Induction Motors
Speed and Slip in Squirrel-Cage Motors
Rotation
Torque and Horsepower
Locked-Rotor Torque
Breakdown Torque
Locked-Rotor kVA/hp
Starting Squirrel-Cage Motors
Review Questions
Review Problems
Chapter 9: Timers and Sensors
Performance Objectives
Time and Timers
Dashpot or Pneumatic Time-Delay Timers
Synchronous Clock Timers
Solid-State Timers
Time-Delay Relays
General Purpose Timing Relays
Control of Programmable Timers
Digital Solid-State Timer/Counter
Single-Stage Version
Time/Count Modes
Dual-Stage Version
Thumbwheel Switches
DIP Switches
Pneumatic Timing Relays
Motor-Driven Timers
Sequence Control
Programmable Timers
Sensors
Solid-State Level Controls
Capacitance-Type Sensor
Temperature Sensing
Thermocouple
Thermistor
Resistance Temperature Devices
Semiconductor Temperature Sensor
Pressure Sensors
Strain Gage Transducers
Piezo-resistive Transducers
Review Questions
Review Problems
Chapter 10: Sensors and Sensing
Performance Objectives
Classes of Sensors
Contact Sensors
Noncontact Sensors
Presence Sensing
Limit Switches
Speed Switches
Operation of the Speed Switch
Pressure Controls
Theory of Operation
Temperature Controls
Wells and Packing Glands
Float Switches
Encoders
Optical Programmable Controller Encoders
Multiplexing
Proximity Switches
Operation
Solid-State Switches
Inductive Cylindrical Switch
Extended-Sensing-Range Inductive Proximity Switch
Compact Inductive Proximity Switch
Self-Contained Low Profile Proximity Switch
Photoelectric Switches
Operation
Features
Photoelectric Light Sources
Mark Sensors
Clear Material Detection
Switch Applications
Automatic Identification
Radio-frequency Identification Systems
The Antenna
The RF Tag
Bar Code Readers and Decoders
Handheld Scanners
Moving-Beam Scanners
Multiplexing
Vision System
Review Questions
Chapter 11: Solenoids and Valves
Performance Objectives
Solenoids
Industrial Solenoids
Tubular Solenoids
Frame Solenoids
Applications
Solenoids as Electromagnets
Solenoid Coils
Servicing Coils
Solenoid Valves in Circuits
Refrigeration Valve
Review Questions
Chapter 12: Motor Starting Methods
Performance Objectives
Electric Motors
Starting the Motor
Reversibility
Uses
Repulsion-Induction Motor
Uses
Capacitor-Start Motor
Reversibility
Uses
Permanent Split-Capacitor Motor
Shaded-Pole Motor
Reversibility
Uses
Split-Phase Motor
Polyphase Motor Starters
Reduced-Voltage Starting Methods
Primary Resistor Starting
Operation
Autotransformer Starting
Operation
Part-Winding Starting
Operation
Advantages and Disadvantages
Wye-Delta or Star-Delta Starters
Operation
Advantages and Disadvantages
Star-Delta (Wye-Delta) Connections
Multispeed Starters
Low-Speed Compelling Relay
Automatic Sequence Accelerating Relay
Automatic Sequence Decelerating Relay
Consequent-Pole Motor Controller
Full-Voltage Controllers
Starting Sequence
Protection Against Low Voltage
Time-Delay Protection
Review Questions
Chapter 13: Solid-State Reduced-Voltage Starters
Performance Objectives
Electromechanical Devices
Reduced-Voltage Starting
Silicon-Controlled Rectifiers
Solid-State Stepless Acceleration
Logic Rack
B-2 Module
B-3 Module
B-4 Module
B-5 Module
B-6 Module
B-7 Voltage Monitor Module
B-8 Energy-Saving Module
Shorted SCR Switch
Elementary Wiring Diagrams for Solid State
Diac
Triac
Light-Emitting Diodes
Using Solid-State Control and Electromagnetic Devices
Surge Suppressors
Lightning Protection
Review Questions
Chapter 14: Speed Control and Monitoring
Performance Objectives
Motor Speed Control
Squirrel-Cage Motors
Synchronous Motors
Excitation
Speed
Starting
Starting Methods
Uses for Synchronous Motors
Wound-Rotor Motors
Speed Regulation by Resistance
Types of Speed Control
Multiswitch Starters
Drum Controllers
Magnetic Starters
Resistors
Solid-State Adjustable-Speed Controllers
Frequency Speed Control
Multispeed Starters
Speed Monitoring
Review Questions
Chapter 15: Motor Control and Protection
Performance Objectives
Motor Control
Manual Starters
Solid-state Motor Controller
Sequence Control
When Starting Any One Requires Another
Automatic Sequence Control
Jogging
Forward or Reverse Jogging
Plugging
Plugging a Motor to Stop from Either Direction
Antiplugging
Braking
Electronic Motor Brake
Mechanical Braking
Thruster Brakes
Magnetic Brakes
Hydraulic Brakes
Motor Protection
Surge Protection and Backspin
Overload Protection
Automatic Reset Overload Relay
Inverse Time Current Relay
Solid-State, Line-Voltage and Line-Current Monitor Relays
Programmable Motor Protection
Protective Module
Remote Temperature Detector Module
Review Questions
Chapter 16: Three-Phase Controllers
Performance Objectives
The Three-Phase Motor
Starters
Simplest Type
Full-Voltage Reversing Starter
Forward-Reverse-Stop
Start-Stop Jog
Reversing Starter
Two-Speed Starter
Duplex Motor Controllers
Medium-Voltage Controllers
Solid-State Motor Controller
Modules
Solid-State Advantages
Motor Control Centers
Review Questions
Chapter 17: Drives
Performances Objectives
Fans, Blowers, and Pumps
Adjustable-Speed Drives
Adjustable-Frequency AC Drives
CSI Inverters
Variable-Voltage Inverters
Pulse-Width-Modulated Inverters
Eddy Current Drives
Variable-Pitch Drives
Wound-Rotor AC Motor Drives
DC Drives
Regulated Speed Drives
Open-Loop Controls (Traditional Approach)
Closed-Loop Controls
DC Drives: Advantages and Disadvantages
DC Drives and Systems
Solid-State Digital AC Drives
Review Questions
Chapter 18: Transformers
Performance Objectives
Transformers
Iron-Core Transformer
Turns Ratio
Autotransformers
Turns Ratio
Transformer Losses
Eddy Current Losses
Hysteresis Losses
Copper Losses
Core Construction
Transformer Oil
EPA Highlights
Autotransformers: Three- and Single-Phase
Impedances
Third Harmonics
Grounding
Buck and Boost Transformers
Calculating the Load
Calculating Single-Phase Kilovolt-Amperes
Three-Phase Buck and Boost Transformers
Calculating Three-Phase Kilovolt-Amperes
Dry-Type Transformers
Cooling
Insulation and Temperature Rise
Taps
Special Transformers
Liquid-Filled Transformers
Safety Notice
Submersible Transformer
Maintenance
Transformer Applications
Distributing Power at High Voltages
Double-Wiring Elimination
Operating 120/240-V Equipment from Power Circuits
Isolating Circuits
Changing from a Four-Wire to Three-Wire Circuit
Stepping-Up or Stepping-Down Voltage
Motor Transformers
Harmonic Mitigating Transformers and AC Line Reactors
Harmonic Mitigating Transformers
Line Reactors
Review Questions
Review Problems
Chapter 19: Power Generation
Performance Objectives
Basic Principle
Sine Wave
Components of the Alternator
Rotors
Stators
Exciters
Types of Alternators
Single-Phase
Two-Phase
Three-Phase
Wye and Delta Configurations
Wye Connection
Delta Connection
Power in a Balanced Wye
Power in a Balanced Delta
Frequency
Load Changes
Armature Resistance
Armature Reactance
Armature Reaction
Voltage Regulation
Standby or Emergency Power Sources
Transfer Switch
Types of Standby Generators
Automatic Transfer Switches
Electronic Loads
Uninterruptible Power Systems
Multiple-Engine Generator Sets
Systems for Paralleling Multiple Power Sources
Selective Load Transfer Systems
Prime Mover Systems
Two-Source Systems
Multiple-Source Systems
Power Management Systems
Peak Load-Sharing Systems
Utility-Isolated Peaking Transfer System
Utility-Paralleled Peaking Systems
Review Questions
Review Problems
Chapter 20: Power Distribution Systems
Performance Objectives
Sources of Commercial AC
Falling-Water Generators
Switchyard
Nuclear Power Generators
Fossil-Fuel Power Generators
Distribution
Types of Distribution Systems
Systems Analysis
Short-Circuit Currents
Fault Currents
Three-Phase Power
Measurement of Power
Transformers
Transformer Construction
Three-Phase Transformer Connections
Switching
Automatic Emergency Power Switching
Switchboards
Panel Boards
Raceways
Aluminum Lay-In Wall Duct and Floor Trench Duct
Cable Tray
Review Questions
Review Problems
Chapter 21: Programmable Controllers
Performance Objectives
NEMA PLC Definition
Solid-State Electronics
Standard Electronic Features in Controls
The Programmable Controller
Input-Output
Interfacing
ASCII Code
Parallel Ports
Serial Ports
The Environment Affects Performance
Electrical Noise
Installation Practices
Grounding
Solid-State Reliability
Backup Operations
Controllers
System Hardware and Programming Equipment
Processors
Input-Output Modules
Intelligent I/O Modules
Display Systems
Cell Controllers
Micro-Cell Controller
Local Area Network
Low Voltage Motor Control Centers
Future of PLCs
Review Questions
Chapter 22: Robots and Robotics
The Robot as a System
Robot History
Classifying Robots
The Explorer Robot
The Classroom Robot
The Entertainment Robot
Work Envelope
Robot Motion Capabilities
Four Systems Classifications for the Arm
Drive Systems for Robots
End-Effectors
Limit Switches
Sensors
LEDs
Proximity Sensors
Power for Robots
Electric Motors
Servo-Controlled Robots
Actuators
Controllers
Microprocess-Based Controllers
Teach Pendant
Programming the Computer to Control the Robot
Software and Computer Code
Sensor Inputs
Vision Systems
Parts Handling
Line Tracking
Computer Integrated Manufacturing
Review Questions
Chapter 23: Troubleshooting and Maintenance
Performance Objectives
Troubleshooting and the Electrician
Preventive Maintenance
Damp and Wet Areas
Prevention of Accidental Shock
Ground-Fault Receptacles
Wiring Devices
Maintenance of Small Electric Motors
Adequate Wiring
Check Internal Switches
Check Load Condition
Extra Care in Lubrication
Keep Commutators Clean
Motors Must Have Proper Service Rating
Replace Worn Brushes
Motor Problems
Ball Bearing Motors
Sleeve Bearing Motors
Common Motor Problems and Their Causes
Problem Diagnosis
Centrifugal Switches
Commutator-Type Motors
Troubleshooting Aids
Connection Diagrams
Small Three-Phase Motor Rating Data
Power Supply Disturbances
Voltage Fluctuations
Transients
Power Outages
Looking for Shorts
Motors with Squirrel-Cage Rotors
Testing the Centrifugal Switch in a Single-Phase Motor
Testing for Short Circuits between Run and Start Windings
Capacitor Testing
Measuring Capacity of a Capacitor
Using Meters to Check for Problems
Using a Volt-Ammeter for Troubleshooting Electric Motors
Clamp-On Volt-Ammeter
Looking for Grounds
Looking for Opens
Troubleshooting Guide
Motor Life
Ventilation
Ambient Temperature
Performance Characteristics
Voltage Unbalance
Motor Protection
DC Motor Problems
Solid-State Equipment Troubleshooting
Review Questions
Chapter 24: Careers in Electricity
Performance Objectives
Industrial Electrician
Industries that Employ Electricians
Careers in Electricity
Electrical Engineer
Construction Electrician
Maintenance Electrician
Limited Energy Electrician
General Information
Information Sources
Starting Your Own Business
The Development of Leadership
Employment of Electricians
Earnings
Related Occupations
The Future
Sources of Additional Information
Appendices
I. DC Motor Trouble Chart
II. Wound-Rotor Motor Trouble Chart
III. Fractional-Horsepower Motor Trouble Chart
IV. Selection of Dual-Element Fuses for Motor-Running Overload Protection
V. Tables and Formulas
VI. Full-Load Currents of AC and DC Motors
VII. Power Factor Correcting Capacitors
VIII. Switch Symbols
IX. Wiring Diagram Symbols
X. Unit Prefixes
XI. Conversion Factors
XII. Decibel Table
XIII. Electrical and Electronic Symbols Used in Schematics
Glossary
Answers to Review Questions and Problems
Index
Color Inserts
