Emcfm by American Technical Publishers

AMERICAN TECHNICAL PUBLISHERS Orland Park, Illinois 60467-5756

Gary J. Rockis Glen A. Mazur

Electrical Motor Controls for Integrated Systems, contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained herein is intended to be an educational resource for the user. American Technical Publishers, Inc. assumes no responsibility or liability in connection with this material or its use by any individual or organization. American Technical Publishers, Inc., Editorial Staff Editor in Chief: Jonathan F. Gosse Vice President — Production: Peter A. Zurlis Art Manager: Jennifer M. Hines Multimedia Manager: Carl R. Hansen Technical Editor: Scott C. Bloom Copy Editor: Dane K. Hamann Cover Design: Melanie G. Doornbos Illustration/Layout: Nicholas W. Basham Joshua P. Hugo Mark S. Maxwell Robert M. McCarthy Thomas E. Zabinski DVD Development: Cory S. Butler Kathryn C. Deisinger Daniel Kundrat Kathleen A. Moster Nicole S. Polak Robert E. Stickley Microsoft, Windows, Windows Vista, PowerPoint, and Internet Explorer are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Adobe, Acrobat, and Reader are registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Intel is a registered trademark of Intel Corporation in the United States and/or other countries. Apple, Macintosh, Mac, Mac OS, and Safari are registered trademarks of Apple, Inc. Firefox is a registered trademark of the Mozilla Foundation. PowerPC is a registered trademark of International Business Machines Corporation. AEMC Instruments is a registered trademark of AEMC Corporation. Basofil is a registered trademark of BASO Fibers. LLC Limited Partnership. Kevlar is a registered trademark of E. I. Du Pont de Nemours and Company. National Electrical Code (NEC) is a registered trademark of the National Fire Protection Association, Inc. NEMA Premium is a trademark of the National Electrical Manufacturers Association. NFPA 70E is a registered trademark of National Fire Protection Association, Inc. Nomex is a registered trademark of E. I. Du Pont de Nemours and Company. Scopemeters is a registered trademark of Fluke Corporation. UL is a registered trademark of the Uni-Loc Corp. of America. Underwriters Laboratories Inc. is a registered trademark of Underwriters Laboratories Inc. Velcro is a registered trademark of Velcro Industries. Wiggy is a registered trademark of Peavey Electronics Corporation. Quick Quiz, Quick Quizzes, and Master Math are either registered trademarks or trademarks of American Technical Publishers, Inc.

This book is printed on recycled paper.

The authors and publisher are grateful to the following companies and organizations for providing information, photographs, and technical assistance.

• • • • • • • • • • • • • • • • • • • • • • • • • • •

ABB Inc., Drives and Power Electronics ABB Power T&D Company Inc. AEMC® Instruments Alemite Corp. Amprobe | Advanced Test Products ASI Robicon Bacharach, Inc. Baldor Electric Company Banner Engineering Canadian National Railway Company Carlo Gavazzi Inc. Carlo Gavazzi Inc. Electromatic Business Unit Cutler-Hammer Datastream Systems, Inc. Eagle Signal Industrial Controls East Penn Manufacturing Co., Inc. Electrical Apparatus Service Association, Inc. FANUC Robotics North America Fluke Corporation Furnas Electric Co. GE Motors & Industrial Systems General Electric Company Grayhill Inc. Greenlee Textron Inc. Guardian Electric Mfg. Co. Hand Held Products Harrington Hoists, Inc.

• • • • • • • • • • • • • • • • • • • • • • • • • •

Heidelberg Harris, Inc. Honeywell’s MICRO SWITCH Division Honeywell Sensing and Control IBM Ideal Industries, Inc. International Rectifier Justrite Manufacturing Company The Lincoln Electric Company March Manufacturing, Inc. Milwaukee Electric Tool Corporation Omron Electronics LLC Pacific Bearing Company Panduit Corp. Predict/DLI Products Unlimited Rockwell Automation, Allen-Bradley Company, Inc. Rockwell Automation/Reliance Electric Rofin Sinar Saftronics Inc. Siemens SMA America, Inc. Sprecher & Scuh Square D Company The Stanley Works Teco UE Systems, Inc.

Chapter

1 2 3 4

Electrical Quantities and Basic Circuits 1-1 Electrical Theory ��3 1-2 Circuits ��18 1-3 Magnetism ��25 1-4 Power ��32

Symbols and Diagrams

2-1 Language of Control ��39 2-2 Electrical Circuits ��47

Test Instruments

3-1 Safety ��59 3-2 General Use Test Instruments ��62 3-3 Specialty Test Instruments ��80

Electrical Safety

4-1 Electrical Safety ��87 4-2 Lockout/Tagout ��92 4-3 Personal Protective Equipment ��95 4-4 Fire Safety ��104 4-5 Confined Spaces ��108 4-6 Overhead Power Line Safety ��110

Control Logic

114

5-1 Basic Rules of Line Diagrams ��115 5-2 Line Diagrams — Signals, Decisions, and Actions ��123 5-3 Logic Functions ��124 5-4 Common Control Circuits ��130 5-5 Control Circuit Troubleshooting ��134

Chapter

7 8 9 10

Mechanical Input Control Devices

140

6-1 Industrial Pushbuttons ��141 6-2 Selector Switches ��145 6-3 Joysticks ��147 6-4 Limit Switches ��148 6-5 Foot Switches ��154 6-6 Pressure Switches ��155 6-7 Temperature Switches ��159 6-8 Flow Switches ��161 6-9 Level Switches ��164 6-10 Preventing Problems When Installing Control Devices ��168

Solenoids

172

7-1 Electromagnets ��173 7-2 Solenoids ��174 7-3 Solenoid Characteristics ��177 7-4 Solenoid Applications ��179 7-5 Troubleshooting Solenoids ��184

Electromechanical Relays

188

8-1 Electromechanical Relays ��189 8-2 Types of Electromechanical Relays ��190 8-3 Troubleshooting Electromechanical Relays ��197

DC Generators

202

9-1 DC Generator Components ��203 9-2 DC Generator Types ��206

AC Generators

210

10-1 AC Generator Components ��211 10-2 AC Generator Types ��212 10-3 Voltage Changes ��220

Chapter

11 12 13 14 15 16

Transformers

224

11-1 Transformers ��225 11-2 Transformer Connections ��229 11-3 Transformer Selection ��232 11-4 Troubleshooting Transformers ��233

Contactors and Magnetic Motor Starters

236

12-1 Manual Switching ��237 12-2 Manual Contactors ��238 12-3 Manual Starters ��241 12-4 Magnetic Contactors ��247 12-5 Magnetic Motor Starters ��256 12-6 Contactor and Magnetic Motor Starter Modifications ��265 12-7 Troubleshooting Contactors and Motor Starters ��267

DC Motors

272

13-1 DC Motor Operation ��273 13-2 DC Motor Construction ��275 13-3 DC Motor Types ��277 13-4 Stepper Motors ��282 13-5 DC Motor Load Requirements ��286 13-6 Troubleshooting DC Motors ��290

AC Motors

296

14-1 AC Motor Types ��297 14-2 AC Motor Maintenance ��306 14-3 Troubleshooting AC Motors ��310

Reversing Motors

322

15-1 Reversing Motors Using Manual Starters ��323 15-2 Reversing Motors Using Drum Switches ��328 15-3 Reversing Motors Using Magnetic Starters ��331 15-4 Magnetic Reversing Starter Applications ��334 15-5 Motor Control Wiring Methods ��337 15-6 Troubleshooting Reversing Power Circuits ��342

Timing and Counting Functions

346

16-1 Timers ��347 16-2 Timing Functions ��350 16-3 Multiple-Contact Timers ��359 16-4 Troubleshooting Contact-Based Timing Circuits ��363 16-5 Counters and Totalizers ��370

Chapter

17 18 19

20 21

Motor Stopping Methods

374

17-1 Friction Brakes ��375 17-2 Plugging ��377 17-3 Electric Braking ��379 17-4 Dynamic Braking ��381

Motor Load, Torque, and Power Quality Requirements 384 18-1 Understanding Motor Loads and Torque Requirements ��385 18-2 Power Quality ��387 18-3 Motor Loads ��392 18-4 Motor Torque Types ��394 18-5 Open and Closed Circuit Transition ��398

Reduced-Voltage Starting Circuits

400

19-1 Reduced-Voltage Starting ��401 19-2 DC Motor Reduced-Voltage Starting ��403 19-3 Reduced-Voltage Starting for Three-Phase Induction Motors ��406 19-4 Primary Resistor Starting ��407 19-5 Autotransformer Starting ��408 19-6 Part-Winding Starting ��410 19-7 Wye-Delta Starting ��413 19-8 Starting Method Comparison ��415 19-9 Troubleshooting Reduced-Voltage Starting Circuits ��418

DC Power Sources

422

20-1 Rectifiers ��423 20-2 DC Power Supply Filters ��427 20-3 Voltage Regulators ��430 20-4 Fuel Cells ��431 20-5 Photovoltaic Cells ��432 20-6 Troubleshooting DC Power Supplies ��434

Semiconductor Input Devices

438

21-1 Thermistors ��439 21-2 Photoconductive Cells ��441 21-3 Photoconductive Diodes ��443 21-4 Pressure Sensors ��444 21-5 Flow Detection Sensors ��445 21-6 Hall Effect Sensors ��447 21-7 Proximity Sensors ��453 21-8 Ultrasonic Sensors ��455

Chapter

Semiconductor Amplification and Switching

458

22-1 Amplification ��459 22-2 Operational Amplifiers ��463 22-3 Field-Effect Transistors ��468 22-4 Troubleshooting Insulated Gate Bipolar Transistors ��477

Chapter

23 24 25 26 27

Semiconductor Power Switching Devices

480

23-1 Solid-State Switches ��481 23-2 Silicon-Controlled Rectifiers ��484 23-3 Triacs ��491 23-4 Diacs ��494 23-5 Unijunction Transistors ��496

Photoelectric Semiconductors, Fiber Optics, and Light-Based Applications

500

24-1 Photoelectric Devices ��501 24-2 Photoelectric Sensors ��505 24-3 Fiber Optics ��510 24-4 Photoelectric Sensor Applications ��511 24-5 Photoelectric Control Applications ��520

Solid-State Relays and Starters

524

25-1 Solid-State Relays ��525 25-2 Electromechanical and Solid-State Relay Comparison ��537 25-3 Troubleshooting Solid-State Relays ��540 25-4 Solid-State Motor Starters ��544

Motor Drives

554

26-1 Motor Drives ��555 26-2 Programming Motor Drives ��561 26-3 DC Motor Drives ��565 26-4 AC Motor Drives ��568 26-5 Troubleshooting Motor Drive Circuits ��584

Programmable Controllers

594

27-1 Programmable Controllers ��595 27-2 Programmable Controller Sections ��603 27-3 Programmable Controller Applications ��622 27-4 Troubleshooting Programmable Controllers ��632

Chapter

28 29 30

638

Power Distribution and Smart Grid Systems 28-1 Electrical Power Distribution � 28-2 Distribution Transformers � � 28-3 Power Quality Problems � � � 28-4 Smart Grids � � � � � � � � � �

� � � �

680

Preventive Maintenance Systems 29-1 Preventive Maintenance Principles 29-2 Alignment � � � � � � � � � � � � � � 29-3 Bearings � � � � � � � � � � � � � � � 29-4 Flexible Belt Drives � � � � � � � � � 29-5 Preventive Maintenance Tests � � �

Predictive Maintenance

� � � � �

639 653 662 672

� � � � �

681 687 693 698 702

708

30-1 Predictive Maintenance Monitoring � � � � � � � � � � � � � � � � � 709 30-2 Maintenance Technician Resources � � � � � � � � � � � � � � � � � 714

Appendix

719

Glossary

741

Index

757

Interactive DVD Contents • Quick Quizzes® • Illustrated Glossary • Flash Cards • Checkpoints

• Interactive Motor Control Enclosure • Applying Your Knowledge • Media Library • ATPeResources�com

Electrical Motor Controls for Integrated Systems is the industry-leading textbook covering electrical, motor, and mechanical devices and their use in industrial control circuits. This textbook provides the structure and content for acquiring the knowledge and skills required in an advanced manufacturing environment. In these fast-changing environments, technicians must be competent in various aspects of mechanical, electrical, and ﬂuid power systems for successful productivity. The textbook also serves as a practical resource for maintenance technicians responsible for production and HVAC equipment. Featuring a new open design, the textbook offers proven and thoroughly updated content in a new format organized into sections based on specific topics. The textbook 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. Expanded content in this edition includes the following: • Electrical safety information on NFPA® 70E, PPE, arc ﬂashes, and arc blasts • Smart grid systems • Energy effi ciency applications • Electrical test instruments Each chapter includes checkpoint questions to reinforce key concepts, Energy Efficiency Practices, and Applying Your Knowledge questions to reinforce key motor control concepts on the Interactive DVD. Answers to the checkpoint questions are located in the Answer Keys. The Appendix contains many useful tables, charts, and formulas. Sections segment each chapter into discrete topics

Section objectives identify the main concepts addressed within that section of the chapter

Chapter introductions preview content to be covered

Checkpoint questions reinforce comprehension of section content

QR Codes at the end of each chapter enable quick access to digital resources

Industrial test instruments are shown in common troubleshooting applications

Energy EfďŹ ciency Practices provide information on topics related to energy efďŹ ciency

Tech Facts provide supplemental information related to topics presented Industrial application photos supplement text and illustrations

The Interactive DVD included with this textbook provides an array of learning tools that reinforce and enhance the information detailed in the book. Information about using the Electrical Motor Controls for Integrated Systems Interactive DVD is included on the last page.

The Interactive DVD is a self-study aid that includes the following: • Quick Quizzes® that provide 20 interactive questions per chapter with embedded links to highlighted content within the textbook and to the Illustrated Glossary. • Illustrated Glossary that provides a helpful reference to commonly used terms. Selected terms are linked to interactive illustrations or media clips. • Flash Cards that provide a self-study/review tool to identify common electrical terms, definitions, industrial electrical symbols, and test tools and equipment. • Checkpoints are questions that allow learners to demonstrate knowledge of section content. • Interactive Motor Control Enclosure that allows learners to interactively assemble and wire a motor control enclosure. • Applying Your Knowledge questions that provide interactive motor control activities. • Media Library that consists of animated illustrations and video clips that reinforce textbook content. • ATPeResources.com, which links to online instructional resources that support continued learning.

Quick Response (QR) codes, located at the end of each chapter, offer easy access to related information via the Internet using mobile device technology. To access content using a QR code, follow these steps: 1. Download a QR code reader app to a mobile device. (Visit atplearning.com/QR for more information.) 2. Open the app and scan the QR code on the book page. 3. Instantly access the digital content.

Workbook The Electrical Motor Controls for Integrated Systems Workbook reinforces concepts and provides design activities for systems included in the fifth edition of Electrical Motor Controls for Integrated Systems. The Workbook contains both Tech-Cheks and Worksheets for each chapter. • Tech-Cheks provide multiple choice, completion, and/or matching questions that reinforce comprehension of key concepts. • Worksheets provide opportunities to apply electrical motor control concepts to practical design problems. The Electrical Motor Controls for Integrated Systems Workbook also includes Certificates of Completion that can be used to document the knowledge and skills learned in four areas: motor control principles, motor control devices, motor control circuits, and motor control methods.

Applications Manual The Electrical Motor Controls for Integrated Systems Applications Manual expands upon the concepts and provides both applications and activities that build on the knowledge and skills acquired using Electrical Motor Controls for Integrated Systems. The Applications Manual contains both applications and activities. • Applications present technical, manufacturing, and troubleshooting data as it appears in service manuals used by industrial electricians. Selected motor control topics highlight the proper use, sizing, connection, and troubleshooting of electrical motor control devices. • Activities offer opportunities for learners to order, install, maintain, and troubleshoot electrical motor control devices and circuits in real-world scenarios. Questions within the activities include identification, completion, short answer, calculations, diagrams, and schematics.

Instructor’s Resource Guide The Electrical Motor Controls for Integrated Systems Instructor’s Resource Guide serves as the primary organizational tool for the instructor. The Interactive DVD and guide provide a comprehensive teaching resource including PowerPoint® Presentations, an Instructional Guide, an Image Library, Assessments, and Answer Keys.

• PowerPoint® Presentations review key concepts in each section and chapter of Electrical Motor Controls for Integrated Systems. PowerPoint® Presentation notes are also provided. • Instructional Guide explains how to best use all the learning tools and resources provided, including detailed Instructional Plans for each chapter. • Image Library provides all of the numbered figures in Electrical Motor Controls for Integrated Systems in a classroom-friendly format. • Assessments are sets of questions based on objectives and key concepts from each chapter and consist of a pretest, posttest, and test banks. The test banks can be used with most test development software packages. • Answer Keys list answers to questions in the pretest, posttest, textbook, workbook, and applications manual.

To obtain information on related products visit the American Technical Publishers website at www.atplearning.com. The Publisher