Emcwbfm by American Technical Publishers

AMERICAN TECHNICAL PUBLISHERS Orland Park, Illinois 60467-5756

Gary J. Rockis Glen A. Mazur

Electrical Motor Controls for Integrated Systems Workbook 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.

National Electrical Code and NEC are registered trademarks of the National Fire Protection Association, Inc., Quincy, MA 02269.

This book is printed on recycled paper.

Electrical Quantities and Basic Circuits Tech-Chek 1_________________________________________________________________________ 1 Worksheets Section 1-1: Electrical Theory_________________________________________________________ 5 Section 1-2: Circuits_________________________________________________________________ 7 Section 1-3: Magnetism_____________________________________________________________ 14 Section 1-4: Power__________________________________________________________________ 15

Symbols and Diagrams Tech-Chek 2________________________________________________________________________ 17 Worksheets Section 2-1: Language of Control____________________________________________________ 19 Section 2-2: Electrical Circuits_______________________________________________________ 24

Test Instruments Tech-Chek 3________________________________________________________________________ Worksheets Section 3-1: Safety__________________________________________________________________ Section 3-2: General Use Test Instruments____________________________________________ Section 3-3: Specialty Test Instruments_______________________________________________

33 35 36 39

Electrical Safety Tech-Chek 4________________________________________________________________________ Worksheets Section 4-1: Electrical Safety________________________________________________________ Section 4-2: Lockout/Tagout_________________________________________________________ Section 4-3: Personal Protective Equipment__________________________________________ Section 4-4: Fire Safety______________________________________________________________ Section 4-5: Confined Spaces________________________________________________________ Section 4-6: Overhead Power Line Safety_____________________________________________

41 45 47 50 51 52 53

Control Logic Tech-Chek 5________________________________________________________________________ Worksheets Section 5-1: Basic Rules of Line Diagrams____________________________________________ Section 5-2: Line Diagrams — Signals, Decisions, and Action___________________________ Section 5-3: Logic Functions________________________________________________________ Section 5-4: Common Control Circuits________________________________________________ Section 5-5: Control Circuit Troubleshooting__________________________________________

55 59 65 66 73 81

Mechanical Input Control Devices Tech-Chek 6________________________________________________________________________ Worksheets Section 6-1: Industrial Pushbuttons__________________________________________________ Section 6-2: Selector Switches_______________________________________________________ Section 6-3: Joysticks_______________________________________________________________ Section 6-4: Limit Switches__________________________________________________________ Section 6-5: Foot Switches__________________________________________________________ Section 6-6: Pressure Switches______________________________________________________ Section 6-7: Temperature Switches___________________________________________________ Section 6-8: Flow Switches__________________________________________________________ Section 6-9: Level Switches_________________________________________________________ Section 6-10: Preventing Problems When Installing Control Devices____________________

83 87 88 89 90 91 92 94 97 98 99

7 Solenoids Tech-Chek 7_______________________________________________________________________ Worksheets Section 7-1: Electromagnets________________________________________________________ Section 7-2: Solenoids_____________________________________________________________ Section 7-3: Solenoid Characteristics_______________________________________________ Section 7-4: Solenoid Applications__________________________________________________ Section 7-5: Troubleshooting Solenoids_____________________________________________

101 105 106 107 109 111

Electromechanical Relays Tech-Chek 8_______________________________________________________________________ Worksheets Section 8-1: Electromechanical Relays______________________________________________ Section 8-2: Types of Electromechanical Relays______________________________________ Section 8-3: Troubleshooting Electromechanical Relays______________________________

113 115 116 119

DC Generators Tech-Chek 9_______________________________________________________________________ 121 Worksheets Section 9-1: DC Generator Components_____________________________________________ 123 Section 9-2: DC Generator Types____________________________________________________ 124

10 AC Generators Tech-Chek 10______________________________________________________________________ Worksheets Section 10-1: AC Generator Components____________________________________________ Section 10-2: AC Generator Types___________________________________________________ Section 10-3: Voltage Changes______________________________________________________

125 127 128 129

11 Transformers Tech-Chek 11______________________________________________________________________ Worksheets Section 11-1: Transformers_________________________________________________________ Section 11-2: Transformer Connections______________________________________________ Section 11-3: Transformer Selection_________________________________________________ Section 11-4: Troubleshooting Transformers_________________________________________

131 133 134 137 140

12 Contactors and Magnetic Motor Starters Tech-Chek 12______________________________________________________________________ Worksheets Section 12-1: Manual Switching_____________________________________________________ Section 12-2: Manual Contactors____________________________________________________ Section 12-3: Manual Starters_______________________________________________________ Section 12-4: Magnetic Contactors__________________________________________________ Section 12-5: Magnetic Motor Starters_______________________________________________ Section 12-6: Contactor and Magnetic Motor Starter Modifications____________________ Section 12-7: Troubleshooting Contactors and Motor Starters_________________________

141 145 147 148 149 151 153 154

13 DC Motors Tech-Chek 13______________________________________________________________________ Worksheets Section 13-1: DC Motor Operation___________________________________________________ Section 13-2: DC Motor Construction________________________________________________ Section 13-3: DC Motor Types_______________________________________________________ Section 13-4: Stepper Motors_______________________________________________________ Section 13-5: DC Motor Load Requirements_________________________________________ Section 13-6: Troubleshooting DC Motors____________________________________________

155 159 160 161 162 163 164

14 AC Motors Tech-Chek 14______________________________________________________________________ Worksheets Section 14-1: AC Motor Types_______________________________________________________ Section 14-2: AC Motor Maintenance________________________________________________ Section 14-3: Troubleshooting AC Motors____________________________________________

165 167 169 170

15 Reversing Motors Tech-Chek 15______________________________________________________________________ Worksheets Section 15-1: Reversing Motors Using Manual Starters_______________________________ Section 15-2: Reversing Motors Using Drum Switches________________________________ Section 15-3: Reversing Motors Using Magnetic Starters_____________________________ Section 15-4: Magnetic Reversing Starter Applications_______________________________ Section 15-5: Motor Control Wiring Methods_________________________________________ Section 15-6: Troubleshooting Reversing Power Circuits______________________________

173 177 179 180 184 186 190

16 Timing and Counting Functions Tech-Chek 16______________________________________________________________________ Worksheets Section 16-1: Timers_______________________________________________________________ Section 16-2: Timing Functions_____________________________________________________ Section 16-3: Multiple-Contact Timers_______________________________________________ Section 16-4: Troubleshooting Contact-Based Timing Circuits_________________________ Section 16-5: Counters and Totalizers_______________________________________________

193 197 198 203 208 212

17 Motor Stopping Methods Tech-Chek 17______________________________________________________________________ Worksheets Section 17-1: Friction Brakes_______________________________________________________ Section 17-2: Plugging_____________________________________________________________ Section 17-3: Electric Braking______________________________________________________ Section 17-4: Dynamic Braking_____________________________________________________

213 215 216 221 222

18 Motor Load, Torque, and Power Quality Requirements Tech-Chek 18______________________________________________________________________ Worksheets Section 18-1: Understanding Motor Loads and Torque Requirements__________________ Section 18-2: Power Quality________________________________________________________ Section 18-3: Motor Loads__________________________________________________________ Section 18-4: Motor Torque Types___________________________________________________ Section 18-5: Open and Closed Circuit Transition_____________________________________

223 227 228 230 232 234

19 Reduced-Voltage Starting Circuits Tech-Chek 19______________________________________________________________________ Worksheets Section 19-1: Reduced-Voltage Starting_____________________________________________ Section 19-2: DC Motor Reduced-Voltage Starting____________________________________ Section 19-3: Reduced-Voltage Starting for 3Ď&#x2020; Induction Motors_______________________ Section 19-4: Primary Resistor Starting_____________________________________________ Section 19-5: Autotransformer Starting______________________________________________ Section 19-6: Part-Winding Starting_________________________________________________ Section 19-7: Wye-Delta Starting____________________________________________________ Section 19-8: Starting Method Comparison__________________________________________ Section 19-9: Troubleshooting Reduced-Voltage Starting Circuits_____________________

235 239 242 244 245 246 247 248 249 250

20 DC Power Sources Tech-Chek 20______________________________________________________________________ Worksheets Section 20-1: Rectifiers_____________________________________________________________ Section 20-2: DC Power Supply Filters_______________________________________________ Section 20-3: Voltage Regulators____________________________________________________ Section 20-4: Fuel Cells____________________________________________________________ Section 20-5: Photovoltaic Cells____________________________________________________ Section 20-6: Troubleshooting DC Power Supplies____________________________________

253 257 258 259 260 261 262

21 Semiconductor Input Devices Tech-Chek 21______________________________________________________________________ Worksheets Section 21-1: Thermistors__________________________________________________________ Section 21-2: Photoconductive Cells________________________________________________ Section 21-3: Photoconductive Diodes______________________________________________ Section 21-4: Pressure Sensors_____________________________________________________ Section 21-5: Flow Detection Sensors_______________________________________________ Section 21-6: Hall Effect Sensors___________________________________________________ Section 21-7: Proximity Sensors____________________________________________________ Section 21-8: Ultrasonic Sensors___________________________________________________

265 269 270 271 272 273 274 275 281

22 Semiconductor Amplification and Switching Tech-Chek 22______________________________________________________________________ Worksheets Section 22-1: Amplification_________________________________________________________ Section 22-2: Operational Amplifiers________________________________________________ Section 22-3: Field-Effect Transistors________________________________________________ Section 22-4: Troubleshooting Insulated Gate Bipolar Transistors_____________________

283 285 287 288 289

23 Semiconductor Power Switching Devices Tech-Chek 23______________________________________________________________________ Worksheets Section 23-1: Solid-State Switches__________________________________________________ Section 23-2: Silicon-Controlled Rectifiers___________________________________________ Section 23-3: Triacs________________________________________________________________ Section 23-4: Diacs________________________________________________________________ Section 23-5: Unijunction Transistors________________________________________________

291 293 294 295 296 297

Photoelectric Semiconductors, Fiber Optics, 24 and Light-Based Applications Tech-Chek 24______________________________________________________________________ Worksheets Section 24-1: Photoelectric Devices_________________________________________________ Section 24-2: Photoelectric Sensors_________________________________________________ Section 24-3: Fiber Optics__________________________________________________________ Section 24-4: Photoelectric Sensor Applications_____________________________________ Section 24-5: Photoelectric Control Applications_____________________________________

299 301 302 303 304 306

25 Solid-State Relays and Starters Tech-Chek 25______________________________________________________________________ Worksheets Section 25-1: Solid-State Relays____________________________________________________ Section 25-2: Electromechanical and Solid-State Relay Comparison___________________ Section 25-3: Troubleshooting Solid-State Relays____________________________________ Section 25-4: Solid-State Motor Starters_____________________________________________

309 311 314 316 317

26 Motor Drives Tech-Chek 26______________________________________________________________________ Worksheets Section 26-1: Motor Drives_________________________________________________________ Section 26-2: Programming Motor Drives____________________________________________ Section 26-3: DC Motor Drives______________________________________________________ Section 26-4: AC Motor Drives______________________________________________________ Section 26-5: Troubleshooting Motor Drive Circuits___________________________________

319 323 329 331 333 335

27 Programmable Controllers Tech-Chek 27______________________________________________________________________ Worksheets Section 27-1: Programmable Controllers_____________________________________________ Section 27-2: Programmable Controller Sections_____________________________________ Section 27-3: Programmable Controller Applications_________________________________ Section 27-4: Troubleshooting Programmable Controllers_____________________________

337 341 342 346 350

28 Power Distribution and Smart Grid Systems Tech-Chek 28______________________________________________________________________ Worksheets Section 28-1: Electrical Power Distribution___________________________________________ Section 28-2: Distribution Transformers_____________________________________________ Section 28-3: Power Quality Problems_______________________________________________ Section 28-4: Smart Grids__________________________________________________________

353 357 358 362 365

29 Preventive Maintenance Systems Tech-Chek 29______________________________________________________________________ Worksheets Section 29-1: Preventive Maintenance Principles_____________________________________ Section 29-2: Alignment____________________________________________________________ Section 29-3: Bearings_____________________________________________________________ Section 29-4: Flexible Belt Drives___________________________________________________ Section 29-5: Preventive Maintenance Tests_________________________________________

367 369 370 374 375 376

30 Predictive Maintenance Tech-Chek 30______________________________________________________________________ 377 Worksheets Section 30-1: Predictive Maintenance Monitoring_____________________________________ 379 Section 30-2: Maintenance Technician Resources____________________________________ 380

Appendix

381

Workbook Electrical Motor Controls for Integrated Systems Workbook is designed to reinforce the concepts and provide system design activities for the material presented in Electrical Motor Controls for Integrated Systems. The Workbook contains both Tech-Cheks and Worksheets for each chapter. Tech-Cheks provide a series of multiple choice questions that are based on each section of the textbook. Always study the assigned section or chapter of the textbook thoroughly before completing the Tech-Cheks. Applying Your Knowledge questions found on the Electrical Motor Controls for Integrated Systems Interactive DVD can be used as additional exercises. Worksheets provide opportunities to apply the concepts and theories in the textbook to practical design problems. The workbook contains a Worksheet for every section of the textbook. See the table of contents for a complete listing. A Certificate of Completion can be used to document instruction provided and activities completed in each section or chapter of the book. The customizable certificate can be found on the Electrical Motor Controls for Integrated Systems Instructor’s Resource Guide Interactive DVD.

Certificate of Completion in

Motor Controls John Smith

has received instruction and completed activities in the following areas Chapter 1: Electrical Quantities and Basic Circuits 1-1 Electrical Theory 1-2 Circuits 1-3 Magnetism 1-4 Power Chapter 2 Symbols and Diagrams 2-1 Language of Controls 2-2 Electrical Circuits

Chapter 5 Control Logic 5-1 Basic Rules of Line Diagrams 5-2 Line Diagrams — Signals, Decisions, and Action 5-3 Logic Functions 5-4 Common Control Circuits 5-5 Control Circuit Troubleshooting

Chapter 3 Test Instruments 3-1 Safety 3-2 General Use Test Instruments 3-3 Specialty Test Instruments

Program Instructor

Jon

Chapter 4 Electrical Safety 4-1 Electrical Safety 4-2 Lockout/Tagout 4-3 Personal Protective Equipment 4-4 Fire Safety 4-5 Confined Spaces 4-6 Overhead Power Line Safety

Institution

St t o

Date

Applications Manual The Electrical Motor Controls for Integrated Systems Applications Manual expands upon the concepts and builds 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.

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 provides a comprehensive teaching reference including PowerPoint® Presentations, an Instructional Guide, an Image Library, Assessments, Answer Keys, and other resources. The Publisher