Electricity and Electronics For Industrial Maintenance

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by: Thomas Kissell

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This reference shows how industrial components and systems operate, how they are installed and maintained, and how to diagnose and service any malfunctions. Using a systems approach, this book provides the perfect blend of theory and application for todays technicians to understand how electrical, electronic control, and PLC parts interact to make complex modern industrial machines operate. This understanding aids troubleshooting of everything from simple circuits to complex PLC controlled systems with electronic variable frequency drives.

Features

Systems approach.

~Ensures students fully understand the theory of operation of each component covered.

IllustrationsShow components as they actually appear within the system.

~Helps students to visually connect to the material covered.

Step-by-step troubleshooting procedures coveredIncluding the use of modern test equipment, ladder diagrams, and wiring diagrams.

Full coverage of safety considerations in the first chapter.

Converting wiring diagrams and ladder diagrams coverageStresses the need for students to be able to move seamlessly between the two diagrams.

~Helps students understand which diagram is best used in each troubleshooting situation.

Broad coverageIncludes basic electrical fundamentals, motor controls and motors, electronics principles, and PLCs.

Table of Contents

1. Shop Safety and Shop Practices.

Introduction.
Safety Glasses, Protective Clothing, and Equipment.
Safety Mats and Equipment to Prevent Fatigue.
Safety Light Curtains and Two-Hand Start Buttons.
Safety Gates and Shields.
Checking Guards and Active Safety Devices.
Cleanliness and Shop Housekeeping.
Leaks.
MSDS.
First Aid, CPR and Portable Defibrillators.
Fire Safety.
Electrical Safety.
Working Safely with Hand Tools and Power Tools.
Safety Briefings and Safety Meetings.
Safety Standards Organizations in the United States, Canada, and Europe.

2. Tools for Electrical Technicians.
Overview of Electrical Tools.
Electrical Meters.
Hole Punches and Hole-Cutting Tools.
Electrical Conduit Bending, Cutting, and Threading Tools.
Electrical Pliers, Wire Cutters, and Wire Strippers.
Screwdrivers for Electrical Installation and Maintenance.
Wrenches for Electrical Maintenance.
Tool Pouches and Tool Belts.
Proper Use of Tools.

3. Fundamentals of Electricity.
Overview of Electricity.
Example of a Simple Electrical Circuit.
Example of Voltage in a Circuit.
Example of Current in a Circuit.
Example of Resistance in a Circuit.
Identifying the Basic Parts of a Circuit.
Wiring Diagram and Ladder Diagram.
Equating Electricity to a Water System.
Using Ohms Law to Calculate Volts, Amperes, and Ohms.
Ohms Law Formulas.
Using Ohms Law to Calculate Voltage.
Using Ohms Law to Calculate Current.
Using Ohms Law to Calculate Resistance.
Using the Ohms Law Wheel to Remember the Ohms Law Formulas.
Calculating Electrical Power.
Presenting All the Formulas.
Using Prefixes and Exponents with Numbers.

4. Voltmeters, Ammeters, and Ohmmeters.
Measuring Volts, Amps, and Ohms.
Measuring Voltage.
Measuring Electrical Current.
Measuring Milliamps.
Creating a Multiplier with a Clamp-on-Type Ammeter.
Measuring Electrical Resistance.
Reading the Scales of a VOM Meter.
Measuring DC Volts and Reading the VOM Scales.
Measuring and Reading the Milliamp Scales on the VOM.
Measuring and Reading Resistance Scales on the VOM.
Making Measurements with Digital VOM Meters.

5. Series Circuits.
Introduction.
Examples of Series Circuits.
Series Switches.
Adding Loads in Series.
Resistor Color Codes.
Decoding a Resistor.
Why Resistor Tolerance Is Important.
Variable Resistors.
Using Ohms Law to Calculate Ohms, Volts, and Amps for Resistors in Series.
Solving for Current in a Series Circuit.
Calculating the Voltage Drop Across Each Resistor.
Calculating the Power Consumption of Each Resistor.
Calculating the Power Consumption of an Electrical Heating Element.
Troubleshooting Series Switches.
Review of Series Circuits.

6. Parallel and Series-Parallel Circuits.
Introduction.
Calculating Voltage, Current, and Resistance in a Parallel Circuit.
Calculating Resistance in a Parallel Circuit.
Calculating Power in a Parallel Circuit.
Reviewing the Principles of Parallel Circuits.
Review of Using Prefixes with Units of Measure.
Series-Parallel Circuits.
Series-Parallel Circuits in Factory Electrical Systems.
Review of Series-Parallel Circuits.

7. Magnetic Theory.
Introduction to Magnetic Theory.
A Typical Bar Magnet and Flux Lines.
Electromagnets.
Adding Coils of Wire to Increase the Strength of an Electromagnet.
Using a Core to Increase the Strength of the Magnetic Field of a Coil.
Reversing the Polarity of a Magnetic Field in an Electromagnet.
Electromagnetic Theory Used to Operate a Basic Generator to Create AC Voltage.
Magnetics Used in Basic Theory of a Simple DC Motor.
Electromagnetic Induction Used in Transformers.
Magnetics Used in Relays and Contactors.
Review of Magnetic Principles.

8. Fundamentals of AC Electricity.
What Is Alternating Current?
Where Does AC Voltage Come From?
Frequency of AC Voltage.
Peak Voltage and RMS Voltage.
Oscilloscope.
The Source of AC Voltage for Factory Electrical Systems.
Measuring AC Voltage in a Disconnect.
Voltage and Current in AC Circuits.
Capacitors.
Resistance and Capacitance in an AC Circuit.
Calculating Capacitive Reactance.
Calculating the Total Opposition for a Capacitive and Resistive Circuit.
Resistance and Inductance in an AC Circuit.
Calculating Inductive Reactance.
Calculating the Total Opposition for and Inductive and Resistive Circuit.
True Power and Apparent Power in an AC Circuit.
Calculating the Power Factor.

Reviews:

9. Transformers and Three-Phase and Single-Phase Voltage

Overview of Transformers
Operation of a Transformer and Basic Magnetic Theory
Connecting a Transformer to a Disconnect for Testing
Transformer Rated for 240V and 208V Primary
Transformer Voltage, Current, and Turns Ratios
Step-up and Step-down Transformers
VA Ratings for Transformers
The 120-VAC Control Transformer
Wiring the Control Transformer for 480-VAC Primary Volts
Wiring the Control Transformer for 240-VAC Primary Volts
Troubleshooting a Transformer
Nature of Three-Phase Voltage
Why Three-Phase Voltage is Generated
Three-Phase Transformers
The Wye-Connected Three-Phase Transformer
The Delta-Connected Three-Phase Transformer
Delta- and Wye-Connected Transformers with a Neutral Terminal
The High Leg Delta System
Three-Phase Voltage on Site
Installing Wiring in a Three-Phase Disconnect
Testing for a Bad Fuse in a Disconnect
Single-Phase Voltage from a Three-Phase Supply
Bus Duct and Bus Disconnect Boxes
Wiring a Duplex Receptacle as a Utility Outlet

10. Relays, Contactors, and Solenoids
Overview of Relays and Contactors in the Control Circuit
The Control Transformer
The Theory and Operation of a Relay
Types of Armature Assemblies for Relays
Pull-in and Hold-in Current
Normally Open and Normally Closed Contacts
Ratings for Relay Contacts and Relay Coils
Identifying Relays by the Arrangement of Their Contacts
Examples of Relays Used in Industrial Electrical Systems
Current Relays and Potential Relays for Starting Single-Phase Compressors
The Difference between a Relay and a Contactor
NEMA Ratings for Contactors
The Function of the Control Circuit
Solenoids Used in Industrial Systems
Basic Parts of a Solenoid Valve
Troubleshooting a Solenoid Valve
11. Motor Starters and Over-Current Controls
Overview of Motor Starters
Why Motor Starters Are Used in Industrial Electrical Systems
The Basic Parts of a Motor Starter
The Operation of the Overload
Exploded View of a Motor Starter
Sizing Motor Starters
Solid-State Motor Protectors
Over-Current Controls
Thermal Overloads
Fuses
Fused Disconnect Panels
Circuit Breakers and Load Centers
12. Motor-Control Devices and Circuits
Introduction
Pilot Devices
Control Circuits and Load Circuits
Jogging Control Circuits
Other Types of Pilot Devices
Enclosures
Conductors
13. Single-Phase AC Motors
Overview of Single-Phase AC Induction Motors
AC Split-Phase Motor Theory
The Rotor
Locked-Rotor Amperage and Full-Load Amperage
Rotor Slip and Torque in an AC Induction Motor
End Plates
The Stator
The Start Winding
The Operation of the Centrifugal Switch
The Run Winding
Multiple-Speed Motors
Motor Data Plates
Wiring Split-Phase Motors for a Change of Rotation and Change of Voltage
Overview of Capacitor-Start, Induction-Run Motors
Theory of Operation for a Capacitor-Start, Induction-Run Motor
Applying Voltage to the Start Winding and Capacitor
Wiring Split-Phase and Capacitor-Start, Induction-Run Motors for 115V
Wiring a Capacitor-Start, Induction-Run Motor for 230V
Wiring a Split-Phase and Capacitor-Start, Induction-Run Motor for a Change of Rotation
Changing Speeds with a Capacitor-Start, Induction-Run Motor
Overview of Permanent Split-Capacitor Motors
Basic Parts and Theory of Operation for a PSC Motor
Applying Voltage to the Start Winding and Capacitor of a PSC Motor
14. Three-Phase Motors
Three-Phase Motor Theory
Basic Parts of a Three-Phase Motor
Theory of Operation for a Three-Phase Motor
Wiring a Simple Three-Phase Motor
Changing Connections in Three-Phase Motors to Change Torque, Speed, or Voltage Requirements
Wiring a Three-Phase Motor in a Wye Configuration
Wiring a Three-Phase Motor in a Delta Configuration
Rewiring a Nine-Lead, Three-Phase, Wye-Connected Motor for a Change of Voltage
Rewiring a Nine-Lead, Three-Phase, Delta-Connected Motor for a Change of Voltage
The 12-Lead, Three-Phase Motor
Wiring a Three-Phase Motor for a Change of Rotation
Controlling a Three-Phase Motor
Controlling the Speed of a Three-Phase Motor
Troubleshooting the Three-Phase Motor
Testing the Three-Phase Motor for Continuity
Testing a Three-Phase Motor for Current
15. DC Motors
Introduction
Magnetic Theory
DC Motor Theory
DC Motor Components
DC Motor Operation
Types of DC Motors
DC Shunt Motors
DC Compound Motors

16. DC Generators
Introduction
Basic Parts and Basic Operation of a DC Shunt Generator
Separately Excited Shunt Generator
Self-Excited Shunt Generator
Compound Generator
Series Generator
Controlling the Amount of Voltage and Its Polarity in a DC Generator
Troubleshooting a DC Generator

17. AC Alternators
Introduction
Theory of Operation of the Alternator
AC Voltage in the Stator
Producing Three-Phase Voltage
Using an Alternator to Produce DC Voltage
Troubleshooting an Alternator

18. Programmable Controllers
Introduction
The Generic Programmable Logic Controller
Understanding How the PLC Controls a Simple Circuit with a Selector Switch and Motor-Starter Coil
Using Change of State and Power Flow to Understand the Stop-Start Circuit
The PLC Program for the Stop-Start Circuit
An Example Programmable Controller Application
The Run Mode and the Program Mode
On-line and Off-line Programming
Features of the Programmable Controller
Classifications of Programmable Controllers
Review the Operation of Programmable Controllers
Addresses for Inputs and Outputs for the MicroLogix PLC
Example Input and Output Instructions for the MicroLogix
More about Mnemonics: Abbreviations for Instructions
Example of a Program with Inputs Connected in Series
Using Timers in a PLC
Counter Applications for Industry
Entering Programs with the Hand-Held Programmer
Programming Basic Circuits into the PLC
Wiring a Stop-Start Circuit to Input and Output Terminals on the PLC
Typical Problems a Technician Will Encounter with PLCs
Troubleshooting the PLC

19. Electronics for Maintenance Personnel
Overview of Electronics Used in Industrial Circuits
Conductors, Insulators, and Semiconductors
Combining Atoms
Combining Arsenic and Silicon to Make N-Type Material
Combining Aluminum and Silicon to Make P-Type Material
The PN Junction
Forward-Biasing the PN Junction
Reverse-Biasing the PN Junction
Using a Diode for Rectification
Half-Wave and Full-Wave Rectifiers
Three-Phase Rectifiers
Testing Diodes
Identifying Diode Terminals with an Ohmmeter
Light-Emitting Diodes
PNP and NPN Transistors
Operation of a Transistor
Typical Transistors
Troubleshooting Transistors
Unijunction Transistors
Operation of the UJT
Testing the UJT
The Silicon-Controlled Rectifier
Operation of a Silicon-Controlled Rectifier
Controlling an SCR
Testing an SCR
Typical SCRs
Diacs
Operation of a Diac
Triacs
Using a Triac as a Switch
Using a Triac for Variable Voltage Control
Testing a Triac
Operational Amplifiers
The Op Amp as an Amplifier
Controlling a Relay with an Op Amp
Controlling the Speed of a Three-Phase Motor with a Variable-Frequency Drive
Operation of the Variable-Frequency Drive Circuit
Solid-State Relays

20. Lockout, Tag-out
Introduction
A Typical Lockout, Tag-out Policy
Determining the Lockout, Tag-out Policy and Procedure
Identifying Sources of Kinetic Energy and Potential Energy
Designing Safety into the Machine
Documentation and Training
OSHA Inspections
What Is Lockout? What Is Tag-Out? Designing a Lockout, Tag-out Procedure for Your Machines
Removing the Lockout, Tag-out Devices and Returning Power to the Machine
Review of Lockout, Tag-out Procedures

21. Troubleshooting
Introduction
What Is Troubleshooting? The Difference between Symptoms and Problelms
Starting the Troubleshooting Procedure
Developing a Ladder Diagram from a Wiring Diagram
Converting a Wiring Diagram from a Ladder Diagram
Auto Mode and Manual Mode
Review of Troubleshooting
Glossary
Index

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