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Motor Control Technology for Industrial Maintenance
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by: Thomas E. Kissell
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For one semester courses in motor control technology or industrial electronics offered to students in industrial maintenance or similar programs
This accessible, in-depth study of motor controls provides a step-by-step understanding of what motor control components look like, their theory of operation, tests that are used to troubleshoot them, and what they look like in electrical diagrams. The text's easy-to-read style compliments the "hands-on" learning experience of its studentswho will become maintenance technicians able to troubleshoot and repair a wide variety of equipment.
1) Shop Safety and Shop Practices
2) Lockout, Tag-out
3) Tools for Electrical Technicians
4) Symbols and Diagrams
5) Overview of Motor Controls
6) Power Distribution and Transformers
7) Manual Control Devices
8) Magnetics, Solenoids, and Relays
9) Contractors and Motor Starters
10) Pilot Devices
11) Photoelectric and Proximity Controls
12) Timers, Counters, and Sequencers
13) DC Motors
14) AC Motors
15) Motor Control Circuits
16) Advanced Motor Control Circuits: Accelerating and Decelerating Circuits
17) AC and DC Drives
18) Programmable Controllers
19) Electronics for Maintenance Personnel
20) Troubleshooting
Features
* Comprehensive coverageFeatures many one-of-a-kind diagrams of older controls.
Prepares students to work on and fix systems that contain both old and new controls when they reach the field.
* Detailed treatment of a wide variety of topicse.g., theory of operation; wiring diagrams needed for installation; adjustment; and troubleshooting techniques for every type of motor control component.
Makes it much easier for students to learn how motor control devices are wired, how they operate, and how to troubleshoot them.
* An early and detailed presentation of safety.
Alerts students to the need for working safely at all times around motor control circuits.
* Detailed chapter of lock-out, tag-out procedures.
Teaches students the life saving procedure that must be followed any time they work on equipment on the factory floor.
* Extensive pictures and diagramsShows exploded view and internal details of the controls being explained.
Helps students see exactly what is inside the components to quickly learn how they operate, and gives them the key to comprehensive understanding for all types of controls.
* Emphasis on the connection between pictures and electrical diagrams of componentsNeeded for installation and troubleshooting.
Familiarizes students with the relationship between the physical characteristics of a component (where terminals are located) and their representation on an electrical diagram.
* Integration of motor controls to programmable controllers and their automated systems.
Enhances students' understanding of how programmable controllers operate when they are integrated with traditional PLCs.
* Troubleshooting techniques throughoutHighlights them as an integral part of each chapter.
Explains to students what meters and test procedures should be used to test each component, both in circuit and when it is removed.
* Unique chapter on troubleshootingChapter 20 explains how to convert a ladder diagram to a wiring diagram and how to convert a wiring diagram to a ladder diagram.
Gives students a full understanding of the strength of both diagrams and when each should be used during installation and troubleshootingto ensure success when they reach the job.
* Detailed chapter on theory of operation, installation, and variable frequency drivesChapter 17.
Teaches students what a VFD is, how it operates, and how to troubleshoot.
* A mixture of wiring diagrams and ladder diagrams in each chapter.
Explains how components operate in circuit.
* Chapter objectives.
Describes in measurable terms what students should learn after reading each chapter.
* Chapter questionsFeatures open-ended, true/false, and multiple choice.
Gives students an opportunity to test their knowledge of key concepts before moving on and allows instructors to assess if students have learned the information.
Reviews:
Preface
This book was written to respond to the needs of modern industry to increase the knowledge base of every person who must install, troubleshoot, and maintain equipment with electrical controls. In the past, this job was delegated directly to only electrical technicians. Today, every company expects a wide variety of personnel to troubleshoot and repair these systems, including maintenance personnel, electricians, electronics technicians, automation technicians, and engineers.
Most of the motor control textbooks on the market today were written for advanced technicians and engineers. This book is designed to be used by anyone who must understand the operation of motor control components in motor control circuits and know how to troubleshoot large complex systems as well as individual components. The book is written so someone who has completed electrical classes in AC and DC fundamentals can easily understand how motor control components operate, and how to install or troubleshoot them. Basic AC and DC theory is integrated directly into each chapter at the point where the theory is used to help reinforce the basic theory students learned in their earlier courses. The author has found that this technique is also very useful for students who learned AC and DC electrical theory several months prior to taking the motor controls class, or for students who really did not understand how the AC and DC electrical theory actually works in application. Objectives are provided at the front of the chapter, and a comprehensive set of questions is provided at the end of each chapter. The questions can be assigned as homework or be used as a final test for each chapter.
The book is designed to be used for a one- or two-course sequence in motor controls. The author intentionally included more information than most classes have time to cover. The large amount of detail is provided so students can refer to the book as a reference when they are on the job and need the details to troubleshoot a component or circuit. The book is also designed so that each chapter is complete and can stand alone. This allows instructors to use only the chapters in their course syllabus, and use the remainder of the book for reference. Another option is to use the book for other electrical courses. For example, Chapter 13 (DC Motors), Chapter 14 (AC Motors), and Chapter 17 (DC and AC Drives) provide enough detail that they can be used in a motors class. Chapter 18 (Programmable Controllers) is complete enough to be used in a PLC class. This would allow students to pay for the book once and use it for multiple classes, which will save them money.
In the past 20 years the technology involved with motor controls has changed drastically, to the point of overwhelming some maintenance personnel and technicians today. Early motor control circuits consisted primarily of a motor starter and several pilot switches, such as pushbuttons and limit switches. When the pilot switches were closed, the motor would run, and if any of the switches were open, the motor would be deenergized.
Today, the technician is responsible for installing, programming, troubleshooting, and repairing programmable controllers and other automated systems that are considered part of the motor control system. A maintenance person or electrical technician in any factory today will probably be expected to work on a traditional motor control circuit with motor starters and pilot devices, process control systems for process heating, motion control systems that include servo systems or robotic applications, and sophisticated electronic and microprocessor-controlled devices.
Since these control systems represent a wide variety of technologies and theories, it is important that a book be available to explain all these systems at an introductory level, so that they are easy to understand. More complex material is added to each chapter so that each chapter contains sufficient information to allow an engineering student to design and install complex motor control systems. The book also provides extensive reference information that is usable when students get jobs and begin to work on the factory floor or for students who are currently working on the job. The book also shows students the value of hands-on learning. Each chapter provides detailed diagrams that can be wired and tested to develop wiring skills for installation and troubleshooting skills for making repairs.
Most students entering the electrical field do not understand that most equipment found in factories today has been designed to operate for 20 years or more. This means that numerous motor control systems that they will be expected to maintain will have been in existence for many years. Many motor control texts do not include these older circuits and components, and maintenance personnel do not have a resource to find out how these older components and circuits operate and how they should troubleshoot them.
The author has taken great pains to ensure that theory of operation, installation, and troubleshooting procedures for these traditional circuits are included in each chapter, so that new technicians can be introduced to them and understand their value. This text also provides information about the newest control circuits being brought into factories that are integrated with solid-state electronics, microprocessor controls, and programmable controllers. The theory of operation and troubleshooting techniques are presented for these types of equipment, too. The book goes into great detail to explain the implementation of old and new controls to programmable controller systems.
Troubleshooting is included in each chapter at the point where each motor control concept is introduced. The final chapter, Chapter 20, also provides a comprehensive in-depth study of how students should approach troubleshooting when they are on the job. This chapter is also unique in that it provides detailed instructions on how to convert a ladder diagram to a wiring diagram, and how to convert a wiring diagram to a ladder diagram. Students must learn to do these diagram conversions when they are troubleshooting so that they fully understand the importance of each.
The author provides information in this text that can be obtained only from years of experience on the factory floor, installing, troubleshooting, and maintaining motor controls and working with the best troubleshooting minds and technicians in the industry today. The massive amount of information is presented in such a way that new technicians can utilize it immediately and continually refer to it as they gain more experience. The book is designed to be the source of knowledge on electrical controls that a student will need to succeed.
About the Author(s)
Thomas Kissell has been a technical instructor and consultant in the field of industrial automation at Terra Community College in Fremont, Ohio for over twenty years. He has spent the majority of his career working directly with area industries, where he taught electricians and technicians directly on the factory floor. This training included installation, troubleshooting, and repair of major automation and motor control systems. The author has integrated this practical approach to troubleshooting and repair into this text, which includes the theory of operation of all traditional motor control components and circuits as well as state-of-the-art controls and control systems used with programmable controllers and robots.
Over the years Thomas Kissell has worked directly with the following companies: Ford Motor Company, General Motors, Texas Instruments, Union Carbide, Libbey Owens Ford, American National Can Company, TRW, Whirlpool Inc., General Mills, Campbell Soup Co., and Heinz USA. The author taught courses to technicians and engineers in these companies, and he was able to work side by side with some of the best electricians and electrical technicians in the world, troubleshooting their most complex problems. At these times, the author became their student, and they taught him the tricks and troubleshooting procedures that consistently located and repaired electrical problems. These procedures have been documented and are included in every chapter of this text.
Thomas Kissell has written numerous other books, including Understanding and Using Programmable Controllers; Motors, Controls and Circuits for Air Conditioning and Refrigeration Systems; Modern Industrial/Electrical Motor Controls; Electricity Fluid Power and Mechanical Systems for Industrial Maintenance; Electricity, Electronics and Control Systems for ITVAC; Industrial Electronics, 2nd ed.; and a lab manual for industrial electronics.