Industrial Motor Control, 7th ed.

INDUSTRIAL MOTOR CONTROL 7E is an integral part of any electrician training. Comprehensive and up to date, this book provides crucial information on basic relay control systems, programmable logic controllers, and solid state devices commonly found in an industrial setting. Written by a highly qualified and respected author, you will find easy-to-follow instructions and essential information on controlling industrial motors and commonly used devices in contemporary industry. INDUSTRIAL MOTOR CONTROL 7E successfully bridges the gap between industrial maintenance and instrumentation, giving you a fundamental understanding of the operation of variable frequency drives, solid state relays, and other applications that employ electronic devices. Cover 1 Half Title 3 Statement 4 Title Page 5 Copyright 6 Contents 7 Preface 13 Ch 1: General Principles of Motor Control 17 Objectives 17 Introduction 17 Installation of Motors and Control Equipment 17 Types of Control Systems 20 Functions of Motor Control 23 Review Questions 25 Ch 2: Symbols and Schematic Diagrams 26 Objectives 26 Introduction 26 Push Buttons 26 Switch Symbols 32 Basic Schematics 35 Sensing Devices 36 Selector Switches 38 Review Questions 42 Ch 3: Manual Starters 43 Objectives 43 Introduction 43 Fractional Horsepower Single-Phase Starters 43 Manual Push Button Starters 47 Troubleshooting 49 Review Questions 50 Ch 4: Overload Relays 51 Objectives 51 Overloads 51 Dual-Element Fuses 52 Thermal Overload Relays 53 Magnetic Overload Relays 59 Overload Contacts 63 Protecting Large Horsepower Motors 66 Review Questions 67 Ch 5: Relays, Contactors, and Motor Starters 68 Objectives 68 Introduction 68 Relays 68 Electromagnet Construction 69 Contactors 77 Mechanically Held Contactors and Relays 81 Mercury Relays 82 Motor Starters 83 Review Questions 91 Ch 6: The Control Transformer 92 Objectives 92 Introduction 92 Review Questions 99 Ch 7: Timing Relays 100 Objectives 100 Introduction 100 Pneumatic Timers 101 Clock Timers 103 Motor-Driven Timers 103 Capacitor Time Limit Relay 104 Electronic Timers 104 Review Questions 110 Ch 8: Pressure Switches and Sensors 111 Objectives 111 Pressure Switches 111 Pressure Sensors 113 Review Questions 116 Ch 9: Float Switches 117 Objectives 117 Introduction 117 Mercury Bulb Float Switch 118 The Bubbler System 119 Review Questions 122 Ch 10: Flow Switches and Sensors 123 Objectives 123 Flow Switches 123 Flow Sensors 126 Review Questions 133 Ch 11: Limit Switches 134 Objectives 134 Introduction 134 Micro Limit Switches 135 Subminiature Micro Switches 136 Limit Switch Application 137 Review Questions 139 Ch 12: Phase Failure Relays 140 Objectives 140 Introduction 140 Effects of Voltage Variation on Motors 140 Review Questions 141 Ch 13: Solenoid and Motor-Operated Valves 142 Objectives 142 Introduction 142 Solenoid Valves 142 Motor-Operated Valves 143 Review Questions 147 Ch 14: Temperature-Sensing Devices 148 Objectives 148 Introduction 148 Expansion of Metal 148 Resistance Temperature Detectors 153 Expansion Due to Pressure 157 Smart Temperature Transmitters 157 Review Questions 158 Ch 15: Hall Effect Sensors 159 Objectives 159 Principles of Operation 159 Hall Generator Applications 160 Review Questions 163 Ch 16: Proximity Detectors 164 Objectives 164 Applications 164 Metal Detectors 164 Mounting 166 Capacitive Proximity Detectors 167 Ultrasonic Proximity Detectors 167 Review Questions 169 Ch 17: Photodetectors 170 Objectives 170 Applications 170 Types of Detectors 170 Mounting 175 Review Questions 177 Ch 18: Basic Control Circuits 178 Objectives 178 Introduction 178 Three-Wire Control Circuits 181 Review Questions 182 Ch 19: Schematics and Wiring Diagrams (circuit 1) 183 Objectives 183 Introduction 183 Review Questions 186 Ch 20: Timed Starting for Three Motors (circuit 2) 187 Objectives 187 Introduction 187 Review Questions 190 Ch 21: Float Switch Control of a Pump and Pilot Lights (circuit 3) 191 Objectives 191 Introduction 191 Review Questions 193 Ch 22: Developing a Wiring Diagram (circuit 1) 194 Objectives 194 Introduction 194 Review Questions 196 Ch 23: Developing a Wiring Diagram (circuit 2) 197 Objectives 197 Introduction 197 Review Question 198 Ch 24: Developing a Wiring Diagram (circuit 3) 201 Objectives 201 Introduction 201 Review Question 202 Ch 25: Reading Large Schematic Diagrams 205 Objectives 205 Introduction 205 Review Questions 211 Ch 26: Installing Control Systems 212 Objectives 212 Introduction 212 Component Location 213 Point-to-Point Connection 213 Using Terminal Strips 215 Review Questions 217 Ch 27: Hand-Off-Automatic Controls 218 Objectives 218 Introduction 218 Review Questions 221 Ch 28: Multiple Push Button Stations 222 Objectives 222 Introduction 222 Developing a Wiring Diagram 224 Review Questions 228 Ch 29: Forward–Reverse Control 229 Objectives 229 Introduction 229 Interlocking 229 Developing a Wiring Diagram 231 Reversing Single-Phase, Split-Phase Motors 231 Review Questions 240 Ch 30: Jogging and Inching 241 Objectives 241 Introduction 241 Jogging Circuits 241 Inching Controls 243 Review Questions 248 Ch 31: Sequence Control 249 Objectives 249 Introduction 249 Sequence Control Circuit 1 249 Sequence Control Circuit 2 249 Sequence Control Circuit 3 250 Automatic Sequence Control 252 Stopping the Motors in Sequence 253 Review Questions 263 Ch 32: DC Motors 264 Objectives 264 Application 264 Speed Control 264 Motor Construction 265 Identifying Windings 265 Types of DC Motors 266 Direction of Rotation 267 Standard Connections 268 Review Questions 270 Ch 33: Starting Methods for DC Motors 271 Objectives 271 Introduction 271 Review Questions 276 Ch 34: Solid-State DC Drives 277 Objectives 277 Introduction 277 The Shunt Field Power Supply 278 The Armature Power Supply 278 Voltage Control 279 Field Failure Control 280 Current Limit Control 280 Speed Control 281 Review Questions 284 Ch 35: Stepping Motors 285 Objectives 285 Introduction 285 Theory of Operation 285 Windings 287 Four-Step Switching (Full Stepping) 287 Eight-Step Switching (Half Stepping) 288 AC Operation 288 Motor Characteristics 289 Review Questions 292 Ch 36: The Motor and Starting Methods 293 Objectives 293 Introduction 293 Starting Methods for Single-Phase Motors 295 Centrifugal Switch 298 Hot-Wire Starting Relay 298 Current Relay 299 Solid-State Starting Relay 300 Potential Starting Relay 300 Review Questions 302 Ch 37: Resistor and Reactor Starting for AC Motors 303 Objectives 303 Introduction 303 Resistor Starting 303 Reactor Starting 306 Step-Starting 308 Review Questions 308 Ch 38: Autotransformer Starting 310 Objectives 310 Introduction 310 Open and Closed Transition Starting 311 Review Questions 315 Ch 39: Wye–Delta Starting 316 Objectives 316 Introduction 316 Wye–Delta Starting Requirements 317 Dual-Voltage Connections 318 Connecting the Stator Leads 319 Closed Transition Starting 320 Overload Setting 323 Review Questions 326 Ch 40: Part Winding Starters 327 Objectives 327 Introduction 327 Overload Protection 329 Dual-Voltage Motors 329 Motor Applications 330 Three-Step Starting 330 Automatic Shut-Down 331 Review Questions 331 Ch 41: Consequent Pole Motors 333 Objectives 333 Introduction 333 Three-Speed Consequent Pole Motors 335 Four-Speed Consequent Pole Motors 342 Review Questions 347 Ch 42: Variable Voltage and Magnetic Clutches 348 Objectives 348 Introduction 348 Voltage Control Methods 349 Magnetic Clutches 350 Eddy Current Clutches 352 Review Questions 353 Ch 43: Braking 354 Objectives 354 Introduction 354 Mechanical Brakes 354 Dynamic Braking 355 Plugging 358 Review Questions 365 Ch 44: Wound Rotor Induction Motors 366 Objectives 366 Introduction 366 Manual Control of a Wound Rotor Motor 368 Timed Controlled Starting 369 Wound Rotor Speed Control 369 Frequency Control 370 Review Questions 373 Ch 45: Synchronous Motors 374 Objectives 374 Introduction 374 Starting a Synchronous Motor 374 Excitation Current 375 The Brushless Exciter 375 Direct-Current Generator 376 Automatic Starting for Synchronous Motors 376 The Field Contactor 377 Out-of-Step Relay 377 The Polarized Field Frequency Relay 377 Power Factor Correction 378 Applications 380 Review Questions 381 Ch 46: Variable Frequency Control 382 Objectives 382 Introduction 382 Alternator Control 383 Solid-State Control 383 IGBTs 384 Inverter Rated Motors 387 Variable Frequency Drives Using SCRs and GTOs 387 Review Questions 391 Ch 47: Motor Installation 392 Objectives 392 Motor Nameplate Data 392 Horsepower 393 Determining Motor Current 403 Overload Size 410 Example Problems 414 Review Questions 421 Ch 48: Developing Control Circuits 423 Objectives 423 Introduction 423 Developing Control Circuits 423 Review Questions 435 Ch 49: Troubleshooting 436 Objectives 436 Introduction 436 Safety Precautions 436 Voltmeter Basics 437 Test Procedure Example 1 439 Test Procedure Example 2 442 Test Procedure Example 3 443 Review Questions 449 Ch 50: Digital Logic 450 Objectives 450 Introduction 450 The AND Gate 451 The OR Gate 452 The INVERTER 453 The NOR Gate 454 The NAND Gate 454 Integrated Circuits 455 Testing Integrated Circuits 455 Review Questions 457 Ch 51: The Bounceless Switch 458 Objectives 458 Introduction 458 Review Questions 461 Ch 52: Start–Stop Push Button Control 462 Objectives 462 Introduction 462 Review Questions 469 Ch 53: Programmable Logic Controllers 470 Objectives 470 Introduction 470 Differences Between PLCs and PCs 470 Basic Components 471 Review Questions 479 Ch 54: Programming a PLC 480 Objectives 480 Introduction 480 Circuit Operation 480 Developing a Program 482 Converting the Program 484 Programming in Boolean 486 Developing the Program 486 Parameters of the Programmable Controller 486 Operation of the Circuit 487 Entering the Program 490 Review Questions 491 Ch 55: Analog Sensing for Programmable Controllers 492 Objectives 492 Introduction 492 Installation 494 The Differential Amplifier 495 Review Questions 495 Ch 56: Semiconductors 496 Objectives 496 Introduction 496 Conductors 496 Insulators 497 Semiconductors 497 Review Questions 501 Ch 57: The PN Junction 502 Objectives 502 The PN Junction 502 Review Questions 505 Ch 58: The Zener Diode 506 Objectives 506 The Zener Diode 506 Review Questions 508 Ch 59: Light-Emitting-Diodes and Photodiodes 509 Objectives 509 Introduction 509 LED Characteristics 510 Testing LEDs 510 LED Lead Identification 512 Seven-Segment Displays 512 Connecting the LED in a Circuit 513 Photodiodes 513 Photovoltaic 513 Photoconductive 514 LED Devices 514 Review Questions 515 Ch 60: The Transistor 516 Objectives 516 The Transistor 516 Review Questions 519 Ch 61: The Unijunction Transistor 520 Objectives 520 The Unijunction Transistor 520 Review Questions 522 Ch 62: The SCR 523 Objectives 523 Introduction 523 The SCR in a DC Circuit 524 The SCR in an AC Circuit 525 Phase Shifting the SCR 526 Testing the SCR 527 Review Questions 527 Ch 63: The Diac 528 Objectives 528 The Diac 528 Review Questions 529 Ch 64: The Triac 530 Objectives 530 Introduction 530 The Triac Used as an AC Switch 531 The Triac Used for AC Voltage Control 532 Phase Shifting the Triac 532 Testing the Triac 533 Review Questions 533 Ch 65: The 555 Timer 534 Objectives 534 Introduction 534 Circuit Applications 536 Review Questions 540 Ch 66: The Operational Amplifier 541 Objectives 541 Introduction 541 Basic Circuits 544 Circuit Applications 545 Review Questions 552 Appendix 553 Glossary 567 Index 573 Cover......Page 1 Half Title......Page 3 Statement......Page 4 Title Page ......Page 5 Copyright......Page 6 Contents......Page 7 Preface......Page 13 Installation of Motors and Control Equipment......Page 17 Types of Control Systems......Page 20 Functions of Motor Control......Page 23 Review Questions......Page 25 Push Buttons......Page 26 Switch Symbols......Page 32 Basic Schematics......Page 35 Sensing Devices......Page 36 Selector Switches......Page 38 Review Questions......Page 42 Fractional Horsepower Single-Phase Starters......Page 43 Manual Push Button Starters......Page 47 Troubleshooting......Page 49 Review Questions......Page 50 Overloads......Page 51 Dual-Element Fuses......Page 52 Thermal Overload Relays......Page 53 Magnetic Overload Relays......Page 59 Overload Contacts......Page 63 Protecting Large Horsepower Motors......Page 66 Review Questions......Page 67 Relays......Page 68 Electromagnet Construction......Page 69 Contactors......Page 77 Mechanically Held Contactors and Relays......Page 81 Mercury Relays......Page 82 Motor Starters......Page 83 Review Questions......Page 91 Introduction......Page 92 Review Questions......Page 99 Introduction......Page 100 Pneumatic Timers......Page 101 Motor-Driven Timers......Page 103 Electronic Timers......Page 104 Review Questions......Page 110 Pressure Switches......Page 111 Pressure Sensors......Page 113 Review Questions......Page 116 Introduction......Page 117 Mercury Bulb Float Switch......Page 118 The Bubbler System......Page 119 Review Questions......Page 122 Flow Switches......Page 123 Flow Sensors......Page 126 Review Questions......Page 133 Introduction......Page 134 Micro Limit Switches......Page 135 Subminiature Micro Switches......Page 136 Limit Switch Application......Page 137 Review Questions......Page 139 Effects of Voltage Variation on Motors......Page 140 Review Questions......Page 141 Solenoid Valves......Page 142 Motor-Operated Valves......Page 143 Review Questions......Page 147 Expansion of Metal......Page 148 Resistance Temperature Detectors......Page 153 Smart Temperature Transmitters......Page 157 Review Questions......Page 158 Principles of Operation......Page 159 Hall Generator Applications......Page 160 Review Questions......Page 163 Metal Detectors......Page 164 Mounting......Page 166 Ultrasonic Proximity Detectors......Page 167 Review Questions......Page 169 Types of Detectors......Page 170 Mounting......Page 175 Review Questions......Page 177 Introduction......Page 178 Three-Wire Control Circuits......Page 181 Review Questions......Page 182 Introduction......Page 183 Review Questions......Page 186 Introduction......Page 187 Review Questions......Page 190 Introduction......Page 191 Review Questions......Page 193 Introduction......Page 194 Review Questions......Page 196 Introduction......Page 197 Review Question......Page 198 Introduction......Page 201 Review Question......Page 202 Introduction......Page 205 Review Questions......Page 211 Introduction......Page 212 Point-to-Point Connection......Page 213 Using Terminal Strips......Page 215 Review Questions......Page 217 Introduction......Page 218 Review Questions......Page 221 Introduction......Page 222 Developing a Wiring Diagram......Page 224 Review Questions......Page 228 Interlocking......Page 229 Reversing Single-Phase, Split-Phase Motors......Page 231 Review Questions......Page 240 Jogging Circuits......Page 241 Inching Controls......Page 243 Review Questions......Page 248 Sequence Control Circuit 2......Page 249 Sequence Control Circuit 3......Page 250 Automatic Sequence Control......Page 252 Stopping the Motors in Sequence......Page 253 Review Questions......Page 263 Speed Control......Page 264 Identifying Windings......Page 265 Types of DC Motors......Page 266 Direction of Rotation......Page 267 Standard Connections......Page 268 Review Questions......Page 270 Introduction......Page 271 Review Questions......Page 276 Introduction......Page 277 The Armature Power Supply......Page 278 Voltage Control......Page 279 Current Limit Control......Page 280 Speed Control......Page 281 Review Questions......Page 284 Theory of Operation......Page 285 Four-Step Switching (Full Stepping)......Page 287 AC Operation......Page 288 Motor Characteristics......Page 289 Review Questions......Page 292 Introduction......Page 293 Starting Methods for Single-Phase Motors......Page 295 Hot-Wire Starting Relay......Page 298 Current Relay......Page 299 Potential Starting Relay......Page 300 Review Questions......Page 302 Resistor Starting......Page 303 Reactor Starting......Page 306 Review Questions......Page 308 Introduction......Page 310 Open and Closed Transition Starting......Page 311 Review Questions......Page 315 Introduction......Page 316 Wye–Delta Starting Requirements......Page 317 Dual-Voltage Connections......Page 318 Connecting the Stator Leads......Page 319 Closed Transition Starting......Page 320 Overload Setting......Page 323 Review Questions......Page 326 Introduction......Page 327 Dual-Voltage Motors......Page 329 Three-Step Starting......Page 330 Review Questions......Page 331 Introduction......Page 333 Three-Speed Consequent Pole Motors......Page 335 Four-Speed Consequent Pole Motors......Page 342 Review Questions......Page 347 Introduction......Page 348 Voltage Control Methods......Page 349 Magnetic Clutches......Page 350 Eddy Current Clutches......Page 352 Review Questions......Page 353 Mechanical Brakes......Page 354 Dynamic Braking......Page 355 Plugging......Page 358 Review Questions......Page 365 Introduction......Page 366 Manual Control of a Wound Rotor Motor......Page 368 Wound Rotor Speed Control......Page 369 Frequency Control......Page 370 Review Questions......Page 373 Starting a Synchronous Motor......Page 374 The Brushless Exciter......Page 375 Automatic Starting for Synchronous Motors......Page 376 The Polarized Field Frequency Relay......Page 377 Power Factor Correction......Page 378 Applications......Page 380 Review Questions......Page 381 Introduction......Page 382 Solid-State Control......Page 383 IGBTs......Page 384 Variable Frequency Drives Using SCRs and GTOs......Page 387 Review Questions......Page 391 Motor Nameplate Data......Page 392 Horsepower......Page 393 Determining Motor Current......Page 403 Overload Size......Page 410 Example Problems......Page 414 Review Questions......Page 421 Developing Control Circuits......Page 423 Review Questions......Page 435 Safety Precautions......Page 436 Voltmeter Basics......Page 437 Test Procedure Example 1......Page 439 Test Procedure Example 2......Page 442 Test Procedure Example 3......Page 443 Review Questions......Page 449 Introduction......Page 450 The AND Gate......Page 451 The OR Gate......Page 452 The INVERTER......Page 453 The NAND Gate......Page 454 Testing Integrated Circuits......Page 455 Review Questions......Page 457 Introduction......Page 458 Review Questions......Page 461 Introduction......Page 462 Review Questions......Page 469 Differences Between PLCs and PCs......Page 470 Basic Components......Page 471 Review Questions......Page 479 Circuit Operation......Page 480 Developing a Program......Page 482 Converting the Program......Page 484 Parameters of the Programmable Controller......Page 486 Operation of the Circuit......Page 487 Entering the Program......Page 490 Review Questions......Page 491 Introduction......Page 492 Installation......Page 494 Review Questions......Page 495 Conductors......Page 496 Semiconductors......Page 497 Review Questions......Page 501 The PN Junction......Page 502 Review Questions......Page 505 The Zener Diode......Page 506 Review Questions......Page 508 Introduction......Page 509 Testing LEDs......Page 510 Seven-Segment Displays......Page 512 Photovoltaic......Page 513 LED Devices......Page 514 Review Questions......Page 515 The Transistor......Page 516 Review Questions......Page 519 The Unijunction Transistor......Page 520 Review Questions......Page 522 Introduction......Page 523 The SCR in a DC Circuit......Page 524 The SCR in an AC Circuit......Page 525 Phase Shifting the SCR......Page 526 Review Questions......Page 527 The Diac......Page 528 Review Questions......Page 529 Introduction......Page 530 The Triac Used as an AC Switch......Page 531 Phase Shifting the Triac......Page 532 Review Questions......Page 533 Introduction......Page 534 Circuit Applications......Page 536 Review Questions......Page 540 Introduction......Page 541 Basic Circuits......Page 544 Circuit Applications......Page 545 Review Questions......Page 552 Appendix......Page 553 Glossary......Page 567 Index......Page 573