Industrial Motor Control

by Herman, Stephen L.

• ISBN13: 9781401838027
• ISBN10: 1401838022
• Edition: 5th
• Format: Paperback
• Copyright: 2004-09-24
• Publisher: CENGAGE Delmar Learning

Summary

A comprehensive and reader-friendly text, Industrial Motor Control, 5E contains crucial, up-to-date information on basic relay control systems, programmable logic controllers, and solid state devices commonly found in an industrial setting. It presents easy-to-follow instructions and the essential information for controlling industrial motors, along with commonly used devices in contemporary industrial settings. Coverage is comprehensive in scope, successfully bridging the gap between industrial maintenance and instrumentation. Readers will gain a fundamental understanding of the operation of variable frequency drives, solid state relays, and other applications that employ electronic devices.

Table of Contents

Preface	ix
Features of the Fifth Edition	ix
Content Highlights	x
About the Author	xi
Acknowledgments	xi
Section 1 Solid-State Devices	2	(68)
Unit 1 General Principles of Electric Motor Control	4	(16)
Motor Control Installation Considerations	4	(2)
Purpose of Controller	6	(2)
Manual Control	8	(1)
Remote and Automatic Control	9	(2)
Starting and Stopping	11	(3)
Speed Control of Motors	14	(2)
Protective Features	16	(1)
Classification of Automatic Motor Starting Control Systems	17	(1)
Troubleshooting	17	(1)
Review Questions	18	(2)
Unit 2 Semiconductors	20	(6)
Conductors	20	(1)
Insulators	21	(1)
Semiconductors	21	(4)
Review Questions	25	(1)
Unit 3 The PN Junction	26	(5)
The PN Junction	26	(4)
Review Questions	30	(1)
Unit 4 The Zener Diode	31	(3)
The Zener Diode	31	(2)
Review Questions	33	(1)
Unit 5 The Transistor	34	(4)
The Transistor	34	(3)
Review Questions	37	(1)
Unit 6 The Unijunction Transistor	38	(3)
The Unijunction Transistor	38	(2)
Review Questions	40	(1)
Unit 7 The SCR	41	(5)
The SCR in a DC Circuit	42	(1)
The SCR in an AC Circuit	43	(1)
Phase Shifting the SCR	44	(1)
Testing the SCR	45	(1)
Review Questions	45	(1)
Unit 8 The Diac	46	(2)
The Diac	46	(1)
Review Questions	47	(1)
Unit 9 The Triac	48	(4)
The Triac Used as an AC Switch	49	(1)
The Triac Used for AC Voltage Control	49	(1)
Phase Shifting the Triac	49	(1)
Testing the Triac	50	(1)
Review Questions	51	(1)
Unit 10 The 555 Timer	52	(7)
Circuit Applications	54	(4)
Review Questions	58	(1)
Unit 11 The Operational Amplifier	59	(11)
Basic Circuits	61	(2)
Circuit Applications	63	(6)
Review Questions	69	(1)
Section 2 Motor Starters and Pilot Devices	70	(128)
Unit 12 Fractional and Integral Horsepower Manual Motor Starters	72	(6)
Fractional Horsepower Manual Motor Starters	72	(2)
Automatic and Remote Operation	74	(1)
Manual Push-Button Line Voltage Starters	75	(1)
Thermal Overload Protection	76	(1)
Review Questions	77	(1)
Unit 13 Magnetic Line Voltage Starters	78	(22)
Magnetic vs. Manual Starters	78	(1)
Starter Electromagnets	79	(2)
Shaded Pole Principle	81	(2)
Magnet Coil	83	(1)
Power (or Motor) Circuit of the Magnetic Starter	84	(1)
Motor Overheat	84	(8)
The AC Magnetic Starter	92	(2)
AC Combination Starters	94	(4)
Review Questions	98	(2)
Unit 14 Push Buttons and Control Stations	100	(8)
Push Buttons	100	(2)
Selector Switches	102	(1)
Control Stations	103	(3)
Review Questions	106	(2)
Unit 15 Relays and contactors	108	(12)
Control Relays	108	(3)
Contactors	111	(2)
AC Mechanically Held Contactors and Relays	113	(3)
Vacuum Contactors	116	(3)
Review Questions	119	(1)
Unit 16 The Solid-State Relay	120	(3)
The Solid-State Relay	120	(2)
Review Questions	122	(1)
Unit 17 Timing Relays	123	(11)
Pneumatic Timers	124	(1)
Clock Timers	125	(1)
Motor-Driven Timers	126	(1)
Capacitor Time Limit Relay	126	(1)
Electronic Timers	127	(6)
Review Questions	133	(1)
Unit 18 Pressure Switches and Regulators	134	(4)
Pressure Sensors	135	(2)
Review Questions	137	(1)
Unit 19 Float Switches	138	(7)
Mercury Bulb Float Switch	139	(1)
The Bubbler System	140	(4)
Review Questions	144	(1)
Unit 20 Flow Switches and Sensors	145	(8)
Flow Sensors	148	(4)
Review Questions	152	(1)
Unit 21 Limit Switches	153	(4)
Micro Limit Switches	154	(2)
Subminiature Micro Switches	156	(1)
Review Questions	156	(1)
Unit 22 Phrase Failure Relays	157	(2)
Review Questions	158	(1)
Unit 23 Solenoid and Motor Operated Valves	159	(6)
Two-way Solenoid Valves	160	(1)
Four-way Solenoid Valves	160	(1)
Motor Operated Valves	161	(3)
Review Questions	164	(1)
Unit 24 Temperature Sensing Devices	165	(11)
Expansion of Metal	165	(5)
Resistance Temperature Detectors	170	(3)
Expansion Due to Pressure	173	(1)
Smart Temperature Transmitters	174	(1)
Review Questions	175	(1)
Unit 25 Hall Effect Sensors	176	(5)
Principles of Operation	176	(1)
Hall Generator Applications	177	(3)
Review Questions	180	(1)
Unit 26 Proximity Detectors	181	(6)
Applications	181	(1)
Circuit Operation	181	(3)
Mounting	184	(1)
Capacitive Proximity Detectors	184	(1)
Ultrasonic Proximity Detectors	185	(1)
Review Questions	186	(1)
Unit 27 Photodetectors	187	(8)
Applications	187	(1)
Types of Detectors	187	(5)
Mounting	192	(2)
Review Questions	194	(1)
Unit 28 The Control Transformer	195	(3)
Review Questions	197	(1)
Section 3 Control Circuits	198	(40)
Unit 29 Basic Control Circuits	200	(3)
Two-Wire Controls	200	(1)
Three-Wire Controls	200	(2)
Review Questions	202	(1)
Unit 30 Schematics and Wiring Diagrams	203	(4)
Review Questions	206	(1)
Unit 31 Timed Starting for Three Motors (Circuit #2)	207	(4)
Review Questions	210	(1)
Unit 32 Float Switch Control of a Pump and Pilot Lights (Circuit #3)	211	(3)
Review Questions	213	(1)
Unit 33 Developing a Wiring Diagram (Circuit #1)	214	(4)
Review Questions	217	(1)
Unit 34 Developing a Wiring Diagram (Circuit #2)	218	(4)
Review Questions	219	(3)
Unit 35 Developing a Wiring Diagram (Circuit #3)	222	(4)
Review Questions	223	(3)
Unit 36 Reading Large Schematic Diagrams	226	(7)
Review Questions	232	(1)
Unit 37 Installing Control Systems	233	(5)
Review Questions	237	(1)
Section 4 Basic Control Circuits	238	(36)
Unit 38 Hand-Off Automatic Controls	240	(3)
Review Questions	241	(2)
Unit 39 Multiple Push-Button Stations	243	(2)
Review Questions	243	(2)
Unit 40 Interlocking Methods for Reversing Control	245	(7)
Mechanical Interlock	245	(2)
Push-Button Interlock	247	(1)
Auxiliary Contact Interlock	248	(2)
Review Questions	250	(2)
Unit 41 Sequence Control	252	(4)
Automatic Sequence Control	254	(1)
Review Questions	255	(1)
Unit 42 Jogging (Inching) Control Circuits	256	(8)
Jogging Control Circuits	256	(1)
Jogging Using a Control Relay	257	(6)
Review Questions	263	(1)
Unit 43 Plugging	264	(10)
Plugging Switches and Applications	264	(3)
Plugging with the Use of a Timing Relay	267	(1)
Alternate Circuits for Plugging Switch	268	(3)
Antiplugging Protection	271	(2)
Review Questions	273	(1)
Section 5 DC Motor Controls	274	(24)
Unit 44 DC Motors	276	(8)
Application	276	(1)
Speed Control	276	(1)
Motor Construction	277	(1)
Identifying Windings	278	(1)
Types of DC Motors	278	(1)
Direction of Rotation	279	(2)
Standard Connections	281	(2)
Review Questions	283	(1)
Unit 45 Across-the-Line Starting	284	(2)
Review Questions	285	(1)
Unit 46 Definite Time Starting Control	286	(3)
Review Questions	288	(1)
Unit 47 Solid-State DC Motor Controls	289	(9)
The Shunt Field Power Supply	289	(1)
The Armature Power Supply	290	(1)
Voltage Control	291	(1)
Field Failure Control	291	(1)
Current Limit Control	292	(2)
Speed Control	294	(2)
Review Questions	296	(2)
Section 6 AC Motor Control	298	(116)
Unit 48 Stepping Motors	300	(8)
Theory of Operation	300	(2)
Winding	302	(1)
Four-Step Switching (Full Stepping)	302	(1)
Eight-Step Switching (Half Stepping)	302	(1)
AC Operation	303	(1)
Motor Characteristics	304	(3)
Review Questions	307	(1)
Unit 49 The Motor and Starting Methods	308	(11)
The Motor	308	(4)
Typical Starting Methods	312	(6)
Review Questions	318	(1)
Unit 50 Primary Resistor-Type Starters	319	(5)
Primary Resistor-Type Starters	319	(4)
Review Questions	323	(1)
Unit 51 Autotransformer Starters	324	(6)
Review Questions	329	(1)
Unit 52 Automatic Starters for Star-Delta Motors	330	(8)
Applications	330	(3)
Overload Protection	333	(1)
Open Transition Starting	333	(1)
Closed Transition Starting	334	(3)
Review Questions	337	(1)
Unit 53 Consequent Pole Motor Control	338	(17)
Mistaken Reversal Caution	342	(1)
Two-Speed Starter with Reversing Controls	342	(1)
Three-Speed Consequent Pole Motors	342	(2)
Four-Speed Consequent Pole Motors	344	(10)
Review Questions	354	(1)
Unit 54 Wound Rotor Motors and Manual Speed Control	355	(3)
Review Questions	357	(1)
Unit 55 Automatic Acceleration for Wound Rotor Motors	358	(7)
Automatic Acceleration with Reversing Control	359	(1)
Automatic Acceleration Using Frequency Relays	359	(5)
Review Questions	364	(1)
Unit 56 Synchronous Motor Operation	365	(4)
Power Factor Correction by Synchronous Motor	366	(2)
Brushless Synchronous Motors	368	(1)
Review Questions	368	(1)
Unit 57 Synchronous Automatic Motor Starter	369	(7)
Rotor Control Equipment	369	(3)
Summary of Automatic Starter Operation	372	(3)
Review Questions	375	(1)
Unit 58 Variable Speed AC Motor Control	376	(8)
Variable Voltage Speed Control	376	(2)
Variable Frequency Control	378	(2)
Control Using SCRs	380	(3)
Review Questions	383	(1)
Unit 59 Magnetic Clutch and Magnetic Drive	384	(7)
Electrically Controlled Magnetic Clutches	384	(4)
Magnetic Drives	388	(2)
Review Questions	390	(1)
Unit 60 Motor Installation
Determining Motor Current	391	(6)
Determining Conductor Size for a Single Motor	397	(2)
Overload Size	399	(1)
Determining Locked-Rotor Current	400	(2)
Short-Circuit Protection	402	(1)
Starter Size	403	(4)
Multiple Motor Calculations	407	(5)
Review Questions	412	(2)
Section 7 Motor Drives	414	(20)
Unit 61 Direct Drives and Pulley Drives	416	(5)
Directly Coupled Drive Installation	416	(2)
Pulley Drives	418	(2)
Review Questions	420	(1)
Unit 62 Developing Control Circuits	421	(13)
Developing Control Circuits	421	(12)
Review Questions	433	(1)
Section 8 Solid-State Motor Control	434	(49)
Unit 63 Digital Logic	436	(8)
The AND Gate	437	(1)
The OR Gate	438	(1)
The INVERTER	438	(1)
The NOR Gate	439	(1)
The NAND Gate	440	(1)
Integrated Circuits	440	(3)
Testing Integrated Circuits	443	(1)
Review Questions	443	(1)
Unit 64 The Bounceless Switch	444	(4)
Review Questions	447	(1)
Unit 65 Start-Stop Push-Button Control	448	(8)
Review Questions	455	(1)
Unit 66 Programmable Logic Controllers	456	(11)
Differences between the PLC and the Common Computer	456	(1)
Basic Components	457	(4)
Internal Relays	461	(5)
Review Questions	466	(1)
Unit 67 Programming a PLC	467	(12)
Circuit Operation	467	(2)
Developing a Program	469	(2)
Converting the Program	471	(2)
Programming in Boolean	473	(1)
Developing the Program	473	(1)
Parameters of the Programmable Controller	473	(1)
Operation of the Circuit	474	(1)
Entering the Program	475	(3)
Review Questions	478	(1)
Unit 68 Analog Sensing for Programmable Controllers	479	(4)
Installation	481	(1)
The Differential Amplifier	482	(1)
Review Questions	482
Appendix
Testing Solid-State Components	483	(7)
Identifying the Leads of a Three-Phase, Wye-Connected Dual-Voltage Motor	490	(4)
Ohm's Law Formulas	494	(1)
Standard Wiring Diagram Symbols	495	(1)
Electronic Symbols	496	(1)
Motor Types and Line Diagrams	497	(1)
Power Supplies	498	(1)
Motor Circuit Elements	498	(1)
Glossary	499	(10)
Index	509