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100% found this document useful (5 votes)
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Understanding Motor Controls - eBook PDF instant download

The document is a promotional material for the eBook 'Understanding Motor Controls, 4th Edition' by Stephen L. Herman, which is available for download. It includes links to various other eBooks related to motor control and development. The content covers safety, basic control circuits, components, and various motor control methods.

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Understanding
Motor
Controls
Fourth Edition

Stephen L. Herman

Australia Brazil Mexico Singapore United Kingdom United States

Copyright 2020 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. WCN 02-200-203
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some third party content may be suppressed. Editorial review has deemed that any suppressed
content does not materially affect the overall learning experience. The publisher reserves the right
to remove content from this title at any time if subsequent rights restrictions require it. For
valuable information on pricing, previous editions, changes to current editions, and alternate
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Understanding Motor Controls, © 2020, 2016 Cengage Learning, Inc.
Fourth Edition Unless otherwise noted, all content is © Cengage.
Stephen L. Herman
ALL RIGHTS RESERVED. No part of this work covered by the copyright herein
may be reproduced or distributed in any form or by any means, except as
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Publisher does not warrant or guarantee any of the products described
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product information contained herein. Publisher does not assume, and
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part, from the readers’ use of, or reliance upon, this material.

Printed in the United States of America


Print Number: 01    Print Year: 2019

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Table of Contents

Preface xiii
Safety Overview 1
General Safety Rules 2
Effects of Electric Current on the Body 3
On the Job 4
Protective Clothing 6
Ladders and Scaffolds 8
Fires 10
Ground-Fault Circuit Interrupters 10
Grounding 12
Review Questions 12

Section 1 Basic Control Circuits and Components 15

Chapter 1 General Principles of Motor Control 16


Installation of Motors and Control Equipment 16
Types of Control Systems 19
Functions of Motor Control 20
Review Questions 23

Chapter 2 Symbols and Schematic Diagrams 24


Sensing Devices 35
Review Questions 39

Chapter 3 Manual Starters 40


Manual Push Button Starters 43
Troubleshooting45
Review Questions 46

Chapter 4 Overload Relays 47


Dual Element Fuses 47
Thermal Overload Relays 47
Magnetic Overload Relays 53
Overload Contacts 56
Protecting Large Horsepower Motors 58
Review Questions 62

iii

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iv Table of Contents

Chapter 5 Relays, Contactors, and Motor Starters 63


Relays63
Electromagnet Construction 64
Contactors71
Mechanically Held Contactors and Relays 74
Mercury Relays 76
Motor Starters 76
Review Questions 84

Chapter 6 The Control Transformer 86


Grounded and Floating Control Systems 89
Transformer Fusing 89
Review Questions 92

Section 2 Basic Control Circuits 93

Chapter 7 Start–Stop Push Button Control 94


Review Questions 106

Chapter 8 Multiple Push Button Stations 107


Review Questions 111

Chapter 9 Forward–Reverse Control 113


Review Questions 123

Chapter 10 Jogging and Inching 124


Inching Controls 127
Review Questions 130

Chapter 11 Timing Relays 132


Pneumatic Timers 133
Clock Timers 134
Cam Or Sequence Timers 134
Electronic Timers 135
Review Questions 141

Chapter 12 Sequence Control 142


Stopping the Motors In Sequence 143
Review Questions 153

Section 3 Sensing Devices 157

Chapter 13 Pressure Switches and Sensors 158


Differential Pressure  159
Typical Application  159
Pressure Sensors  163
Review Questions 166

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Table of Contents v

Chapter 14 Float Switches and Liquid Level Sensors 167


Mercury Bulb Float Switch 167
The Bubbler System 168
Review Questions 173

Chapter 15 Flow Switches 174


Review Questions 178

Chapter 16 Limit Switches 179


Micro Limit Switches 179
Subminiature Micro Switches 181
Limit Switch Application 181
Review Questions 183

Chapter 17 Temperature Sensing Devices 184


Expansion of Metal  184
Resistance Temperature Detectors  188
Expansion Due to Pressure  191
Review Questions 192

Chapter 18 Hall Effect Sensors 193


Principles of Operation 193
Hall Generator Applications 194
Review Questions 197

Chapter 19 Proximity Detectors 198


Applications198
Metal Detectors 198
Mounting199
Capacitive Proximity Detectors 200
Ultrasonic Proximity Detectors 201
Review Questions 202

Chapter 20 Photodetectors 203


Applications203
Types of Detectors 203
Mounting208
Photodetector Application 210
Review Questions 213

Chapter 21 Reading Large Schematic Diagrams 214


Review Questions 219

Chapter 22 Installing Control Systems 220


Component Location 220
Point-to-Point Connection 221
Using Terminal Strips 222
Review Questions 225

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vi Table of Contents

Section 4 Starting and Braking Methods 227

Chapter 23 Across-the-Line Starting 228


Direct Current Motors 231
Review Questions 233

Chapter 24 Resistor and Reactor Starting for AC Motors 234


Resistor Starting 234
Reactor Starting 234
Step Starting 236
Review Questions 240

Chapter 25 Autotransformer Starting 241


Open and Closed Transition Starting 243
Review Questions 246

Chapter 26 Wye-Delta Starting 247


Wye-Delta Starting Requirements 248
Dual Voltage Connections 249
Connecting the Stator Leads 250
Closed Transition Starting 253
Overload Setting 256
Review Questions 256

Chapter 27 Part Winding Starters 258


Overload Protection 258
Dual Voltage Motors 259
Motor Applications 259
Three-Step Starting 260
Automatic Shutdown 261
Review Questions 263

Chapter 28 Direct Current Motors 264


Field Windings 264
Armature Windings 264
Series Motors 265
Shunt Motors 265
Compound Motors 267
Field Loss Relay 267
External Shunt Field Control 268
Controlling Compounding 269
Cumulative and Differential Compounding 270
Testing the Motor for Cumulative or
Differential Compounding 271
Direction of Rotation 271
Determining the Direction of Rotation 272
Review Questions 274

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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
Table of Contents vii

Chapter 29 Single -Phase Motors 275


Centrifugal Switch 276
Hot-Wire Starting Relay 277
Current Relay 279
Solid-State Starting Relay 279
Potential Starting Relay 281
Dual Voltage Motors 282
Reversing the Direction of Rotation 282
Multispeed Motors 283
Multispeed Fan Motors 285
Review Questions 286

Chapter 30 Braking287
Mechanical Brakes 287
Dynamic Braking 287
Dynamic Braking for Alternating Current Motors 289
Plugging289
Review Questions 297

Section 5 Wound Rotor, Synchronous,


and Consequent Pole Motors 299

Chapter 31 Wound Rotor Motors 300


Manual Control of a Wound Rotor Motor 301
Timed Controlled Starting 302
Wound Rotor Speed Control 304
Frequency Control 304
Review Questions 306

Chapter 32 Synchronous Motors 308


Starting a Synchronous Motor 308
Excitation Current 309
The Brushless Exciter 309
Direct Current Generator 309
Automatic Starting for Synchronous Motors 310
The Field Contactor 310
Out-of-Step Relay 310
The Polarized Field Frequency Relay 310
Power Factor Correction 311
Applications313
Review Questions 314

Chapter 33 Consequent Pole Motors 315


Three-Speed Consequent Pole Motors 319
Four-Speed Consequent Pole Motors 319
Review Questions 329

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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
viii Table of Contents

Section 6 Variable Speed Drives 331

Chapter 34 Variable Voltage and Magnetic Clutches 332


Voltage Control Methods 332
Magnetic Clutches 333
Eddy Current Clutches 334
Review Questions 336

Chapter 35 Solid-State DC Motor Controls 337


The Shunt Field Power Supply 337
The Armature Power Supply 337
Voltage Control 338
Field Failure Control 338
Current Limit Control 339
Speed Control 340
Review Questions 343

Chapter 36 Variable Frequency Control 344


Alternator Control 344
Solid-State Control 344
Some Related Problems 345
IGBTs346
Advantages and Disadvantages of lGBT Drives 347
Inverter Rated Motors 347
Variable Frequency Drives Using SCRs and GTOs 348
Features of Variable Frequency Control 349
Review Questions 352

Section 7 Motor Installation 355

Chapter 37 Motor Installation 356


Motor Nameplate Data  356
Manufacturer’s Name  356
RPM  357
Determining Motor Current  367
Determining Conductor Size for a Single Motor  371
Overload Size  373
Determining Locked-Rotor Current  374
Short-Circuit Protection  375
Starter Size  377
Example Problems  380
Multiple Motor Calculations  382
Review Questions  386

Section 8 Programmable Logic Controllers 387

Chapter 38 Programmable Logic Controllers 388


Differences between PLCs and PCs  388
Basic Components  388
Review Questions 396

Copyright 2020 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. WCN 02-200-203
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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
Table of Contents ix

Chapter 39 Programming a Programmable Logic Controller 397


Circuit Operation 397
Developing a Program 398
Converting the Program 399
Entering a Program 402
Programming Considerations 402
Review Questions 403

Chapter 40 Analog Sensing for Programmable


Logic Controllers 404
Installation405
The Differential Amplifier 406
Review Questions 407

Section 9 Developing Control Circuits


and Troubleshooting 409

Chapter 41 Developing Control Circuits 410


Developing Control Circuits 410
Review Questions 421

Chapter 42 Troubleshooting422
Safety Precautions  424
Voltmeter Basics  424
Test Procedure Example 1  426
Test Procedure Example 2  428
Test Procedure Example 3  429
Motors  432
Review Questions 440

Chapter 43 Direct Drives and Pulley Drives 442


Directly Coupled Drive Installation 442
Pulley Drives 443
Review Questions 445

Chapter 44 Semiconductors446
Conductors446
Insulators446
Semiconductors447
Review Questions 450

Chapter 45 The PN Junction 451


The PN Junction 451
Review Questions 454

Chapter 46 The Zener Diode 455


The Zener Diode 455
Review Questions 457

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x Table of Contents

Chapter 47 Light-Emitting Diodes and Photodiodes 458


LED Characteristics 458
Testing LEDs 458
LED Lead Identification 459
Seven-Segment Displays 459
Connecting the LED in a Circuit 460
Photodiodes461
Photovoltaic462
Photoconductive462
LED Devices 462
Review Questions 463

Chapter 48 The Transistor 464


The Transistor 464
Review Questions 466

Chapter 49 The Unijunction Transistor 467


The Unijunction Transistor 467
Review Questions 469

Chapter 50 The SCR 470


The SCR in a DC Circuit 470
The SCR in an AC Circuit 471
Phase Shifting the SCR 472
Testing the SCR 473
Review Questions 474

Chapter 51 The Diac 475


The Diac 475
Review Questions 476

Chapter 52 The Triac 477


The Triac Used as an AC Switch 477
The Triac Used for AC Voltage Control 478
Phase Shifting the Triac 478
Testing the Triac 479
Review Questions 480

Chapter 53 The 555 Timer 481


Circuit Applications 483
Review Questions 487

Chapter 54 The Operational Amplifier 488


Basic Circuits 490
Circuit Applications 491
Review Questions 497

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Table of Contents xi

Section 10 Laboratory Exercises 499


Laboratory Exercises 500
Foreword 500
Parts List for Laboratory Exercises 500
Suppliers 501

Exercise 1 Basic Control 503


Review Questions 512

Exercise 2 START–STOP Push Button Control 513


Review Questions 524

Exercise 3 Multiple Push Button Stations 525


Review Questions 530

Exercise 4 Forward–Reverse Control 533


Review Questions 540

Exercise 5 Sequence Control 542


Review Questions 549

Exercise 6 Jogging Controls 551


Review Questions 560

Exercise 7 On-Delay Timers 563


Review Questions 568

Exercise 8 Off-Delay Timers 570


Review Questions 576

Exercise 9 Designing a Printing Press Circuit 578


Review Questions 583

Exercise 10 Sequence Starting and Stopping


for Three Motors 584
Review Questions 591

Exercise 11 Hydraulic Press Control 592


Review Questions 600

Exercise 12 Design of Two Flashing Lights 601


Review Questions 603

Exercise 13 Design of Three Flashing Lights 604


Review Questions 606

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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
xii Table of Contents

Exercise 14 Control for Three Pumps 607


Review Questions 614

Exercise 15 Oil Pressure Pump Circuit for a Compressor 615


Review Questions 618

Exercise 16 Autotransformer Starter 619


Review Questions 623

Appendix 624
Identifying the Leads of a Three-Phase, Wye-Connected,
Dual-Voltage Motor 624
Glossary 629
Index 632

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Preface

A Note from the Author


I have taught the subject of motor control for over 30 years. I have tried different methods
and found that some are more successful than others. Understanding Motor C ­ ontrols is the
accumulation of this knowledge. I am sure other methods may work equally well, but the
methods and information presented in this textbook have worked the best for me. My goal
in writing this textbook is to present the subject of motor control in a way that the average
student can understand. I have three main objectives:
• Teach the student how to interpret the logic of a schematic diagram.
• Teach the student how to properly connect a circuit using a schematic diagram.
• Teach the student how to troubleshoot a control circuit.
Understanding Motor Controls assumes that the student has no knowledge of m ­ otor con-
trols. The student is expected to have knowledge of basic Ohm’s law and basic circuits, such as
series, parallel, and combination. The book begins with an overview of safety. A discussion of
schematics (ladder diagrams) and wiring diagrams is presented early. The discussion of sche-
matics and wiring diagrams is intended to help students understand the written language of
motor controls. Standard NEMA symbols are discussed and employed throughout the book
when possible. The operation of common control devices is presented to help students under-
stand how these components function and how they are used in motor control circuits. Basic
control circuits are presented in a manner that allows students to begin with simple circuit
concepts and progress to more complicated circuits.
The textbook contains examples of how a schematic or ladder diagram is converted into
a wiring diagram. A basic numbering system is explained and employed to aid students
in making this conversion. This is the most effective method I have found of teaching a
student how to make the transition from a circuit drawn on paper to properly connecting
components in the field.
Understanding Motor Controls also covers solid-state controls for both DC and AC
­motors. Variable frequency drives and programmable logic controllers are covered in de-
tail. I explain how to convert a ladder diagram into a program that can be loaded into a
PLC. The book contains many troubleshooting problems that help the student understand
the logic of a control system. Circuit design is also used to help the s­ tudent develop the
concepts of circuit logic.
Understanding Motor Controls contains 16 hands-on laboratory exercises that are
­designed to use off-the-shelf motor control components. A list of materials and suggested
vendors is given for the components used in the exercises. The laboratory exercises begin
with very basic concepts and connections and progress through more complicated circuits.

xiii

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xiv Preface

Supplements
An online Instructor Companion website contains an Instructor Guide with answers to
end-of-chapter review questions, test banks, and Chapter presentations done in Power-
Point, and testing powered by Cognero.
Cengage Learning Testing Powered by Cognero is a flexible, online system that
­allows you to:
• author, edit, and manage test bank content from multiple Cengage Learning solutions
• create multiple test versions in an instant
• deliver tests from your LMS, your classroom, or wherever you want
Contact Cengage Learning or your local sales representative to obtain an instructor
account.
Accessing an Instructor Companion Website from SSO Front Door
1. Go to: http://login.cengage.com and login using the Instructor email address and
password.
2. Enter author, title or ISBN in the Add a title to your bookshelf search box, click on
Search button.
3. Click Add to My Bookshelf to add Instructor Resources.
4. At the Product page click on the Instructor Companion site link.

New Users
If you’re new to Cengage.com and do not have a password, contact your sales representative.

Acknowledgments
Wes Mozley, Albuquerque Tech
Ralph Potter, Bowling Green Technical College
Richard Schell, Luzerne County Community College
Terry Snarr, Idaho State University
Ron Stadtherr, Ridgewater College
William Quimby, Shelton State Community College
Stephen Vossler, Lansing Community College
Keith Dinwiddie, Ozarks Community College

New for the Fourth Edition


Extended information for sizing overload relay heaters.
Additional review questions to selected chapters.
Upgraded and additional illustrations.
Extended explanation for how an electronic on-delay timer operates.
Extended information on float switch circuits.
Extended coverage of photodetectors.
Extended coverage of wye-delta starting.
Extended coverage of direct current motors.
The addition of electronic components and circuits frequently used in motor control
applications

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Copyright 2020 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
Safety Overview

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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
Safety Overview

Objectives After studying this chapter the student will be able to:
• State basic safety rules. • Discuss lockout and tagout procedures. • Discuss classes of fires.
• Describe the effects of electric current on • Discuss types of protective clothing. • Discuss ground-fault circuit
the body. • Explain how to properly place a straight interrupters.
• Discuss the origin and responsibilities ladder against a structure. • Discuss the importance of grounding.
of OSHA. • Discuss different types of scaffolds.
• Discuss material safety data sheets.

S
afety is the job of each individual. You should be con- taking time to think before acting. Many technicians have
cerned not only with your own safety but with the been killed by supposedly “dead” circuits. Do not depend
safety of others around you. This is especially true for on circuit breakers, fuses, or someone else to open a cir-
persons employed in the electrical field. Some general rules cuit. Test it yourself before you touch it. If you are working
should be followed when working with electric equipment on high-voltage equipment, use insulated gloves and meter
or circuits. probes to measure the voltage being tested. Think before
you touch something that could cost you your life.

General Safety Rules Avoid Horseplay


Never Work on an Energized Jokes and horseplay have a time and place but not when
someone is working on an electric circuit or a piece of mov-
Circuit If the Power Can Be ing machinery. Do not be the cause of someone’s ­being
Disconnected injured or killed and do not let someone else be the cause
of your being injured or killed.
When possible, use the following three-step check to make
certain that power is turned off.
1. Test the meter on a known live circuit to make sure the
meter is operating.
Do Not Work Alone
2. Test the circuit that is to become the de-energized cir- This is especially true when working in a hazardous location
cuit with the meter. or on a live circuit. Have someone with you who can turn off
the power or give artificial respiration and/or cardiopul-
3. Test the meter on the known live circuit again to make monary resuscitation (CPR). Several electric shocks can
certain the meter is still operating. cause breathing difficulties and can cause the heart to go
Install a warning tag at the point of disconnection so into fibrillation.
people will not restore power to the circuit. If possible, use
a lock to prevent anyone from turning the power back on.
Work with One Hand When
Think Possible
Of all the rules concerning safety, this one is probably the The worst kind of electric shock occurs when the current
most important. No amount of safeguarding or idiot proof- path is from one hand to the other, which permits the
ing a piece of equipment can protect a person as well as current to pass directly through the heart. A person can

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   Safety Overview 3

survive a severe shock between the hand and foot but it A current of 2 to 3 milliamperes (mA) (0.002 to 0.003
would cause death if the current path was from one hand amperes) usually causes a slight tingling sensation, which
to the other. increases as current increases and becomes very noticeable
at about 10 milliamperes (0.010 amperes). The tingling sen-
sation is very painful at about 20 milliamperes. Currents
Learn First Aid between 20 and 30 milliamperes cause a person to seize
the line and be unable to let go of the circuit. Currents
Anyone working on electric equipment, especially those between 30 and 40 milliamperes cause muscular paralysis,
working with voltages greater than 50 volts, should make an and those between 40 and 60 milliamperes cause breathing
effort to learn first aid. A knowledge of first aid, ­especially difficulty. When the current increases to about 100 milliam-
CPR, may save your own or someone else’s life. peres, breathing is extremely difficult. Currents from 100 to
200 milliamperes generally cause death because the heart
usually goes into fibrillation, a condition in which the heart
Avoid Alcohol and Drugs begins to “quiver” and the pumping action stops. Currents
above 200 milliamperes cause the heart to squeeze shut.
The use of alcohol and drugs has no place on a work site.
When the current is removed, the heart usually returns to
Alcohol and drugs are not only dangerous to users and
a normal pumping action. This is the operating principle
those who work around them; they also cost industry mil-
of a defibrillator. The voltage considered to be the most
lions of dollars a year. Alcohol and drug abusers kill thou-
dangerous to work with is 120 volts, because that generally
sands of people on the highways each year and are just as
causes a current flow of between 100 and 200 milliamperes
dangerous on a work site as they are behind the wheel of a
through most people’s bodies. Large amounts of current
vehicle. Many industries have instituted testing policies to
screen for alcohol and drugs. A person who tests positive
generally receives a warning the first time and is fired the 0.100–0.200 (DEATH) THIS RANGE GENERALLY CAUSES
AMPERES FIBRILLATION OF THE HEART. WHEN THE
second time. HEART IS IN THIS CONDITION, IT VIBRATES AT
A FAST RATE LIKE A "QUIVER" AND CEASES TO
PUMP BLOOD TO THE REST OF THE BODY.

Effects of Electric Current


on the Body 0.060–0.100 (EXTREME DIFFICULTY IN BREATHING)
AMPERES
Most people have heard that it is not the voltage that
kills but the current. This is true, but do not be misled
into thinking that voltage cannot harm you. Voltage is the
force that pushes the current though the circuit. It can
be compared to the pressure that pushes water through 0.040–0.060 (BREATHING DIFFICULTY)
a pipe. The more pressure available, the greater the vol- AMPERES
ume of water flowing through the pipe. Students often ask
how much current will flow through the body at a particu-
lar voltage. There is no easy answer to this question. The
0.030–0.040 (MUSCULAR PARALYSIS)
amount of current that can flow at a particular voltage
AMPERES
is determined by the resistance of the current path. Dif-
ferent people have different resistances. A body has less 0.020–0.030 (UNABLE TO LET GO OF THE CIRCUIT)
resistance on a hot day when sweating, because salt water AMPERES
is a very good conductor. What one eats and drinks for
0.010–0.020 (VERY PAINFUL)
lunch can have an effect on the body’s resistance as can AMPERES
the length of the current path. Is the current path between
0.009–0.010 (MODERATE SENSATION)
two hands or from one hand to one foot? All of these fac- AMPERES
tors affect body resistance.
Figure S–1 illustrates the effects of different amounts
0.002–0.003 (SLIGHT TINGLING SENSATION)
of current on the body. This chart is general—some ­people
AMPERES
may have less tolerance to electricity and others may have
a greater tolerance. Figure S–1 The effects of electric current on the body.

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4 Safety, Basic Electricity, and Ohm’s Law

can cause severe electric burns that are often very serious Employer Responsibilities
because they occur on the inside of the body. The exterior
of the body may not look seriously burned, but the inside Section 5(a)1 of the Occupational Safety and Health Act
may be severely burned. basically states that employers must furnish each of their
employees a place of employment that is free of recog-
nized hazards that are likely to cause death or serious
injury. This places the responsibility for ­compliance on
On the Job employers. Employers must identify hazards or potential
hazards within the work site and eliminate them, con-
OSHA trol them, or provide employees with suitable protection
from them. It is the employee’s responsibility to follow
OSHA is an acronym for Occupational Safety and Health the safety procedures set up by the employer.
Administration, U.S. Department of Labor. Created by To help facilitate these safety standards and procedures,
Congress in 1971, its mission is to ensure safe and healthful OSHA requires that an employer have a competent per-
workplaces in the United States. Since its creation, son oversee implementation and enforcement of these
workplace fatalities have been cut in half, and occupational standards and procedures. This person must be able to
injury and illness rates have declined by 40%. Enforcement recognize unsafe or dangerous conditions and have the
of OHSA regulations is the responsibility of the Secretary authority to correct or eliminate them. This person also
of Labor. has the authority to stop work or shut down a work site
OSHA standards cover many areas, such as the handling until safety regulations are met.
of hazardous materials, fall protection, protective cloth-
ing, and hearing and eye protection. Part 1910 Subpart S
deals mainly with the regulations concerning electrical
safety. These regulations are available in books and can be
Msds
accessed at the OSHA website at www.osha.org. MSDS stands for material safety data sheets, which are
provided with many products. They generally warn users
of any hazards associated with the product. They outline
Hazardous Materials the physical and chemical properties of the product; list
precautions that should be taken when using the product;
It may become necessary to deal with some type of haz- and list any potential health hazards, storage consideration,
ardous material. A hazardous material or substance is any flammability, reactivity, and, in some instances, radioactiv-
substance that if exposed to may result in adverse effects ity. They sometimes list the name, address, and telephone
on the health or safety of employees. Hazardous materials number of the manufacturer; the MSDS date and emer-
may be chemical, biological, or nuclear. OSHA sets stan- gency telephone numbers; and, usually, information on
dards for dealing with many types of hazardous materials. first aid procedures to use if the product is swallowed or
The required response is determined by the type of haz- comes in contact with the skin. Safety data sheets can be
ard associated with the material. Hazardous materials are found on many home products such as cleaning products,
required to be listed as such. Much information concern- insecticides, and flammable liquids.
ing hazardous materials is generally found on material
safety data sheets (MSDS). (A sample MSDS is shown in
Table S-1 at the end of this unit) If you are working in an Trenches
area that contains hazardous substances, always read any It is often necessary to dig trenches to bury conduit. U
­ nder
information concerning the handling of the material and some conditions, these trenches can be deep enough to
any safety precautions that should be observed. After a bury a person if a cave-in occurs. Safety regulations for the
problem exists is not the time to start looking for informa- shoring of trenches is found in OSHA Standard 1926 Sub-
tion on what to do. part P App C titled “Timber Shoring for Trenches.” These
Some hazardous materials require a Hazardous Mate- procedures and regulations are federally mandated and
rials Response Team (HAZMAT) to handle any problems. must be followed. Some general safety rules should be fol-
A HAZMAT is any group of employees designated by the lowed, such as:
employer that are expected to handle and control an actual
or potential leak or spill of a hazardous material. They are 1. Do not walk close to trenches unless it is necessary. This
expected to work in close proximity to the material. A can cause the dirt to loosen and increase the possibility
HAZMAT is not always a fire brigade, and a fire brigade of a cave-in.
may not necessarily have a HAZMAT. On the other hand, 2. Do not jump over trenches if it is possible to walk around
HAZMAT may be part of a fire brigade or fire department. them.

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   Safety Overview 5

Figure S–2 Place a barricade around a trench and use a ladder Figure S–3 A confined space is any space having a limited
to enter and exit the trench. means of entrance or exit.

3. Place barricades around trenches (Figure S–2). Lockout and Tagout Procedures
4. Use ladders to enter and exit trenches.
Lockout and tagout procedures are generally employed
to prevent someone from energizing a piece of equipment
by mistake. This could apply to switches, circuit breakers,
Confined Spaces or valves. Most industries have their own internal policies
and procedures. Some require that a tag similar to the one
Confined spaces have a limited means of entrance or
shown in Figure S–4 be placed on the piece of equipment
exit (Figure S–3). They can be very hazardous workplaces,
being serviced; some also require that the equipment be
often containing atmospheres that are extremely harmful
locked out with a padlock. The person performing the
or deadly. Confined spaces are very difficult to ventilate
work places the lock on the equipment and keeps the key
because of their limited openings. It is often necessary for
in his or her possession. A device that permits the use of
a worker to wear special clothing and use a separate air sup-
multiple padlocks and a safety tag is shown in Figure S–5.
ply. OSHA Section 12: “Confined Space Hazards” lists rules
This is used when more than one person is working on the
and regulations for working in a confined space. In addition,
same piece of equipment. Violating lockout and tagout
many industries have written procedures that must be fol-
procedures is considered an extremely serious offense in
lowed when working in confined spaces. Some general rules
most industries and often results in immediate termination
include the following:
of employment. As a general rule, there are no first-time
1. Have a person stationed outside the confined space to warnings.
watch the person or persons working inside. The outside After locking out and tagging a piece of equipment, it
person should stay in voice or visual contact with the should be tested to make certain that it is truly ­de-energized
inside workers at all times. He or she should check air before working on it. A simple three-step procedure is gen-
sample readings and monitor oxygen and explosive gas erally recommended for making certain that a piece of elec-
levels. tric equipment is de-energized. A voltage tester or voltmeter
that has a high enough range to safely test the voltage is
2. The outside person should never enter the space, even
employed. The procedure is as follows:
in an emergency, but should contact the proper emer-
gency personnel. If he or she enters the space and 1. Test the voltage tester or voltmeter on a known
become incapacitated, no one would be available to ­energized circuit to make certain the tester is working
call for help. properly.
3. Use only electric equipment and tools that are approved 2. Test the circuit you intend to work on with the volt-
for the atmosphere found inside the confined area. It age tester or voltmeter to make sure that it is truly
may be necessary to obtain a burning permit to operate de-energized.
tools that have open brushes and that spark when they 3. Test the voltage tester or voltmeter on a known ener-
are operated. gized circuit to make sure that the tester is still working
properly.
4. As a general rule, a person working in a confined space
should wear a harness with a lanyard that extends to the This simple procedure helps to eliminate the possibility of
outside person, so the outside person could pull him or a faulty piece of equipment indicating that a circuit is de-
her to safety if necessary. energized when it is not.

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6 Safety, Basic Electricity, and Ohm’s Law

Protective Clothing
Maintenance and construction workers alike are usually
required to wear certain articles of protective clothing, dic-
tated by the environment of the work area and the job being
performed.

Head Protection
Some type of head protection is required on almost any work
site. A typical electrician’s hard hat, made of nonconductive
plastic, is shown in Figure S–6. It has a pair of safety goggles
attached that can be used when desired or necessary.

Eye Protection
Eye protection is another piece of safety gear required on
almost all work sites. Eye protection can come in ­different
forms, ranging from the goggles shown in ­Figure S–6 to
the safety glasses with side shields shown in Figure S–7.
Common safety glasses may or may not be prescription
glasses, but almost all provide side protection (Figure S–7).
Sometimes a full face shield may be required.

Hearing Protection
Section III, Chapter 5 of the OSHA Technical Manual
includes requirements concerning hearing protection. The
need for hearing protection is based on the ambient sound
Figure S–4 Safety tag used to tagout equipment. level of the work site or the industrial location. Workers

Figure S–5 The equipment can be locked out by several different Figure S–6 Typical electrician’s hard hat with attached safety
people. goggles.

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   Safety Overview 7

Figure S–8 Leather gloves with rubber inserts.


Figure S–7 Safety glasses provide side protection.

are usually required to wear some type of hearing protec-


tion when working in certain areas, usually in the form of
earplugs or earmuffs.

Fire-Retardant Clothing
Special clothing made of fire-retardant material is required
in some areas, generally certain industries as opposed to
all work sites. Fire-retardant clothing is often required for
maintenance personnel who work with high-power sources
such as transformer installations and motor-control cen-
ters. An arc flash in a m
­ otor-control center can easily catch
a person’s clothes on fire. The typical motor-control center
can produce enough energy during an arc flash to kill a per-
son 30 feet away.

Figure S–9 Kevlar gloves protect against cuts.


Gloves
Another common article of safety clothing is gloves. Electri-
cians often wear leather gloves with rubber inserts when it is
necessary to work on energized circuits (Figure S–8). These SHOULDER D-RING
STRAPS
gloves are usually rated for a certain amount of voltage. They
should be inspected for holes or tears before they are used.
LANYARD
Kevlar gloves (Figure S–9) help protect against cuts when CHEST
stripping cable with a sharp blade. STRAP
LEG
Safety Harness STRAPS

Safety harnesses provide protection from falling. They


buckle around the upper body with leg, shoulder, and chest
straps; and the back has a heavy metal D-ring (Figure S–10).
A section of rope approximately 6 feet in length, called a
lanyard, is attached to the D-ring and secured to a stable
structure above the worker. If the worker falls, the lanyard Figure S–10 Typical safety harness.

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8 Safety, Basic Electricity, and Ohm’s Law

limits the distance he or she can drop. A safety harness the sections. Two end sections are connected by X braces
should be worn: that form a rigid work platform (Figure S–13). Sections of
scaffolding are stacked on top of each other to reach the
1. When working more than 6 feet above the ground or
desired height.
floor
2. When working near a hole or drop-off
3. When working on high scaffolding Rolling Scaffolds
A safety harness is shown in Figure S–11. Rolling scaffolds are used in areas that contain level floors,
such as inside a building. The major difference between a
rolling scaffold and those discussed previously is that it is
Ladders and Scaffolds equipped with wheels on the bottom section that permit it
to be moved from one position to another. The wheels usu-
It is often necessary to work in an elevated location. When ally contain a mechanism that permits them to be locked
this is the case, ladders or scaffolds are employed. Scaf- after the scaffold is rolled to the desired location.
folds generally provide the safest elevated working plat-
forms. They are commonly assembled on the work site
from standard sections (Figure S–12). The bottom sections
usually contain adjustable feet that can be used to level

Figure S–12 Typical section of scaffolding.

Figure S–11 Safety harness. Figure S–13 X braces connect scaffolding sections together.

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   Safety Overview 9

Hanging or Suspended Scaffolds Like straight ladders, step ladders are designed to withstand
a certain load capacity. Always check the load capacity
Hanging or suspended scaffolds are suspended by cables before using a ladder. As a general rule, ladder manufactur-
from a support structure. They are generally used on the ers recommend that the top step not be used because of the
sides of buildings to raise and lower workers by using hand danger of becoming unbalanced and falling. Many people
cranks or electric motors. mistakenly think the top step is the top of the ladder, but it
is actually the last step before the ladder top.
Straight Ladders
Ladders can be divided into two main types, straight and 3 FT.
step. Straight ladders are constructed by placing rungs
between two parallel rails (Figure S–14). They generally
contain safety feet on one end that help prevent the
ladder from slipping. Ladders used for electrical work
are usually wood or fiberglass; aluminum ladders are
avoided because they conduct electricity. Regard-
less of the type of ladder used, you should check
its load capacity before using it. This information is
found on the side of the ladder. Load capacities of LADDER 20 FT.
200 pounds, 250 pounds, and 300 pounds are common. Do
not use a ladder that does not have enough load c­ apacity
to support your weight plus the weight of your tools and
the weight of any o ­ bject you are taking up the ladder
with you.
Straight ladders should be placed against the side of a
building or other structure at an angle of approximately 76˚
76° (Figure S–15). This can be accomplished by moving
the base of the ladder away from the structure a distance
5 FT.
equal to one fourth the height of the ladder. If the ladder is
20 feet high, it should be placed 5 feet from the base of the Figure S–15 A ladder should be placed at an angle of
structure. If the ladder is to provide access to the top of ­approximately 76°.
the structure, it should extend 3 feet above the structure.
HIGHEST USABLE STEP
Step Ladders TOP STEP
LADDER TOP
Step ladders are self-supporting, constructed of two sec-
tions hinged at the top (Figure S–16). The front section has
two rails and steps, the rear portion two rails and braces.

SPREADER

Figure S–14 Straight ladder. Figure S–16 Typical step ladder.

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