FOREWORD We need to teach the basic fundamentals of machine tool electrification. Those mainly affected are the thousands of small builders and users, and to some extent, the large manufacturer. Most selling organizations, both large and small, include many thousands of manufacturers’ agents, distributors, sales engineers and maintenance personnel. These are the people charged with the responsibility for selling machines and keeping them operating. The success or failure of installations may depend on the ability of these people to maintain and troubleshoot equipment properly. The personnel involved need to understand electrical components and their symbols. With this knowledge, they are in a better position to read and understand elementary circuit diagrams. Three areas where education is needed are in troubleshooting, maintenance and electrical standards. 1, Troubleshooting machine control circuits involves locating and properly identifying the nature and magnitude of a fault or error. This fault may be in the circuit design, physical wiring or in the components and equipment used. The time required and the technique or system used to locate and identify the error is important. Of like importance are the time and expense involved to put the machine back into normal operating condition. 2. Preventative maintenance would eliminate the need for most troubleshooting. Many machines are allowed to operate until they literally “fall apart.”” 3. A reasonable set of standards should be followed. If the intended result is the improvement of design and application to reduce down-time and promote safety, electrical standards can be extremely helpful. Where should the edu- cation start? The answer is at the beginning and keep it simple. Even a basic concept, such as the relation between a component and its symbol, can be of benefit to the user. viiTABLE OF CONTENTS Introduction to Electrical Control. Chapter 1 Control Transformers... . Chapter 2 Fuses, Disconnect Switches, and Circuit Breakers. Chapter 3 Oil-tight Units. Chapter 4 Control Relays, Time-delay Relays, and Contactors . Chapter 5 Solenoids...... Chapter 6 Limit Switches .. Chapter 7 Pressure Switches . Chapter 8 Temperature Controllers and Switches . Chapter 9 Timers... Chapter 10 Counters , Chapter 11 Motor Starters. . Chapter 12. Application of Electric Heat . Chapter 13 Control Circuits........ Chapter 14 Use of Electrical Codes and Standards. Chapter 15. Troubleshooting . s Chapter 16 Designing for Easy Maintenance . Chapter 17 Power Factor Correction Chapter 18 Introduction to Solid-state Control... . Chapter 19 Introduction to Programmable Control. Appendix A Glossary . Appendix B_ Summary of Electrical Symbols Appendix C Units of Measurement... . . ‘ Appendix D Rules of Thumb for Electrical Motors. Appendix E Electrical Formulas. i Appendix F Tables. . ae : Index. . . ee ee 106 122 127 187 187 208 220 239 263 276 331 352 359 365 369 371 372 379